4 2.4L Gasoline

Refine MPV Workshop Manual Gasoline Engine
Chapter I Gasoline engine (2.4 L4)
Section I General
Refine MPV mainly adopt technologies of Hyundri, Korea. All gasoline engines used are 2.4L inline 4-cylinder
engine. This type of engine has two models: one imported from Korea using Hyundri control system; the other
made in China using Delphi control system. These two models have roughly the same mechanic part. Only slight
difference exists in application of some elements. These will be explained in details later in the maintenance
manual.
I. Engine ID code
Engine ID code is printed on cylinder below the exhaust manifold.
ID code of domestic engine consists of 12 digits.
G 4 J S ☆ 4 1 0 0 0 3 6 9 ☆
1 2 3 4 5 6 7
1. Engine fuel
G— gasoline
D— diesel
2. Range of engine
4— inline 4-cylinder
3. Engine development serial number
-1-
B— 4D56 engine
J— SIRIUS II
4. Engine displacement
B— 2607cc
H— 2467cc
S— 2351cc
5. Year of manufacture
Y— 2000 1— 2001 2— 2002 3— 2003 4— 2004 5— 2005
6. Type of engine
Type of engine Code Type of engine Code

Gasoline CKD 1 Diesel CKD 2
engine engine
Domestic 3 Domestic 4
7. Engine ex-factory No.

000001— 999999
ID code of imported engine consists of 11 digits.
D 4 B H Y 0 0 0 0 0 1
1 2 3 4 5 6
1. Engine fuel
G— gasoline
D— diesel
2. Range of engine
4— inline 4-cyliner
3. Engine development serial number
B— 4D56 engine
J— SIRIUS II
4. Engine displacement
B— 2607cc
H— 2467cc
S— 2351cc
5. Year of manufacture
Y— 2000 1— 2001 2— 2002 3— 2003 4— 2004 5— 2005
6. Engine production serial number
-2-
000001— 999999
II. Size and parameters
Item Size/parameter Limit value

General
Type Inline, dual top-arranged cam
Number of cylinders 4
Bore 86.5 mm
Stroke 100 mm
Displacement 2351 cc
Compression ratio 10:1
Ignition sequence 1-3-4-2
Valve timing
Intake valve
Open (BTDC) 18º
Close (ABDC) 54º
Exhaust valve
Open (BBDC) 56º
Close (ATDC) 8º
Cylinder head
Cylinder gasket surface planeness Max. 0.03 mm 0.2 mm
Manifold mounting surface planeness 0.15 mm 0.3 mm
Valve seat hole repair enlarged dimensions
Intake
0.3 mm O.S. 35.3-35.325 mm
0.6 mm O.S. 35.6-35.625 mm
Exhaust
0.3 mm O.S. 33.3-33.326 mm
0.6 mm O.S. 33.6-33.625 mm
Valve guide pipe hole repair enlarged
dimensions (intake and exhaust)
0.05 mm O.S. 12.05-12.068 mm
0.25 mm O.S. 12.25-12.268 mm
0.50 mm O.S. 12.50-12.518 mm
-3-
Camshaft
Cam height
Intake 35.493 mm 34.993mm
Exhaust
Manual transmission 35.204 mm 34.704mm
Automatic transmission 35.204 mm 34.704mm
Journal OD 26 mm
Bearing clearance 0.040-0.076 mm
End clearance 0.1-0.15 mm
Item Size/Parameters Limit value

Valve
Valve length
Intake 109.5 mm
Exhaust 109.5 mm
Valve stem OD
Intake 6.565-6.580 mm
Exhaust 6.530-6.550 mm
Conical angle 45º-45º5’
Valve head thickness (edge)
Intake 1.0 mm 0.7 mm
Exhaust 1.5 mm 1.0 mm
Clearance between valve stem and valve guide pipe
Intake 0.020-0.047 mm 0.1 mm
Exhaust 0.050-0.085 mm 0.15 mm
Valve guide pipe
Length
Intake 45.5 mm
Exhaust 50.5 mm
Exceeding dimensions for maintenance 0.05,0.25,0.50 mm
Valve seat
Seat contact width 0.9-1.3 mm
Seat conical angle 44º-44º
Maintenance dimensions 0.3 mm
0.6 mm tolerance
Valve spring
Free length 45.82 mm 44.82 mm
Load bearing 25.3kg/40mm
Skewness At assembling height 4º
Less than 1.5º
Cylinder body
Bore 86.5±0.03 mm
Out-of-round degree and conical degree of bore Less than 0.01 mm
-4-
Cylinder gasket surface planeness Less than 0.05 mm 0.1 mm

Piston
OD 86.47-86.5 mm
Clearance between piston and cylinder 0.02-0.04 mm
Ring groove width
No.1 1.22-1.24 mm
No.2 1.51-1.53 mm
Oil ring 2.81-2.83 mm
Maintenance dimensions 0.5 mm tolerance
Item Size/parameters Limit value

Piston ring
Lateral clearance
No.1 0.03-0.07 mm
No.2 0.02-0.06 mm 0.1 mm
Oil ring 0.06-0.15 mm
End clearance
No.1 0.25-0.35 mm 0.8 mm
No.2 0.40-0.55 mm 0.8 mm
Oil ring side blade 0.10-0.40 mm 1.0 mm
Connecting rod
Camber 0.05 mm
Twisting 0.1 mm
Lateral clearance between connecting rod 0.10-0.25 mm 0.4 mm
large head and crankshaft 48-48.015 mm
Connecting rod journal OD 0.015-0.048 mm 0.1 mm
Connecting rod bearing clearance
Crankshaft main bearing clearance 0.018-0.036 mm 0.1 mm
No.1,2,4,5 journal 0.024-0.042 mm
No.3 journal
Crankshaft
Journal OD 56.982-57.000mm
Journal out-of-round degree 小于 0.015 mm
Journal conical degree 小于 0.005 mm
Axial clearance 0.05-0.25 mm 0.25mm
Flywheel
Bouncing 0.13 mm
Oil pressure at idling 80 kPa
[at oil temperature of 75-90℃] (11.6 psi)
Engine oil pump
Top clearance
Driving gear 0.16-0.21 mm 0.25 mm
-5-
Driven gear 0.18-0.21 mm 0.25 mm

Lateral clearance
Driving gear 0.08-0.14 mm 0.25 mm
Driven gear 0.06-0.12 mm 0.25 mm
Safety spring
Free length 46.6 mm
At loading [61N] 40.1 mm
Item Size/parameters Limit value

Right balance shaft
Front journal dia. 41.959-41.975mm
Rear journal dia. 40.951-40.967mm
Clearance
Front 0.020-0.061 mm
Rear 0.050-0.091 mm
Left balance shaft
Front journal dia. 18.467-18.480mm
Rear journal dia. 40.951-40.967mm
Clearance
Front 0.020-0.054 mm
Rear 0.042-0.083 mm
Cooling mode With forced circulation by fans
Cooling system capacity 7.0L
Thermostat
Type Paraffin type
Normal opening temperature 82℃
Range of opening temperature 80℃-84℃
Fully-open temperature 95℃
Radiator cover
Main valve open pressure 107.9±14.7 kPa
(1.1±0.15 kg/cm²,15.64±2.13 psi)
Main valve close pressure 83.4 kPa(0.85 kg/cm²,12.1 psi)
Vacuum valve open pressure -6.86 kPa(-0.07 kg/cm², -1.00psi)
Exhaust pipe
Silencer Expansion resonance type
Hanging system Rubber hanging device
Coolant temperature sensor
Type Thermistor type
Resistance
-6-
20℃ 2.45±0.14 KΏ
80℃ 0.3222KΏ
Notes:
O.D: outer diameter
I.D: inner diameter
U.S: undersize
O.S: oversize
III. Tightening torque
Item Nm Item Nm
Engine support separator bolts 90-110 Generator support bolts 20-25
Engine support nuts 60-80
Generator coupling bolts
Engine support bolts 60-80
M9×90 8-12
Engine support frame bolts and nuts 55-65
Front stop rolling support to beam bolts 40-55 M8×40 20-25
Front stop rolling separator bolts/nuts 50-65 Engine water pump to cylinder bolts 20-27
Rear stop rolling support to beam bolts 50-65 Engine coolant temperature sensor 20-40
Rear stop rolling separator bolts/nuts 50-65
Engine coolant inlet sealing bolts 10-15
Propeller shaft support bolts 60-80
Propeller shaft mounting separator bolts 90-110
AC compressor and support 23-27
Power steering gear oil pump and 35-4
support
Front exhaust pipe & exhaust manifold 30-40 Oil tray (upper and lower) 10-12
Rocker arm cover bolts 8-10 Oil tray drain plug 35-45
Central cover bolts 4-5 Engine oil strainer 15-22
Camshaft sprocket bolts 80-100 Engine oil pump sprocket nuts 50-60
Camshaft bearing cover bolts 19-21 Engine oil pressure switch 8-12
Crankshaft position sensor 10-13 Engine oil filter support bolts 20-27
Throttle valve seat 15-22 Engine oil pump bolts 15-18
Air filter mounting bolts 8-10 Oil seal cover bolts 10-12
Crankshaft sprocket bolts 110-130 Front cover bolts 20-27
Damper pulley with crankshaft sprocket 20-30 Driven gear bolts 34-40
Cylinder head bolts (cold engine) Engine cooling pump pulley bolts 8-10
Using new parts 63+ loosen all Timing belt upper hood 8-10
bolts Timing belt lower hood 8-10
-7-
Not using new parts +20+90º+90º Safety plug 40-50

Intake manifold support 18-25 Flywheel 130-140
Tension pulley support bolts 23-27 Driving disc 130-140
Automatic tension pulley bolts 20-27 Timing belt right rear hood 10-12
Tension pulley belt pulley bolts 43-55 Timing belt left rear hood (upper) 10-12
Idler bolts 30-42 Connecting rod cap bolts 20+90º
Front exhaust pipe clamping bolts 20-30 Crankshaft bearing cover bolts 25+90º
Engine suspension device
M18 25-30
M10 35-55
Item Nm Item Nm
Air filter mounting bolts 8-10 Oxygen sensor 40-50
Syntonizer mounting bolts (nuts) 8-10 Thermal protector to exhaust manifold bolts 12-15
Throttle valve to intake manifold 15-22 Air filter support bolts 10-13
Intake manifold mounting bolts (M8) 15-20 Exhaust manifold hood/exhaust pipe 12-15
Intake manifold mounting nuts 30-42 connecting bolts
Tensile rod support to tensile rod bolts 35-55 Oxygen sensor to exhaust manifold 40-50
Ignition coil bolts 8-12 Front exhaust pipe support bolts 20-30
Power transistor bolts 10-12 Main silencer lifting lug support bolts 10-20
Front exhaust manifold to cylinder bolts 20-30 Engine oil ruler 12-15
Central exhaust pipe to catalytic converter 30-40 Stud bolts 30-40
nuts Tension device arm assembly 17-26
Central exhaust pipe to main silencer bolts 30-40 Balance shaft bolts 34-40
Central exhaust pipe to support bolts 10-15 Starter motor/cylinder connecting bolts 27-35
Hanging device to engine body bolts 10-15 Radiator fan motor bolts 8-10
Hanging device to main silencer bolts 10-15 Oil transmission pipe to cylinder body 10-13
Exhaust manifold nuts (8) 25-30
Exhaust manifold nuts (10) 35-55
IV. Common troubleshooting

Phenomena Possible causes Correction
Low Cylinder gasket damaged Replace gasket
compression Piston ring worn or damaged Replace piston ring
pressure Worn piston or cylinder Repair or replace piston and/or cylinder
Valve seat worn or damaged Repair or replace valve and/or seat ring
Fall of engine Insufficient engine oil height Check engine oil height
oil pressure Engine oil pressure switch fault Replace engine oil pressure switch
Clogged engine oil filter Replace engine oil filter
Engine oil pump gear or cover worn Replace engine oil pump gear or cover
-8-
Thinning of engine oil Replace engine oil and find cause

Engine oil safety valve failed (open) Repair
Excessive bearing clearance Replace bearing
High engine oil Engine oil safety valve failed (closed) Repair
pressure
Excessive Engine stop baffle loose (front, rear) Re-tighten
engine Propeller shaft mounting shaft loose Re-tighten
vibration Engine mounting support loose Re-tighten
Central mechanism loose Re-tighten
Propeller shaft mounting baffle damaged Replace
Engine mounting guard plate damaged Replace
Engine stop baffle damaged Replace
Phenomena Possible causes Repair

Valve noise Engine oil too thin (low oil pressure) Adjust
Valve stem or guide pipe worn or damaged Replace
Noise of connecting rod and main Insufficient engine oil supply Check oil height
bearing Thin or diluted engine oil Adjust, find cause
Excessive bearing clearance Replace
Noise timing belt Incorrect belt tension (engine tension pulley, Adjust belt tension
timing belt)
Low coolant level Coolant leakage
Radiator core connector damaged Replace
Hose corroded or cracked (radiator/heater hose) Replace
Radiator cover valve or spring faulty Replace
Thermostat faulty Replace
Engine cooling pump faulty Replace
Clogged radiator Foreign matter in coolant Replace
Too high (abnormal) coolant Thermostat faulty Replace
temperature Radiator cover faulty Replace
Cooling system flow not free Replace
Driving belt loose or fallen Adjust or replace
Engine cooling pump faulty Replace
Temperature sensor wire faulty Repair or replace
Fan faulty Repair or replace
Faulty thermal sensor on radiator Replace
Insufficient coolant Add coolant
Too low (abnormal) coolant Thermostat Replace
temperature Temperature sensor line faulty Repair or replace
Leakage in engine oil cooling Loose hose and piping connector Re-tighten
system Hose and piping clogged or damaged Replace
Electric cooling fan not operating Damaged fuse Replace or repair
Gas leakage from exhaust pipe Loose connector Re-tighten
-9-
Piping or silencer damaged Repair or replace

Abnormal noise Baffle plate in silencer broken-away Replace
Rubber hanging device damaged Replace
Piping or silencer in contact with vehicle body Correct
Piping or silencer damaged Repair or replace
V. Special tools
Tool (No. and description) Figure Purpose
Balance shaft bearing puller Removal of balance shaft front
(09212-32000) bearing
Balance shaft bearing puller Removal of balance shaft rear

(09212-32100) bearing
(used along with
09212-32300)
Balance shaft bearing mounting device Mounting of balance shaft

(09212-32200) front/rear bearings
(used along with
09212-32300)
Guide plate Removal & mounting of

(09212-32300) balance shaft rear bearing
(used along with 09212-32100.
09212-32200)
- 10 -
Screw plug wrench Removal and mounting of

(09213-33000) front cover cap plug
Crankshaft front oil seal mounting device Mounting of crankshaft front

(09214-32000) oil seal
(used along with
09214-32100)

Crankshaft front oil seal guide pipe Mounting of crankshaft front
(09214-32100) oil seal
(used along with
09214-32000)
Camshaft oil seal mounting device Mounting of camshaft oil seal

(09221-21000) (used along with
09221-21100)
Camshaft oil seal guide rod Used as guide rod when

(09221-21100) pressing in camshaft oil seal
(used along with
09221-21000)
Cylinder head bolt sleeve Removal and mounting of

(09221-32001) cylinder head bolts
- 11 -
Valve guide pipe mounting device Removal and mounting of

(09222-21200，09222-21200B) front cover cap plug

Valve spring compressor Removal and mounting of
(09222-28000) intake/exhaust valve
Valve spring compressor seat
(09222-28100)
Valve stem oil seal mounting device Mounting of valve stem oil
(09222-28200) seal
Valve guide pipe mounting accessory Mounting of valve guide pipe

(09222-28400)
Crankshaft rear oil seal mounting device 1． Mounting of engine rear

(09231-21000) oil seal
2． Mounting of crankshaft
rear oil seal
- 12 -
Piston pin removal set Removal and mounting of

(09234-33001) piston ring

Insertion plate Removal and mounting of
(09234-33002) piston pin
(used along with
09234-33001)
Cross beam stud bolt sleeve Removal and mounting of

(09624-38100) cross beam stud bolts
09353-38000 For measurement of fuel oil

Fuel oil pressure gauge connector pressure, connect fuel oil
pressure gauge to oil supply
pipeline
- 13 -
09353-24100
Fuel oil pressure gauge and hose
- 14 -
Refine MPV Workshop Manual Engine Mechanism
Section II Engine mechanism
I. Replacement of timing belt
Timing belt upper cover
Timing belt
Generator bracket
20-25
Engine cooling pump
pulley
Timing belt left rear

8-10 cover(lower)
Timing belt left rear
cover(upper)
Driving belt
(A/C, power steering) Shock-absorbing pulley
Balancer axis sprocket
Camshaft sprocket
Tension pulley arm

Tension pulley Crankshaft sprocket “B”
arm Timing belt “B”
Tension pulley “B”
Sensor chip
Idle pulley
Oil pump sprocket
Crankshaft sprocket
Automatic tensioner Special washer
- 14 -
Dismantling:
1. Loosen fixing bolts on engine timing belt
upper hood cover and remove this cover.
2. Remove fixing bolts on crankshaft belt disk and

remove this disk.
3. Loosen fixing bolts on engine timing belt lower hood

cover and remove this cover.
4. Turn engine crankshaft clockwise so that cylinder 1 piston

reaches compression upper dead center; align timing markings.
Note: At this time, timing markings on camshaft sprocket and
cylinder head hood are just aligned and dowel pin of camshaft
sprocket shall be just at upper side.
5. Loosen the two fixing bolts on automatic tensioner and

remove the tensioner.
- 15 -
6. Remove loose timing belt.

Note:
If the time belt will be used again, ensure unchanged
rotational stress direction. An arrow pointing to rotation
direction shall be put on the belt.
7. Remove camshaft timing gear fixing bolts and remove this gear.
8. Loosen the 2 fixing bolts on crankshaft position sensor and

remove this sensor.
9. To remove engine oil pump gear, first remove a sight screw

plug at left side of engine, then insert a screwdriver of about 8mm
dia. for about 60mm to lock left balance shaft.
10. Remove engine oil pump gear fixing bolts and remove this gear.
- 16 -
11. Loosen right balance shaft timing gear fixing bolts and balance
shaft belt tensioner bolts, remove the eccentric tensioner.
12. Remove right balance shaft driving belt and driving gear.
13. Remove crankshaft driving gear and signal disc.
Inspection:
1. Check for abnormal wear, crack, or damage on camshaft gear, crankshaft gear, tensioner and idler; if yes,
timely replace such parts;
2. Check rotation resistance and movement noise of tensioner and idler; if abnormal, timely replace them;
3. In case of oil/grease leakage on tensioner and idler, timely replace them;
4. Check wear of tappet head and damage of tensioner; if serious, timely replace them;
5. Measure exposed length of tensioner tappet; if larger than standard value, replace it;
Standard value: 14.5mm
6. Use bench vice to slowly press the automatic tensioner. If the tappet easily retracts, replace the tensioner.
Shim iron
Warning: Shim iron

Flat washer
Tensioner must be placed on bench vice horizontally.
Pad both ends of tensioner with wood or soft metal to
prevent damage.
- 17 -
Installation:
1. Install timing gear inside crankshaft signal disc.
Rotate crankshaft so that the gear is aligned to timing
mark on cylinder. Ensure cylinder 1 piston at compression
upper dead center.
2. Install right balance shaft gear and align timing marking

on cylinder.
3. Install timing belt and eccentric tensioner; press tensioner

hard with hand and tighten fixing bolts (tightening torque: 15-22Nm).
Note: To install eccentric wheel, face flange forward. When
turning bolt, do not rotate balance shaft; otherwise the belt will
be too tight.
4. Check belt tensioning: When the belt is pressed with finger,

belt deviation shall be 5-7mm; to measure tensioning force by
instrument, standard value is listed in the table below.
Range Pressure Torque
139mm 0.42kg/c ㎡ 50-100Nm
5. Tighten right balance shaft gear fixing bolts.
6. Install crankshaft position sensor signal disc and timing belt gear.
Warning: Do not fit sensor blade in the wrong way; otherwise belt may break accidentally.
7. Install crankshaft timing gear retainer block and bolts; tighten the bolts (to 110-130Nm).
- 18 -
8. Install crankshaft position sensor and tighten 2

fixing bolts.
9. Install camshaft belt gear, align timing mark on cylinder

head hood, and tighten bolts (to 80-100Nm).
Note: At this time, camshaft gear dowel pin is just above.
10. Install engine oil pump driving gear and align timing.
Use a screwdriver to lock balance shaft from sight hole, and
tighten driving gear bolts (to 50-60Nm).
11. Use bench vice to slowly press automatic tensioner till hole
on housing is aligned with hole on plunger. Insert pin to lock.
Fit tensioner on body (torque: 20-27Nm).
12. According to belt operation direction, wind belt on timing

gear and tensioner counterclockwise in the sequence: crankshaft
timing gear-engine oil pump gear-idler-exhaust camshaft gear-gas
intake camshaft gear- tensioner.
13. Remove the pin in automatic tensioner, take out the screw driver
in balance shaft sight hole, and fit screw plug (apply sealant:
THREE BOND NO.121B).
- 19 -
14. Rotate crankshaft for a number of turns. Check alignment of timing markings. Measure extended distance of
top of automatic tensioner mandrel.
Standard value: 5.5-9mm
15. Install timing belt lower cover and upper cover. Tighten bolts (torque for A: 10-12N; torque for B: 8-10N).
II. Oil tray and centralized filter
Removal:
1. Open engine oil filling port cover, loosen oil drain bolt on oil tray, and drain engine oil.
2. Remove 19 fixing bolts on oil tray in the sequence shown.
Note: Bolts can be long or short.
3. Remove 2 fixing bolts on the centralized filter; remove the filter.
- 20 -
4. Remove 4 fixing bolts on engine oil guide plate;

remove this guide plate.
Installation:
1. Clean to remove glue-like residue on oil tray jointing
surfaces; install engine oil baffle plate and centralized filter.
2. Apply sealant in the groove at edge of oil tray. According
to the sequence shown in the figure, install and tighten oil tray
fixing bolts (tightening torque: 10-12Nm).
Note: Sealant thickness shall be 4mm. Install the oil tray
within 15min after application of sealant.
III. Engine oil pump and balance shaft

Front bearing
Rear bearing
Right balance shaft
Gasket
Left balance shaft
20-27 Front
cover Driving
gear
15-18
Oil pump cover
Driven gear bolt
Driven gear Upper end of oil pan
34-40 Gasket
O-ring
Oil strainer
10-12
Oil filter
Plug cover Lower end of oil pan
20-27
Washer
15-22
Oil drain plug

Torque: Nm
35-45
- 21 -
Removal:
1. Rotate engine to cylinder 1 piston upper dead
center and remove engine timing belt.
2. Remove balance shaft sight hole at left side of
engine, insert a screw driver of about 8mm dia. for
about 60mm to lock left balance shaft.
Screwdriver
Plug
3. Loosen engine oil pump gear fixing bolts and

remove this gear.
4. Use special tool to remove left balance shaft outer

blocking cover on engine oil pump assembly housing,
remove fixing bolts from left balance shaft to engine oil
pump driven gear.
5. Remove right balance shaft fixing bolts, the eccentric

tensioner, driving belt, and right balance shaft gear and shaft
sleeve.
6. Drain engine oil and remove oil tray.
7. Remove engine oil pump assembly fixing bolts.
8. Remove engine oil pump assembly housing/seal pad.
- 22 -
9. Take out 2 balance shafts (left and right)
10. Remove fixing bolts on engine oil pump housing,

engine oil pump cover and engine oil pump gear.
Inspection:
1. Check for clogging of all oil holes on engine oil pump
house; clean these holes when necessary;
2. Check balance shaft front shaft sleeve for wear, damage
and blocking/biting of balance shaft;
3. Check engine oil pump housing for crack or other damage;
if yes, replace it;
4. Check oil seals for wear, damage or aging; if yes, make
replacement;
5. Fit engine oil pump gear in this pump. Under close mating
condition, rotate gear to see if it rotates freely. Check that there
is no channel like wear on jointing surface between oil pump housing
and engine oil pump cover gear faces.
Fit oil pump driving gear and driven gear in engine oil pump housing.
Measure crest clearance of gears.
Reference value: Driving gear: 0.16-0.21mm

Driven gear: 0.18-0.21mm
Limit value: Driving gear: 0.25mm
Driven gear: 0.25mm
6. Check end clearance of engine oil pump gear
Reference value: Driving gear: 0.08-0.14mm

Driven gear: 0.06-0.12mm
Limit value: Driving gear: 0.25mm
Driven gear: 0.25mm
- 23 -
Replacement of balance shaft sleeve:

1. Use special tool to remove right balance shaft
front shaft sleeve from cylinder body.
Front bearing
2. Use special tool to remove right balance shaft rear

shaft sleeve from cylinder body. Rear bearing
3. Use special tool to remove left balance shaft rear shaft Rear bearing
sleeve from cylinder body. At this time, use special tool to
fix shaft sleeve removing device at front end of cylinder.
4. Use special tool to fit left balance shaft rear shaft sleeve on cylinder.
Note: There is no oil hole on left balance shaft rear shaft sleeve.
For installation, apply engine oil on rear shaft sleeve outer
surface and surface of shaft sleeve mounting hole on cylinder
body.
Rear bearing
- 24 -
5. Use special tool to fit right balance shaft sleeve on cylinder body.
Note:
To determine alignment of oil holes on shaft sleeve with oil
holes on cylinder body, apply engine oil on outer surface of
shaft sleeve.
5. Use special tool to fit right balance shaft front shaft

sleeve on cylinder body.
Note:
Determine oil hole alignment on shaft sleeve/cylinder body.
Bearing
Cylinder body
Installation:
1. Apply engine oil on engine oil pump gear and align 2

timing markings.
- 25 -
2. Fit engine oil pump housing on engine oil pump housing assembly with bolts.
3. Install left and right balance shafts to their positions.

4. Use special tool, i.e. crankshaft front oil seal mounting device
(09214-32000) to install crankshaft front oil seal into engine oil
pump housing assembly.
Oil seal Front cover
5. Place special tool (09214-32100) at front end of crankshaft and

apply a thin layer of engine oil on outer surface of this tool to
facilitate mounting of engine oil pump housing. Fit a new engine
oil pump housing sealing gasket on the housing assembly and
tighten all bolts to set torque (20-27Nm).
6. Install fixing nut from left balance shaft to engine oil pump,
screw in blocking piece and use special tool for tightening.
7. Insert a screwdriver into bolt hole at left side of cylinder, and
then check if the balance shaft is at correct position. Later, install
engine oil pump driving gear pulley, replace and tighten fixing bolts.
- 26 -
8. Install right balance shaft driving gear, eccentric wheel,

and crankshaft inner timing gear; align timing markings;
install right balance shaft timing belt; press eccentric wheel
tensioning belt; tighten fixing bolts.
9. Align timing markings and install timing belt; withdrawal
screwdriver from cylinder side, and install bolts with sealant
applied.
IV. Cylinder head assembly

Rocker arm central hood
8-10
Breathing
19-21 Rear bearing cover
Intake camshaft CPS crankshaft position sensor

Front bearing cover
Gear shaft oil seal

Support
Exhaust camshaft
Sensor column
80-100
Rocker arm hydraulic gap adjuster
Camshaft sprocket
80-100
Oil supply valve
- 27 -
Removal:
1. Remove cylinder head hood fixing bolts and remove this hood.
2. Remove ignition coil and HV line.
3. Remove cylinder head hood fixing bolts, cylinder head

hood and sealing gasket.
4. Remove timing belt hood cover and timing belt.
5. Use special tool (09221-32001) to remove cylinder head Camshaft pulley side
bolts in the following sequence.
6. Carefully put down cylinder head assembly and remove
cylinder gasket.
- 28 -
Inspection:
1. Carefully check for crack, damage or water leakage in
cylinder head; if a crack is found, replace cylinder head assembly;
2. Completely remove sundries, sealing residue and accumulated
carbon; clear oil path and then use compressed air to ensure no
clogging of oil path.
3. Check planeness of cylinder head surface. If this planeness

exceeds maintenance limit, replace cylinder head or carry out
precision processing of this surface.
Cylinder head planeness:
Standard tolerance— — less than 0.05mm
Maintenance limit— — 0.2mm
4. Check cylinder gasket for ablation, cylinder score and damage

etc.; if any, carry out replacement.
Note: Use original manufacturer cylinder gasket for replacement;
otherwise fault such as incorrect compression ratio may occur.
Installation:
1. Face marked side of gasket toward cylinder head;
2. Carefully align cylinder head to dowel pin on cylinder and install it;
3. According to sequence shown, tighten cylinder head bolts to specified torque.
Tightening torque:
Camshaft pulley side
For used bolts: 20Nm+90°+90°
For new bolts: 63Nm+ loosen +20Nm+90°+90°
- 29 -
V. Valve mechanism
0
With new parts: 63+released+20+90 +900
Without new parts: 20+900+900
Cylinder cover bolt Lock blade

Valve spring base
Washer Valve tappet sealing member
Lock blade
Valve spring
Valve spring base
Valve tappet sealing member Valve spring base
Valve spring Inlet valve pipe
Valve spring base
Exhaust valve pipe
Cylinder head
Intake valve seat ring Exhaust valve seat ring
Intake valve Exhaust valve
Cylinder head washer
Cylinder block
Torque: Nm
Removal:
1. Use a wrench to lock hexagonal fixing part of camshaft, use another wrench to remove camshaft sprocket
fixing bolts, and remove camshaft sprocket.
- 30 -
2. Loosen camshaft bearing cover tightening bolts, remove

camshaft bearing cover, camshaft, rocker arm and valve clearance
adjuster, and then place them in correct sequence and direction.
3. Use special tool press down valve spring seat, and remove valve
lock piece; do not press compression spring too hard, just press to the
extent that the lock piece can slide out of groove; otherwise valve stem
may bend.
4. If valve lock piece cannot come out when the spring is pressed,
remove compression tool and place a suitable pipe on spring seat so
that valve lock piece will not be hit. Place a piece of wood at head of
the valve (facing combustion chamber side of cylinder head toward
work table). Then use a hammer to tap end of the pipe.
5. Put on special compression tool again to compress valve spring;
it shall be possible to take out the lock piece. After taking out the lock
piece, slowly loosen bolts and remove the compression tool.
6. Remove valve spring seat, valve spring, valve (from under).
7. Place each set of valve, valve lock piece, valve spring and
spring seat in a plastic bag, and number them to facilitate reassembling Cylinder 1
according to original cylinder position.
- 31 -
8. Use pliers to remove valve oil seal.
Note: Valve oil seal must not be re-used.
Inspection:
1. Valve
Use hair brush to clean valve. Check wear and deform of B
end of each valve. If necessary, carry out replacement.
Damaged A end shall also be repaired.
Replace valve if shown dimension exceeds limit.
Standard values
Intake valve: 1.0mm
Exhaust valve: 1.5mm
Margin
Maintenance limits
Intake valve: 0.7mm
Nonperpendicularity
2. Valve spring
Check free height of each valve spring; replace if necessary.
Use a ruler to measure perpendicularity of each valve spring;
replace if perpendicularity range is exceeded.
Standard values Free height
Free length: 45.82mm
Loading: 25.3kg/40mm
Perpendicularity deviation: 1.5°or less.
Maintenance limits
Free length: 44.82mm
Perpendicularity deviation: 4°
3. Valve guide pipe

Check gap between valve stem and valve guide pipe; if limit is
exceeded, replace with new enlarged guide pipe. Valve
Gap between valve stem and valve guide pipe guide bar
Standard values
Bar dia.
Intake valve: 0.020-0.047mm
Guide pipe ID
Exhaust valve: 0.050-0.085mm
Maintenance limits
Intake valve: 0.1mm
- 32 -
Repair of valve seat ring:

1. Through calibration, check wear of valve guide pipe; replace
worn guide pipe and then correct seat ring.
Miller
2. Use valve seat guide bar and reamer to correct valve seat.
Guide bar
3. After correction, use grinding paste to carefully grind valve
Exhaust Intake
and valve seat.
Seat ring replacement:

1. Cut valve seat from inside to reach replaced dimension
(thinner wall); then replace valve seat ring.
2. Again bore valve seat hole on cylinder head to reach
enlarged valve seat diameter.
New hole
3. Prevent falling before matching valve seat, or heating
cylinder head to nearly 250℃ or cooling valve seat by liquid Old hole
Cut
nitrogen.
Valve guide pipe replacement

1. Use special tool to press existing guide pipe out through
bottom of cylinder head.
2. Grind new guide pipe to match valve. Cylinder head
Valve guide
pipe
3. Use special tool to press in valve guide pipe. Pressing of

Intake guide pipe Exhaust guide pipe
valve guide pipe must start from top of cylinder head. Note that
guide pipe length is different for intake valve and exhaust valve.
4. After pressing and fitting of valve guide pipe, fit the valve.
Check for smooth movement.
- 33 -
Installation:
1. Clean each part; oil rotating/moving parts;
2. Use special tool to press new valve oil seal to
specified position.
Valve stem
Sealing
member
Valve spring base

Note:
After dismantling, valve oil seal must be replaced. If
installation of valve oil seal is wrong, adverse effect will Vitreous enamel Spring seat
coating side
occur on oil seal lip and eccentricity, resulting in engine
oil leaking into valve guide pipe.
3. Apply engine oil on each valve, insert valve into guide Valve stem
Spring
pipe, and insert valve into valve oil seal (not too hard). After Sealing
insertion, check if valve can move smoothly. member
4. To install valve spring, face the end with paint toward

Spring
valve spring upper seat.
seat
5. Use special tool or other suitable tool to compress

spring and fit lock piece. After installation of valve, confirm
that installation of lock piece is correct.
6. Clean sealing surface connecting cylinder body and
cylinder head.
7. Check cylinder gasket marking and face the side with
Marking toward cylinder head for installation.
8. Tighten cylinder head tightening bolts according to

shown sequence. Camshaft pulley side
- 34 -
VI. Crankshaft link mechanism and cylinder body

130-140
Flywheel
Rear plate
Oil seal cover Oil seal
Belt hood cover
10-12
130-140
Crankshaft lining
Upper bushing
Thrust bearing
Crankshaft
Connecting disc Drive disc
Lower bushing
Thrust bearing
Bearing cover
25
25
Removal:
1. Remove engine timing system, cylinder head part, oil tray part, flywheel, front cover and engine oil pump
assembly part.
2. Remove rear baffle and rear oil seal.
3. Remove piston crank large head cover bolts and piston crank large head bearing cover, and push piston out
from top of cylinder.
- 35 -
Note:
Make markings on piston crank bearing cover so that correct position and direction can be ensured in
re-installation. To push piston crank, never use hard steel object to tap piston crank bearing (to avoid
damage and deform).
4. According to proper sequence, loosen and remove crankshaft
main bearing cover bolts, remove main bearing cover and crankshaft,
and place bushings in proper sequence according to numbering.
Inspection:
1. Crankshaft
Check damage, uneven wear and crack of crankshaft main
journal and connecting rod journal. Also check oil holes.
Check chamfer and OD of crankshaft journal.
Standard values:
Main journal OD: 56.98— 257.000mm
Connecting rod shaft OD: 44.980— 45.000mm
2. Main bearing and connecting rod bearing

Carefully check each bushing for peeling, fusion, pull and
improper contact; replace if yes.
Measurement of oil film gap
Oil film gap is obtained by comparison of measured crankshaft
main journal OD and main bushing OD.
Standard values:
Crankshaft 1st, 2nd, 4th, 5th main bushing: 0.018— 0.036mm
Crankshaft 3rd main journal: 0.024— 0.042mm
Connecting rod bushing: 0.015— 0.048mm
Limit value: 0.1mm
Use of plastic gauge

Normally, we can also use plastic gauge to measure oil film gap. First clean to remove engine oil, grease and other
impurities on bushing and main journal. Place plastic gauge of the same width as that of main bushing so that it is
parallel to journal (avoid engine oil hole). Fit crankshaft, main bushing and main bearing cover, ands tighten to
specified torque. In this process, do not rotate the crankshaft. Remove main bearing cover and at the widest place,
measure the width according to the trace on plastic gauge. If measured oil film gap exceeds the limit value,
replace bushing or select bushing of smaller size. To install a new crankshaft, make sure to use bushing of
standard size. If after replacement of bushing, standard oil film gap cannot be obtained, grind main journal and
connecting rod journal to reduce the size. Also, select bushing of corresponding size.
- 36 -
3. Oil seal
Check front and rear oil seals for damage (including damage
of surface); replace if yes.
4. Main bearing cover
After fitting main bearing cover, ensure smooth rotation of
crankshaft and correct axial clearance. If axial clearance exceeds
limit value, replace bushing.
Standard value: 0.05— 0.25mm
5. Flywheel
Check for damage or wear of contact surface between flywheel
and clutch disc; replace flywheel if this damage or wear is serious.
Separation gap on contact surface between flywheel and clutch:
Limit value: 0.13mm.
Check flywheel tooth ring for damage, crack and wear; replace
tooth ring is necessary.
6. Cylinder body
— — Check cylinder hole for scratch, rust and corrosion;
— — Use cylinder gauge to measure cylinder hole at A and B
Position 1: 1st gas ring position
Position 2: cylinder hole center position
Position 3: cylinder hole bottom end position
If cylindrical degree requirement for cylinder hole is exceeded,

or cylinder wall has been seriously worn or scratched, boring and
grinding of cylinder hole shall be carried out again, and then
enlarged piston and piston ring shall be installed.
Standard value:
Cylinder hole: 86.5+0.03mm
Cylinder hole cylindrical degree: max. 0.01mm
— — Use lathe to remove any bulging on cylinder surface
— — Piston operating size and marking, mm
Sameness marking: 0.50
Size: 0.50 0. S.
— — Bore and expand cylinder hole again. Ensure specific Measurement point
oil gap between enlarged piston and cylinder hole. Also
ensure the same increment of all pistons used. Standard
measurement method for piston OD is to measure the diameter
at 2mm above end of piston apron.
Oil gap between piston and cylinder hole: 0.02— 0.04mm.
- 37 -
— — Check planeness of top surface. If limit value is exceeded,

process to min. limit or replace.
Standard value: max. planeness is 0.05mm.
Limit value: top surface planeness is 0.1mm.
Note:
To install cylinder cover, wear <0.2mm is permitted.
— — Boring of cylinder hole
Enlarged piston to be selected as per max. cylinder hole (datum)
Sameness marking: 0.50
Size: 0.50mm
Note: Piston size is inscribed on piston top.

Measure OD of piston used and then calculate size of new cylinder hole. New cylinder hole size=piston OD
+0.02~0.04mm (oil gap between piston and cylinder hole)-0.02 (grinding margin)
Note:
To prevent deform of cylinder hole due to temperature rise, drill, bore and grind cylinder hole according to
ignition sequence.
Check oil gap between piston and cylinder hole.
Note: To drill cylinder body, the 4 cylinders must be processed at the same time and not just one.
Without slot With slot
Lower bearing Without slot

Upper bearing
bush
bush
Thrust bearing (central)

Installation:
1. At body side, fit a main bushing with groove (upper bushing)
2. At main bearing side, fit a main bushing w/o groove (lower bushing)
3. Fit thrust piece.
4. Apply grease on main journal and connecting rod journal, then fit crankshaft.
5. Install main bearing cover; ensure arrow pointing to engine front end. Number on cover must be correct.
6. Tighten main bearing cover bolts to specified torque (25Nm+90°).
7. Rotate crankshaft to ensure free rotation of crankshaft; check crankshaft axial clearance.
8. Use special tool to fit new oil seal into oil seal holder.
Note: After dismantling, oil seal must be replaced (with a new one). To install oil seal in oil seal holder,
ensure facing oil hole in oil seal downward.
9. Fit new oil seal holder gasket and the holder (tightening torque: 10— 12Nm).
10. Fit rear baffle on cylinder body. Fit flywheel assembly and tighten flywheel bolts to specified torque
(130-140).
- 38 -
VII. Piston crank
No.1 piston ring

No.2 piston ring
Oil ring
Piston
Piston pin
Bolt
Connecting rod
Upper bearing bush
Lower bearing bush
Connecting rod bearing cap
20
Plastic locknut
Torque: Nm
Removal:
Detacher
1. Remove fixing bolts from connecting rod large head
cover to crankshaft, remove bushings and place them
Support
according to proper sequence and directions. bracket
2. Push connecting rod to remove piston fro upper part
Support
of cylinder, remove upper bushing and place according to fork
proper sequence and direction.
3. Place connecting rod bearing cover and connecting
rod according to proper sequence and direction.
4. Use special tool to press out piston pin.
5. Use piston ring caliper to remove piston ring.
Inspection:
1. Piston and piston pin
Check for scratch, wear and other defect on each piston; replace if any (piston ring shall be replaced along with
piston).
Check assembling of piston pin inside pin hole. Under room temperature, it must be possible to push piston pin in
pin hole smoothly by hand.
- 39 -
2. Measurement of piston ring lateral clearance

As shown in the figure, measure piton ring lateral clearance.
If measured value exceeds limit value, replace piston ring with
a new one and then measure lateral clearance again. If limit
value is still exceeded, replace piston and piston ring along with.
If lateral clearance is smaller than limit value, just replace the
piston ring.
Standard value of piston ring lateral clearance:
No.1 piston ring: 0.03— 0.07mm
No.2 piston ring: 0.02— 0.06mm
Oil ring: 0.06— 0.15mm
Press the ring
downward with
3. Piston ring opening clearance piston
Place piston ring in cylinder hole and lightly press piston
downward to push the piston ring to its correct position.
Use a gauge to measure opening clearance. If limit value
of this clearance is exceeded, replace piston ring.
Standard value of piston ring opening clearance:
No.1 piston ring: 0.25— 0.35 mm
End clearance
No.2 piston ring: 0.40— 0.55 mm
Oil ring sheeting ring: 0.10— 0.40mm
Piston ring opening clearance limit value:
No.2 piston ring: 0.8mm
Oil ring sheet ring: 1.0mm
Inner chamfer type
4. Connecting rod
Check wear of connecting rod; replace if mounting surface is
damaged. Lower tangent type
Installation:
1. Fit lining ring of piston oil ring;
2. Fit upper and lower sheet ring of piston oil ring.
Note: No.1 ring
Upper blade opening
opening
To install upper sheet ring, first place one end between piston ring
groove and lining ring, then use finger to press down a part of
Engine front
sheet ring so that it can be fitted in ring groove as shown. To install
sheet ring, do not use piston ring tensioner. Use above method to fit No.2 ring opening Lower blade
and expander opening
lower sheet ring. opening
3. Apply lubricant around piston and piston ring, then use piston ring
tensioner to fit No.2 piston ring and No.1 piston ring.
Note:
To fit piston ring, keep its opening away from opening of nearby
piston ring as much as possible. Ensure that openings are not on the
same side, nor on the direction of piston pin.
- 40 -
3. Use special tool to install piston pin, connecting rod

and piston together (note front/rear direction).
4. Use piston ring compression device to press piston
ring; fit piston and piston ring in the body.
5. Ensure that ID forward markings on piston and
connecting rod point to engine front end.
6. To install connecting rod large head cover, ensure that Cylinder
markings on connecting rod and large head cover are on
Cut
the same side. Tighten connecting rod nut (to 20Nm+90°).
7. Check connecting rod lateral clearance. Standard value:
0.10-0.25mm; limit value: 0.4 mm.
VIII. Cooling fan and water pump
Generator V-belt
Fan clutch
Water pump pulley
A/C compressor V-belt (vehicle with A/C)
Cooling fan
- 41 -
Removal:
1. Drain engine cooling water and dismantle cooling
Water pump
water pump inlet pipe.
pulley
2. Loosen fixing bolts on engine cooling fan and fan
clutch, remove this fan and this clutch.
Generator
3. Loosen generator fixing bolts and adjusting bolts, Crankshaft
pulley
push generator inward to loosen driving belt, and remove pulley
the driving belt.
4. Remove water pump belt pulley bolts and this pulley.
5. Remove generator support and automatic tensioner wheel.
6. Remove water pump housing fixing bolts and the water
pump.
Inspection:
1. Check belt for crack, aging and damage.
2. Check fan blades for damage and crack.
3. Check for crack or damage on fan center shaft hub bolt
holes.
4. Check water pump for crack, wear and damage; replace
water pump parts if necessary.
5. Check water pump bearing for damage, abnormal noise
and sluggish rotation; replace water pump parts if necessary.
6. Check seals for leakage; replace water pump parts if necessary.
7. Check engine cooling water for leakage; replace water pump
seals if leaking.
Installation:
1. Clear engine cooling water pump body and cylinder sealing
gasket surface.
2. Fit new “O”seal ring in the groove at front end edge of engine
Cooling fan
cooling water pipe, and wet it with water (oil or grease must not
be used) Fan clutch
3. Install a new engine cooling water pump seal gasket and a new
engine cooling water pump part; tighten bolts to specified torque
(20— 27Nm).
4. Install timing belt and timing belt hood cover.
5. Install engine cooling water pump pulley and drive belt; pull
generator support tight.
6. Install engine cooling fan and clutch.
- 42 -
IX. Dismantling of air intake system
Spacer Fuel supply line
10-13
Fuel pressure
regulator
Fuel injector
Gasket
15-22
Pressure stabilizing
chamber
Intake manifold
absolute pressure &
intake temperature
sensor
Power transistor
10-12
Idle actuator
Throttle body Intake manifold
Torque:
扭矩 Nm
Dismantling:
1. Remove air filter, intake hose, vacuum pipe, throttle valve.
- 43 -
2. Remove acceleration pedal pull wire.
3. Remove oil injection nozzle harness and water

pipe pressing bolts on intake manifold.
4. Loosen 2 oil rail pressing bolts, remove harness support,

and pull oil rail and oil injector assembly outward.
Note:
During removal and installation, use care to prevent fall of nozzle
washer; replace this washer after dismantling.
5. Rotate and pull out oil injector from oil rail.
Note: Use new oil injector seal rubber ring for installation.
6. Loosen fixing bolts connecting air intake manifold assembly to

cylinder body. Remove air intake manifold assembly and gasket.
Inspection:
1. Check nozzle for carbon accumulation, sintering and coke;
clean or replace nozzle if any.
2. Check air intake manifold for crack and leakage.
3. Check air intake manifold gasket for damage; replace if any.
Installation:
Installation sequence is the revere of dismantling sequence.
- 44 -
X. Dismantling of exhaust system
Heat shield Locknut 25-30
Exhaust manifold
Exhaust manifold
gasket
25-35
Heat shield
Oxygen sensor
12-15
Front exhaust pipe
30-40
Torque: Nm
Dismantling:
1. Loosen 3 fixing bolts on exhaust manifold protective hood,
remove the hood.
2. Loosen 3 fixing bolts from front exhaust pipe
to front contact agent, remove front exhaust pipe.
3. Disconnect harness plugs of front and rear oxygen sensor.
4. Loosen fixing bolts from exhaust manifold to cylinder body,
remove this manifold and its gasket.
Installation:
Sequence of installation is the reverse of sequence of dismantling.
XI. Engine and transmission assembly

- 45 -
Dismantling:
1. Remove accessories, harness connectors and pipelines
around engine.
2. Drain coolant and engine oil from engine and disconnect

cooling system pipeline at AC compressor.
3. Place support legs and lift the vehicle to suitable height with lifter.
4. Place engine support below the vehicle.
5. Remove bolts on connectors from stabilizing bar to lower swing arm.
6. Remove 4 fixing bolts from engine support cross beam to chassis.
- 46 -
7. Remove transmission shifting lever, clutch slave cylinder,

backing light switch connector, and speed sensor connector.
8. Remove 4 fixing bolts from transmission support cross beam to chassis.
9. Remove lower swing arm connecting bolt assembly and put

down engine and transmission assembly.
Installation:
Install engine and transmission assembly according to reverse
sequence of dismantling of this assembly.
- 47 -
Refine MPV Workshop Manual Hyundri Control System
Section III Engine Control System (Hyundri)

I. General
1. Brief introduction to the system
Multi-point fuel injection system consists of sensors detecting engine operating conditions, power control module
(PCM) that controls the system according to signals given by these sensors, and actuators under the control by
PCM.
PCM performs various functions such as fuel injection control, idling air intake control and ignition timing control
Besides, PCM is also provided with some diagnosis and testing modes, so that in case of a problem,
troubleshooting is simplified.
Fuel injection control

Number of oil injections and injection timing of oil injectors are controlled so that optimum air/fuel mixture is
obtained for ever changing engine operating status. At air intake of each cylinder, an oil injector is fitted. Under
the action of pressure, fuel is delivered by fuel pump to oil injectors. Pressure of the fuel pump is controlled by
fuel pressure regulator. Regulated fuel is distributed to each oil injector. This is what multi-point injection means.
When the engine is in cold state or operating under high load, to maintain engine performance, PCM provides
thick air/fuel mixture by executing “open loop”control. Besides, when the engine is at the state of mechanical
equivalent of heat, or in normal operating conditions, PCM executes “closed loop”control of air/fuel mixture by
means of signals from heating type oxygen sensors, so as to obtain theoretical air/fuel mixing ratio and optimum
discharge effect through 3-element catalysis.
Fuel injection
pulse
Cylinder
Cylinder
Cylinder
Cylinder
Cylinder
Cylinder
Cylinder
Cylinder
One engine cycle One engine cycle
Simultaneous multi-point injection system
Sequential multi-point injection system
Idling speed control

During idling, optimum rotation speed is maintained by controlling air flow through throttle valve according to
idling state and change of engine load. According to engine coolant temperature and air conditioning load, PCM
drives idling speed control (ISC) motor to maintain engine operation at preset objective idling speed. Besides,
throttle valve air flow will be regulated according to engine load, so as to avoid fluctuation of engine rotation
speed.
Ignition timing control
Ignition power transistor is installed in ignition primary loop. Primary current flowing into ignition coil is
controlled by opening and closing of this transistor. This transistor controls ignition timing and obtains optimum
ignition timing according to engine operating status. Ignition timing is determined by PCM according to engine
rotation speed, amount of air intake, engine coolant temperature and atmospheric pressure.
- 48 -
Injection pulse
Engine speed (rpm)
Other control functions
1) Fuel pump control: When the engine starts or during engine operation, fuel pump relay will close to supply
current to fuel pump.
2) Air conditioning compressor clutch relay control: open or close AC compressor clutch.
3) Fan relay control: speed of radiator fan and condenser fan will be controlled according to engine coolant
temperature and vehicle speed.
4) Control of evaporation exhaust purification.
2. General specification of operating elements

Item Size/Parameter
Type Rheostat
Throttle position sensor (TPS) Resistance at limit idling 3.5-6.5kΩ
Throttle
Output voltage at limit idling 300-900 mV
valve
Type Dual coil
Idling speed control (ISC) actuator
Resistor 90-100Hz
Mass air flow (MAF) sensor Type Thermal film sensor
Type Thermistor
Intake air temperature (IAT) sensor
Resistor 2.33-2.97kΩ (20℃)
Type Thermistor
Engine coolant temperature (ECT)
Resistor 2.5kΩ20℃
sensor
Sensor 0.3kΩ80℃
Heating type oxygen sensor Type Zirconium oxide
(HO2S)
Vehicle speed sensor (VSS) Type Hall effect
Camshaft position (CMP) sensor Type Hall effect
Crankshaft position (CKP) sensor Type EM type
Type Electronic magnetic
Oil injector
valve type
Actuator
Quantity 4 pieces
Resistor 13-16Ω (20℃)
- 49 -
Evaporation exhaust purification Type Operating cycling type
control EM valve
Fuel pressure 300±1.5 kPa
Pressure regulator Pressure
regulator (3.35±0.06kg/cm²)
Fuel tank capacity 65L
Fuel tank
Return oil system Provided
Carbon tank Volume/nominal operating capacity 3.0L/150g
3. Standard data
Item Standard value
Basic ignition timing At limit idling speed: BTDC 8º±5º
Basic ignition timing
Ignition timing grounding At limit idling speed: BTDC 5º±5º
D－range (auto transmission) 700±100rpm
Limit idling speed P, N－range (auto transmission, manual 750±100rpm (air conditioning off)
transmission) 900±100rpm (air conditioning on)
Vacuum hose disconnected At limit idling speed: 330－350 kPa
Fuel pressure
Vacuum hose connected At limit idling speed: about 270 kPa
Evaporation carbon tank purification control EM valve resistance 20-32Ω
4. Tightening torque
Item N·
m
Oil supply pipe mounting bolts 10-15
Engine coolant temperature sensor 20-40
Heating type oxygen sensor 40-50
Heating type oxygen sensor connector support bolts 8-12
Fuel pressure regulator mounting bolts 4-6
HP hose with fuel main pipeline 30-40
HP hose with fuel filter 25-35
HP hose to fuel supply pipe 3-4
Fuel pump assembly to fuel tank 2-3
HP hose on fuel tank 30-40
Throttle valveto purification tank 15-20
Throttle valve arm support bolts 8-12
Idling speed control actuator 6-8
Fuel delivery to fuel tank 2-3
- 50 -
II. Common troubleshooting
1. Basic inspections of engine

For engine troubleshooting, a very important point is inspection of basic systems of engine. In case of any of the
following: engine cannot start, idling speed is not stable, or speed cannot be increased, check the following basic
systems:
1) Power supply
a) Batteries b) Fuse (line) c) Fuse
2) Engine body grounding
3) Fuel supply
a) Fuel pipeline b) Fuel filter c) Fuel pump
4) Ignition system
a) Spark plug b) HV cable c) Ignition coil
5) Emission control system
a) PCV system (positive crankcase ventilation) b) Vacuum leakage
6) Other
a) Ignition timing b) Idling speed
Common fault of MFI (multi-point fuel injection) system is poor connection of harness connectors. It is very
important to check all harness connectors and confirm tight connection.
2. Table of common troubleshooting guide for engine
Note: Numbers in the following table show sequence numbers of inspections.
Main fault Starting Poor
Poor idling speed
Failed start Difficult start running
combustion not complete
Engine surging or poor

Engine cannot reverse
Incorrect fast idling

Ejgine running but
Engine cannot tur
High idling speed
Secondary
Poor idling speed
Low idling speed
With engine cold
Engine reversing
With engine hot
acceleratoin
fault
Knocking
Instable
Always
Inspection point
Starter relay 1
Starter 2 2 1
Parking/neutral switch (auto 3
transmission) or clutch starting
switch (manual transmission)
Flywheel (manual transmission) 4 3
or drive board (auto transmission)
Mass air flow sensor circuit 4 3 10 7
Idling control actuator 5 3 3 3 3 3 2 7 2
Fuel pressure regulator 6 5 5 5 4 11 1
Engine coolant temperature 7 4 1 1 2 2 1 2 8 6
sensor circuit
Compression 8 8 8 5
- 51 -
Piston ring 9 9
Ignition timing 10 11 14
Timing marking 9 12
Oil injector 10 13 8 8 7 4 13 15 4
PCM (power control module) 11 14 9 9 4 8 5 14 16 5
Air conditioning circuit 2 6
Connecting rod bearing 3
Crankshaft bearing 4
Fuel mass 1 2 2 1 3 3
Spark plug 2 3 4 2
Fuel pump 6 6 6 5 12
Fuel pipeline 7 7 7 6 13
Ignition circuit 2 11 3
Air intake temperature sensor 12 4 4 1 4 9 1
circuit
Throttle pedal wire 1
TP (throttle position) sensor 5 6
circuit
Cylinder head 15
Clutch (manual transmission) 1
Brake cannot separate correctly 2
Oxygen sensor circuit 10
Crankshaft position sensor
Battery voltage
Main fault Engine stop Other Oil

filling
Secondary fault
After step-down
of throttle pedal
Excesive fuel
After release of
Diffcult filling;
consumption
overflow/back
throttle pedal
Engine too
Soon after
During AC
overheat
operation
injection
Engine
startup
Inspection point
cold
Fuel mass 1
Fuel pressure regulator 2 4 2
Fuel pump 3
Fuel pipeline 4 5
ISC actuator 5 1 2
MAF sensor circuit 6 1 2 13
Engine coolant temperature sensor 7 11
circuit
Oil injector 8 6 10
ECM 9 7 3 3 17
TP sensor circuit 2 12
Spark plug 6 8
Air conditioning circuit 14
Fuel leakage 1 1
Acceleration pedal wire 3
Clutch (manual transmission) 4
Brake in action when pedal is 5
released
Compression 7
- 52 -
Piston ring 8
Ignition timing 9
Oxygen sensor circuit 15
Air intake temperature sensor 16
circuit
Coolant leakage 1
Cooling fan 2
Temperature switch 3
Radiator and radiator cover 4
Thermostat 5
Timing belt 6
Engine cooling pump 7
Engine oil pump 9
Cylinder head 10
Engine body 11
Engine coolant temperature 12 3
transducer
Crankshaft position sensor 11 8 4 4
Filling port valve hose－clogging 1
Carbon tank filter net－pollution 2
Fuel cutoff valve－operating 3
3. Engine common troubleshooting procedure
Communication with detection tool not possible
Measure battery voltage at data Check harness between power supply and
Abnormal
connection connectors (voltage between dataconnection connectors; repair if
pin 16 and ground) required
Normal
Check harness between data

Abnormal
Measure data connection connectors connection connectors and ground
●Conduction between pin 4 and ground wire; repair if required
●Conduction between pin 5 and ground
Normal
Use another detection tool Abnormal Data connection connector or wire

faulty
Normal
Repair detection tool
Connection between detection tool and PCM failed

Comment Possible reason
- 53 -
Possibly due to one of the following ● PCM power supply circuit faulty
● PCM not powered up ● PCM faulty
● PCM ground circuit faulty ● Circuit between PCM and DLC disconnected
● PCM faulty
● PCM/detection tool connection wire unsuitable
Engine not starting

Check power supply Abnormal ● Batteries
1. Connection
2. Specific weight/charging system
Normal 3. Driving belt
4. Voltage
●Line fuse
Check starting system ●Ignition switch

● Starter relay
● Starter
● Wire
- 54 -
Difficult starting of engine
Check fault code Diag. fault code Diagnosis fault code

●Use diagnosis instruments
Normal code
Check for vacuum leakage ●Filter cover

Abnormal
●Oil ruler
●Vacuum hose connector
●PCV hose
●Hose between throttle valve and
air intake manifold
Check ignition ●HV cable

●Loose oil injector connector ●Ignition coil; ignition power
Abnomal
●To start engine with handle, keep transistor
spark plug wire 8-10mm from engine. ●Spark plug
Check for strong spark.
Normal
(Continued on next page)
- 55 -
(Continued from last page)
Check ignition timing Diagnosis Diagnosis fault code

2.414 (N-range, AC closed) fault code ●Use diagnosis instruments
Check fuel supply to injectors ●Engine oil filling port cover

●Fuel in fuel tank Abnormal ●Engine oil ruler
●Fuel pressure ●Vacuum hose connector
●PCV hose
Check spark plug

Standard: 1.0-1.1 mm ●HV cable
●Check compression if required Abnormal ●Ignition coil, ignition power transistor
●Spark plug
Check MFI electric circuit ● Line connector

Abnormal ● Power supply to PCM
① Line fuse
② Fuse
③ MFI control relay
● Engine coolant temperature sensor
●Air intake temperature sensor
● Fuel injection signal circuit
① Fuel injector
② PCM
● Throttle valve position sensor
● MAF sensor
Poor idling or engine stop
- 56 -
Check diagnosis fault code Read diagnosis fault code

Abnormal ●Use diagnosis instrument
Normal
Check leakage of vacuum ●Engine oil filling port cover

Abnormal ●Engine oil ruler
Normal ●Vacuum hose connector
●PCV hose
●Hose between throttle valve/air intake manifold
Check fuel supply to injectors ●Fuel pipeline (leak, deform)
●Fuel in tank Abnormal ●Fuse
●Fuel pressure ●Fuel pump
●Fuel filter
Normal ●Fuel pressure regulator
Check air filter element Clean or replace

Abnormal
Normal
Check idling speed Adjust idling speed

AC closed: 750±100
Abnormal
Normal
Check ignition timing
Adjust idling timing
8º±5ºbefore upper dead center Abnormal
Normal
Check spark plug

Check cylinder pressure
Standard: 1.0-1.1 mm Abnormal
●Check cylinder pressure if required
●Cylinder pressure
Limit value:
12kg/cm²
[250-400rpm]
Normal
- 57 -
Check fuel pressure ●Fuel pump

Abnormal ●Fuel filter
Check injector Injection pump status

Abnormal
Normal
Check MFI electric circuit ●Wire connection

Abnormal ●Power supply to PCM
① Line fuse
② Fuse
●Engine coolant temperature sensor
●Injection signal circuit
① Injector line
② PCM
- 58 -
Engine surging or poor acceleration
Check clutch or brake Slipping clutch

Abnormal Brake engaged
Normal
Check for vacuum leak in air intake ●Oil filling port cover
pipeline Abnormal ●Engine oil ruler
●Hose connector
Normal ●PCV hose
Check air filter Clean or replace air filter

Abnormal
Normal
Check MAD meter Check diagnosis fault code

Abnormal Use diagnosis instrument
Normal
Check ignition; ●HV cable

Check loose injector connector; Abnormal ●Ignition coil
After start of engine, keep spark plug
8-10mm from engine body; check for
strong spark
Normal
Check ignition timing Adjust idling timing

BTDC (before top dead center) 8º+5º Abnormal
Normal
Check fuel pressure ●Fuel pump

Abnormal ●Fuel filter
Check fuel injectors Fuel injection pump

Abnormal
Normal
- 59 -
Check spark plug Check cylinder pressure

Standard: 1.0-1.1 mm Abnormal
●Check cylinder pressure if required
●Cylinder pressure
Limit value:
12.0kg/cm²
[250-400 rpm]
Normal
Check MFI electric circuit ●Wire connection

Abnormal ●Power supply to PCM
① Line fuse
② Fuse
●Engine coolant temperature sensor
●Fuel injection signal circuit
① Fuel injection line
② PCM
4. Engine common troubleshooting
- 60 -
Fault characteristics Causes of fault Repair

Engine cannot start Low batteries Charge or replace batteries
Loose, corroded or worn battery wires Repair or replace wires
Speed range switch faulty (auto transmission) Adjust or replace switch
Molten fuse Replace fuse
Starter motor faulty Repair starter motor
Ignition switch faulty Replace ignition switch
Engine starts slowly Low batteries Charge or replace batteries
Loose, corroded or worn battery wires Repair or replace wires
Starter motor faulty Repair starter motor
Starter operating Starter motor faulty Repair or replace starter
continuously motor
Ignition switch faulty Replace ignition switch
Drive gear tooth broken or starter motor faulty Repair starter motor
Starter runs but engine
Tooth ring gear tooth broken Replace flywheel tooth ring
cannot start
gear or torque converter
Engine fault due to Fuel pipeline or hose bent or twisted Repair or replace
insufficient fuel supply Fuel pipe or hose clogged Clean or replace
Element of fuel filter in fuel tank clogged Replace
Water in fuel filter Replace or clean fuel tank
and fuel pipeline
Inside of fuel tank dirty or rusted Clean or replace
Fuel pump faulty (filter in pump clogged) Replace
Fuel vapor discharge Incorrect arrangement of carbon tank EM line Correct
system faulty (release Carbon tank solenoid valve line broken Correct
pressure when fuel filling Carbon tank solenoid valve line folded, bent,
cover is removed) cracked or clogged Replace
Fuel tank cover faulty Replace
Overflow valve (2-way valve) failed Replace
III. Diagnosis of fuel injection control system
- 61 -
1. Engine fault indicator
After turning on by ignition key, the engine does not operate and engine fault indicator (MIL) will light up for 5s
to show that the indicator is normal. If this indicator does not light up, check for broken wire in harness, molten
fuse or damaged bulb.
If MFI system part (sensor, PCM and fuel injector etc.) is damaged, fuel supply may be interrupted or correct
amount of fuel cannot be supplied accoding to engine operating conditions. The following are possible:
 Engine has difficulty in startup or cannot start at all;
 Idling speed is not stable;
 Running performance is poor.
At this time, engine fault indicator (MIL) will flash to prompt driver that there is problem in the vehicle. However,
if the same fault is not detected in 3 consecutive cycles, MIL indicator will automatically go out.
MIL will indicate faults of the following items:

●catalyst
●fuel system
●Mass air flow (MAF) sensor
●Intake air temperature (IAT) sensor
●Engine coolant temperature (ECT) sensor
●Throttle position sensor (TPS)
●front oxygen sensor Fault indicator
●front oxygen sensor heater
●rear oxygen sensor
●rear oxygen sensor heater
●fuel injector
●fire accident
●Crankshaft position (CKP) sensor
●Camshaft position (CMP) sensor
●evaporation exhaust control system
●Vehicle speed sensor (VSS)
●idling speed control
●PCM
2. Fuel injection system self-diagnosis

● Diagnosis fault codes are set as follows:
PCM first detects the fault and then diagnosis fault code will be recorded. When the engine starts again, the same
fault may be detected (in cyclic operation). However, for fire accident due to too thick or too thin fuel in fuel
system, diagnosis fault code will be recorded in the first detection.
● Erasing diagnosis fault codes:
After recording a diagnosis fault code, if PCM does not detect the same fault in 40 operation cycles, this code will
be erased from PCM record. However, for fire accident due to too thick or too thin fuel in fuel system, diagnosis
fault code will be erased in case of the following two cases:
◆ operating conditions (engine speed, engine coolant temperature etc.) are the same with those of first record of
the fault;
- 62 -
◆ the same fault is not detected by PCM in 80 operation cycles.
Note: Once the vehicle enters closed loop operation, an “operation cycle”is completed.
3. Reading and removal of fault codes
1. Turn off ignition switch;

2. Connect detection tool to data connection connector on lower anti-bump pad;
3. Turn on ignition switch;
4. Use detection tool to check diagnosis fault code;
5. Repair faulty part according to results of diagnosis;
6. Erase diagnosis fault code;
7. Disconnect detection tool.
Signal
Ground wire K line
L line Power
Cruise Air bag
supply
Note:
When battery voltage is too low, diagnosis fault codes cannot be read. Before starting a test, check battery
voltage and charging system.
If battery or PCM connector is disconnected, codes will be erased. Before fully reading out diagnosis fault
codes, do not disconnect batteries.
IV. Multi-point fuel injection (MFI) control system
- 63 -
1. Troubleshooting diagnosis flowpath
Collect user information
Verify user comments

Several reoccurrences Only one reoccurrence
Check diagnosis fault code Check diagnosis fault code
Fault diagnosis code Fault diagnosis code No code
No code or
connection
with detection Record diagnosis result and
tool failed then erase
Reference MFI fault clearing Try to repeat fault No

procedure characteristics characteristics
Several
Good
Read fault diagnosis code
Show fault diagnosis code Do not show fault diagnosis code
Intermittent fault
Reference fault diagnosis
(reference ”How to handle
code checklist
intermittent faults”)
2. Fault diagnosis codes checklist

Diagnosis Code Content
P0101 Air mass flow circuit range/performance problem
- 64 -
P0102 Air mass flow circuit low input
P0103 Air mass flow circuit high input
P0112 Intake air temperature circuit low input
P0113 Intake air temperature circuit high input
P0115 Engine coolant temperature circuit fault
P0116 ECT circuit range/performance fault
P0125 For closed loop fuel control, coolant temperature is not enough
P0122 Throttle position sensor circuit low input
P0123 Throttle position sensor circuit high input
P0134 Control time to enter closed loop fuel control is too long
P0133 Oxygen sensor circuit fault (group 1, sensor 1)
P0132 Oxygen sensor circuit disconnected (group 1, sensor 1)
P0135 Oxygen sensor heater circuit fault (group 1, sensor 1)
P0136 Oxygen sensor circuit disconnected (group 1, sensor 2)
P0140 Oxygen sensor circuit shortcircuit (group 1, sensor 2)
P0171 Fuel too thin in fuel system
P0172 Fuel too thick in fuel system
P0201 Fuel injector circuit fault (cylinder 1)
P0300 Detect random fire accident
P0301 Fire accident detection (cylinder 1)
P0325 Knockmeter circuit fault
P0335 Crankshaft position sensor circuit fault
P0340 Camshaft position sensor circuit fault
P0350 Ignition coil fault
P0320 Ignition failure sensor fault
P0421 Heated catalystic efficiency below critical point
P0443 Evaporation exhaust control system-purification control valve circuit fault
P0500 Vehicle speed sensor fault
P0507 Idling speed control- rotation speed high
P1330 Ignition timing adjustment fault
Fault diagnosis code checklist (for diagnosis not on vehicle)
Diagnosis Content
Code
- 65 -
P0100 Mass or volume air flow circuit fault
P0110 Intake air temperature circuit fault
P0115 Engine coolant temperature circuit fault
P0120 Throttle position circuit fault
P0325 Knockmeter circuit fault
P0350 Ignition coil fault
P1330 Ignition timing adjustment fault
Fault ranges related to diagnosis fault codes

Note: All possible causes are not listed for each diagnosis item.
Diagnosis code Diagnosis item Fault range
P0100 Mass or volume air flow Dirty air filter
P0101 circuit range/performance ●Missing engine oil cover or ruler, or incorrect
installation thereof
●Leakage in intake air system
●Pollution, aging or damage of mass air flow sensor
●Mass air flow sensor or throttle position sensor fault
●Poor connection among ECM and MAFS or TPS
Note::
If MAFS-related code appears, before this
troubleshooting, carry out all related repair.
P0102 Mass or volume air flow ●Short circuit to ground between MAFS and ECM
circuit low input ●Broken signal line between MAFS and EGM
●MAFS fault
Diagnosis code Diagnosis item Fault range

P0103 Mass or volume air ●Short circuit to battery between MAFS and ECM
flow circuit high input ●Grounding open circuit between MAFS and EGI main relay
●Grounding open circuit, poor connection or short circuit to
- 66 -
battery between MAFS and ECM
●MAFS fault
P0110 Intake air temperature ●Short circuit to ground between IAT sensor and ECM
P0112 circuit low input ●IAT sensor line-to-line short circuit
●IAT sensor fault
P0113 Intake air temperature ●Open circuit or short circuit to battery between IAT sensor
circuit high input and ECM
●IAT sensor fault
P0115 Engine coolant ●Open circuit or short circuit to battery between ECTS and
temperature circuit ECM
fault ●Short circuit to ground between ECTS and ECM
●ECTS fault
P0116 Engine coolant ●After engine starts and detection/calculation to obtain change
temperature sensor of coolant temperature, display of measured coolant
circuit range/ temperature does not change (ECT sensor input port clogged)
performance problem ●Poor connection between ECT sensor and ECM
●Misplaced, loose or corroded terminals
●ECTS dirty due to foreign matter
●ECTS fault
Note:
If any ECTS-related code appears, before this
troubleshooting, carry out all ECTS-related repairs.
P0120 Throttle position ●Poor connection between TPS and ECM
circuit fault ●Misplaced, loose or corroded terminals
P0120 Throttle position ●Polluted or aged TPS;
sensor circuit fault ●Broken line or short circuit between TPS5V datum and ECM
●Broken line or short circuit between TPS signal and ECM
●TPS line short circuit
●TPS fault
P0122 Throttle position ●Short circuit to ground between TPS and ECM
sensor circuit low ●Open circuit or short circuit to ground between TPS and
input ECM
●Short circuit to ground between ECM and fuel tank pressure
sensor FTPS)
●TPS or FTPS fault
P0123 Throttle position ●Open circuit or short circuit to battery between TPS and ECM
sensor circuit high ●Broken line between TPS and ECM
input ●TPS fault
Diagnosis Diagnosis item Fault range

code
P0125 For closed loop fuel ●After engine starts, time required before feedback operation
control,coolant is too long (signal input by ECT sensor for closed loop
- 67 -
temperature is not operation is not enough)
enough ●Poor connection between ECT sensor and ECM
●ECTS fault
P0130 Oxygen sensor circuit ●Short circuit to ground between oxygen sensor and ECM
fault(group 1, sensor 1)
P0132 Oxygen sensor circuit ●Short circuit to battery between oxygen sensor and ECM
high input (group 1,
sensor 1)
P0133 Oxygen sensor circuit ●Reversed connection of front and rear oxygen sensors
slow response (group 1, ●Fuel supply system fault
sensor 1) ●Leakage in intake air system
●Leakage in exhaust system
●MAFS grounding circuit fault
●Oxygen sensor fault
Note:
In case of fire, purification of solenoid value, MAFS or
oxygen sensor heater code, before this troubleshooting,
carry out all repairs related to these codes.
P0134 No detection action of ●Pollution, deterioration and aging of oxygen sensor
oxygen sensor circuit ●Misplaced, bent, loose or corroded connection terminals
(group 1, sensor 1) ●Oxygen sensor fault
Note: In case of fire, purification of solenoid valve or
oxygen sensor heater code, before this troubleshooting,
carry out all repairs related to these codes.
P0135 Oxygen sensor heater ●Molten or missing oxygen sensor fuse
circuit fault (group 1, ●Short circuit to battery between front oxygen sensor and
sensor 1) ECM
●Broken line between front oxygen sensor and ECM
●Front oxygen sensor fault
P0136 Oxygen sensor circuit ●Short circuit between rear oxygen sensor and ECM
fault (group 1, sensor 2) ●Rear oxygen sensor fault
P0140 Oxygen sensor circuit ●Short circuit to ground between oxygen sensor and ECM
short circuit (group 1, ●Front oxygen sensor fault
sensor 2)
P141 Oxygen sensor heating ●Molten or missing oxygen sensor fuse
mechanical equilavent of ●Short circuit to battery between rear oxygen sensor and ECM
heat device circuit fault ●Disconnection between rear oxygen sensor and ECM
(group 1, sensor 2) ●Rear oxygen sensor fault

code
P171 Fuel system too thin ●Ignition system fault (Ignition coil/spark plug/ignitioncable)
(group 1) ●Fuel supply system fault (fuel tank/pressure regulator/carbon tank
purifying valve)
- 68 -
●Fuel injector clogged
●Fuel injector fault
●Leakage in intake air system
●Leakage exhaust system
Note:
If codes related to fuel injector, oxygen sensor, ECTS or MAFS are
stored, before this troubleshooting, carry out all repairs related to
these codes.
P0201 Injector circuit high ●Disconnection between injector fuse and injector
input (cylinder 1) ●Open circuit or short circuit to battery between fuel injector and ECM
P0202 Injector circuit high ●Fuel injector fault
input (cylinder 2)
P0203 Injector circuit high
input (cylinder 3)
P0204 Injector circuit high
input (cylinder 4)
P0300 Detection of random ●Vacuum leakage in intake air system
fire ●CKP sensor circuit fault
●CKP sensor fault
●Ignition coil fault
P0301 Detection of fire ●Ignition coil or spark plug lead wire fault
(cylinder 1) ●Spark plug fault
P0302 Detection of fire ●Low compression pressure due to molten cylinder gasket and leaking
(cylinder 2) valve or piston ring
P0303 Detection of fire ●Low/high fuel pressure due to pressure regulator fault, clogged fuel
(cylinder 3) pipeline, clogged fuel filter, fuel pump fault
P0304 Detection of fire ●Fuel injector circuit fault
(cylinder 4) ●Fuel injector fault
Note: In case of fuel injector code (or undefined code), before this
troubleshooting, carry out all repairs related to these codes.
P0325 Knockmeter circuit ●Open circuit or short circuit to ground between knock meter and ECM
fault (group 1) ●Large resistance between knockmeter/ECM
●Knockmeter fault
P0335 Crankshaft position ●Short circuit to ground between CKP sensor and ECM
sensor circuit fault ●Open circuit or short circuit to battery between CKP and ECM
(group 1) ●CKP sensor line short circuit
●Poor connection between CKP connector and harness connector
●Air clearance exceeding permitted value
●Faulty object wheel clearance
●CKP sensor fault

code
P0340 Camshaft position sensor ●Short circuit to ground between CMP sensor and ECM
circuit fault ●Open circuit or short circuit to battery between CMP and ECM
●CMP sensor line short circuit
- 69 -
●Poor connection between CMP connector and harness connector
●CMP sensor fault
P0350 Ignition primary/secondary ●Ignition system fault
coil circuit fault ●Poor connection
●Fault of line between ignition coil and ECM
●Ignition coil fault
P0420 Deterioration of main ●Catalytic converter aging
catalyst efficiency (group 1) Note: In case of codes related to oxygen sensor, MAFS,
injector, P0170 or P0173, before this troubleshooting, carry out
all repairs related to these codes.
P0421 Deterioration of main ●Catalytic converter aging
catalyst efficiency (group 2) Note: In case of codes related to oxygen sensor, MAFS,
injector, P0170 or P0173, before this troubleshooting, carry out
all repairs related to these codes.
P0443 Evaporation exhaust control ●PCSV fault
system purification control ●Disconnection between PCSV and ECM
valve circuit fault
P0500 Vehicle speed sensor circuit ●Disconnection between fuse and VVS
fault ●Disconnection between VSS and ground
●Disconnection between VSS and ECM
●Short circuit to battery or ground between VSS and ECM
●VSS fault
P0507 Idlding speed control system ●Incorrect adjustment of throttle pull wire
higher than expected ●Leakage in intake air system between cylinder head and throttle
valve
●PCV valve or PCSV fault
●Poor connection in TPS circuit or TPS fault
●Large resistance between IAC valve and ECM
●IAC valve fault
Note: In case of codes related to TPS, MAFS, fuel injector or
IAC valve, before this troubleshooting, carry out all repairs
related to these codes.
P1330 Ignition timing adjustment ●Open circuit or short circuit to battery between ROM
modification tool and ECM
●Short circuit to ground between ROM modification tool and
ECM
●Disconnection between ROM correction tool and ECM
V. Detection of fuel injection system elements
Following are reference waveform diagrams of main sensors. The following data have been measured after full
preheating of engine, under no load conditions, and with engine fast accelerated to 4800rpm. Main sensors include:
CMP, CKP, TPS, MAFS, throttle position sensor, rear oxygen sensor, front oxygen sensor and fuel injection pulse.
Each type of value is only for reference and accurate value may change.
- 70 -
*CMP and CKP
When stepping down throttle pedal, force shall be applied
gradually and releasing of throttle shall also be gradual.
*MAFS and TPS

When stepping down throttle pedal, MAFS shall rise. In
the instant when “throttle position sensor”closes, i.e. when
throttle pedal is released, MAFS shall fall. When stepping
down throttle pedal, TPS shall rise; conversely, TPS shall fall.
*Front oxygen sensor and rear oxygen sensor

After stepping down throttle pedal, values of front and
rear oxygen sensors shall rise at once; conversely, these
values shall fall.
*Fuel injection pulse

When stepping down throttle pedal, this pulse shall rise;
when the pedal is released, this pulse shall fall.
1. Engine coolant temperature sensor (ECT)

Engine coolant temperature sensor consists of a thermistor fixed in plastic socket and 3 insertion plates connected
to it. With change of engine coolant temperature, resistance of thermistor will change accordingly, converting
different coolant temperatures to different electric signals for output to electric control elements in ECM, thereby
controlling fuel supply thickening, ignition timing and idling.
- 71 -
Circuit diagram
Engine water temperature
Output voltage
Resistance
Water temperature Water temperature
Inspection of sensors
Use of diagnosis instruments
Inspection item Data display Inspection conditions Intake air temp. Testing parameter
Engine coolant Sensor Ignition switch: When -20℃ -20℃
temperature sensor temperature On or engine operating When 0℃ 0℃
When 20℃ 20℃
When 40℃ 40℃
- 72 -
When 80℃ 80℃
Use of multimeter
1. Remove ECT sensor from intake air manifold;
2. Partly dip temperature sensing part of ECT sensor in hot engine coolant to check resistance.
Temperature (℃) Resistance (kΩ)

0 5.9
20 2.5
40 1.1
80 0.3
3. If resistance differs greatly from standard value, replace sensor.
Harness inspection procedure:
1 Check ground circuit conductivity

●Connector: disconnected
Normal 2
Connector at the
wiring harness Abnormal Repair harness
side (H)
- 73 -
Measure power supply voltage

●Connector: disconnected
●Ignition switch: on
●Voltage (V): 4.5-4.9V
Normal End
Connector at the
wiring harness
side (H)
Abnormal Repair harness
Fault correction procedure
Engine: operating
Yes
No
Check for normal line connection Repair line
Yes
No
Check for normal ECT sensor operation Replace ECT sensor
Yes
No
Check for normal cooling sysem with Replace thermostat
thermostat on (reference chapter EM)
Yes
Erase diagnosis test code (DTC) from memory and

test for the same code again
Replace ECM
DTC: diagnosis test code

ECM: engine control module
ECT: engine coolant temperature
- 74 -
Use of voltmeter
Inspection item Coolant temperature Testing parameter

Engine coolant temperature sensor output voltage When 0℃ 4.05V
When 20℃ 3.44V
When 40℃ 2.72V
When 80℃ 1.25V
Fault correction guide

During engine preheating operation, if idling speed is not high enough or engine generates black smoke, engine
coolant temperature sensor maybe faulty.
Installation
1. Apply LOCTITE 962T sealant or equivalent on threaded parts;
2. Install engine coolant temperature sensor and tighten to specified torque.
Tightening torque: 20-40Nm
3. Tighten connection harness connector.
2. Manifold absolute pressure (MAP) sensor

The manifold absolute pressure (MAP) sensor converts intake air manifold pressure to voltage signals. ECM uses
these signals to determine engine load conditions.
The intake air temperature (IAT) sensor is a resistance type sensor installed inside MAP sensor.
According to intake air signals from sensor, ECM controls provision of required amount of fuel injection.
Circuit diagram
Manifold sensor power Ground

absolute supply (5V)
pressure
input
- 75 -
Inspection Data Inspection conditions Engine status Testing
item display parameter
MAP Intake air ●Engine coolant temperature: 18℃ Idling speed 0.8V
sensor manifold ●All lights, electric cooling fans and accessories When throttle Rise from
pressure closed pedal is 0.8 to 2.4V
●Gear: neutral (auto transmission vehicle P suddenly
range) stepped down at
●Steering wheel: middle position idle speed
Harness inspection procedure

1 Measure power supply voltage
●Plug: disconnected Normal 2
●Ignition switch: On
●Voltage (V): 4.8-5.2
Harness side Abnormal Repair harness

connector (A)
2 Check ECM and air flow sensor for broken

line and short circuit with ground wire and 3
short circuit with ground. Normal
●MAP sensor circuit: disconnected
●ECM: disconnected
connector (A)
Check conduction of grounding circuit

●Plug: disconnected Normal End

connector (A)
- 76 -
Fault correction procedure (MAP sensor)
Engine: operating
Yes
No
Check for normal line harness & connection Repair or replace
Yes
No
否
Check for normal MAP sensor output voltage Repair MAP sensor
Yes
Erase DTC from memory and test again for

the same code
Yes
Replace ECM


Under the following conditions, MIL (fault display indicator) will light up, or DTC will be displayed on diagnosis
instrument.
1. Manifold pressure is kept larger or equal to 4.5V for 4 seconds.
2. Manifold pressure is kept smaller or equal to 0.2V for 4 seconds.
Inspection of sensor [MAP sensor]
1. Connect voltmeter between MAP sensor terminals 1 and 4
Terminal 4: MAP sensor ground
Terminal 1: MAP sensor output
2. Measure terminal voltage
Engine status Test parameter

Ignition switch: On 4-5V
At idling speed 0.8-2.4V
3. If voltage deviates greatly from standard value, replace MAP sensor assembly.
- 77 -
3. Air flow (MAF) sensor and intake air temperature (IAT) sensor
Thermal film type mass air flow sensor consists of thermal film sensor, hood and measurement channels (bridged
branch, sensor element). Since change of air flow causes change of amount of heat exchange between thermal
film detection surface and air flow, by detecting heat exchange at thermal film probe, air flow can be measured.
MAF sensor generates pulses to repeat opening and closing at 5V voltage supplied by engine control module,
resulting in change of thermal film probe temperature and resistance.
IAT sensor Sensor ground MAF Power

signal supply
Engine control module (ECM)
Engine: operating
Yes
No
Check for normal line harness & connection Repair or replace
Yes
Check for normal IAT sensor output voltage No Repair IAT sensor
Yes
Erase DTC from memory and again test for

the same code
Yes
Replace ECM
DTC: diagnosis test code; ECM: engine control module
- 78 -
1. If the engine accidentally stops, start engine and shake MAF sensor harness; if engine stops, check if contact
of MAF sensor connector is normal.
2. When ignition switch is turned on (not starting the engine), if MAF sensor output voltage is not 0, check for
fault in MAF sensor or ECM.
3. If engine can idle when MAF sensor output voltage is not in specified range, check the following:
Inspection item Inspection conditions Testing parameter

Mass air flow sensor output voltage Idle speed 0.5V
2000rpm 1.0V
● If fluctuating air flow enters MAF sensor, check if air pipe is broken or air filter is clogged.
● If combustion is not good in cylinder, check for fault in spark plug, ignition coil and fuel injector, and incorrect
matching.
4. Check installation direction of MAFS.
Note:
●When the vehicle is new (within first 500km), air flow of MAFS will be about 10% higher than standard;
●Use accurate digital voltmeter;
●Before inspection, preheat engine till engine coolant temperature reaches 80-90℃.

●Voltage (V): battery voltage

connector
2 Check for open circuit between PCM and

air flow sensor and grounding Normal 3
short circuit
●PCM connector: disconnected
●MAF sensor connector: disconnected
connector
- 79 -
●Plug: disconnected Normal End

connector
4. Throttle position (TP) sensor

TP sensor is of rheostat type and its output voltage changes with rotation of throttle valve. According to change of
voltage, ECM will detect opening of throttle valve.
Circuit diagram
Terminal voltage (V)
Minimum Maximum
Throttle rotation angle
Inspection of sensor
Use HI-SCAN
Inspection Data display Inspection Throttle Testing parameter
- 80 -
item conditions
TP sensor Sensor Ignition switch: At idle speed position 300-900mV
voltage On Slow opening Increase with opening of throttle
Full opening 4,250-4,700mV
Use voltmeter
1. Disconnect throttle position sensor connector.
2. Measure resistance between terminal 2 (sensor ground) and 1 (sensor PS).
Standard value: 3.5-6.5kΩ
3. Connect a pointer type ohmmeter between terminal 2 and 3 (sensor output).

4. From idle position, slowly operate throttle to fully open position and check steady change of resistance in
proportion with throttle opening angle.
5. If the resistance exceeds specified value or cannot change steadily, replace TP sensor.
Tightening torque: 1.5-2.5Nm TP sensor connector

(sensor side, front view)
Measure TPS power supply voltage

●Voltage (V): 4.5-5.0

connector

●Connector: disconnected Normal 3

connector
ECM harness
side connector Check for open circuit, short circuit, or
grounding of PCM and TPS Normal End
- 81 -
Harness side
connector
●TPS connector: disconnected

TPS signals are very important in control of automatic transmission. If this sensor is faulty, shaft vibration and
other defects may occur.
5. Idle speed control actuator

Idle speed control actuator is of duel coil type and has two coils, which are driven by separate driving levels in
ECM. According to pulse load factor, balance of electromagnetic forces of these coils will cause the motor turn by
different angles. In order to be parallel to throttle, a bypass hose is arranged, in which idling speed actuator is
installed.
Circuit diagram
Idle Speed Actuator(ISA)
Connector at the ISA side
Connect to
the
connector
Connector at the wiring

harness side (A)
ON OFF
Engine: operating
Yes
Check for normal line connection between
- 82 - Maintenance line
ECM and ISC actuator
No
Yes
No
Yes
No
Yes


Under the following conditions, fault indicator will light up or DTC will be displayed on diagnosis instrument.
● Short circuit or open circuit at primary voltage side of ECM;
● Ignition closed loop control in ECM does not follow the correct sequence;
● When the ignition switch is turned on, idling speed air control system has open circuit or short circuit.
Use diagnosis instrument
Inspection item Inspection conditions Instrument display Type

Idling speed control actuator Start engine ISCA Driving
Measure TPSE power supply voltage

●Voltage (V): battery voltage Repair harness
Harness side Abnormal Check power supply
connector
Harness side connector Check for open circuit, short circuit and
grounding beween ECM and
idling speed control actuator Normal End
●ECM connector: disconnected
Harness side ●ISC actuator connector: disconnected
connector Abnormal Repair harness
- 83 -
Inspection of actuator
1. Disconnect the connector on ISC actuator;
2. Measure resistance between terminals.
Standard values:
Between terminals 3 and 2: 10.5-14Ω
ISC actuator side
Between terminals 1 and 3: 10-12.5Ω (20℃) connector
3. Connect connector to ISC actuator.
6. Heating type oxygen sensor (HO2S)

Heating type oxygen sensor detects oxygen concentration in exhaust gas, convert it to a voltage signal and send it
to ECM. When air/fuel mixing ratio is thicker than theoretical air/fuel ration, oxygen sensor output will be about
1V; when air/fuel mixing ratio is thinner (oxygen concentration in exhaust gas is higher), this output will be about
0V. Based on this signal, ECM controls fuel injection rate, so that air/fuel ration is maintained at theorectical value.
Oxygen sensor has a heating element that ensures sensor performance under all running conditions.
Circuit diagram
Connect the connector
Rear Front
oxygen oxygen
sensor sensor
Heating Signal Grounding Signal Heating
Engine Control Module (ECM)
1. If oxygen sensor is defective, abnormal high emission will occur.

2. If oxygen sensor is found normal but sensor output voltage is not in specified range, check the following
(related to air/fuel ratio control system):
● Defective fuel injector
●Air leakage in intake air manifold
● Faulty MAFS, IATS, atmospheric pressure sensor and ECTS
Inspected Inspection conditions Engine status Test parameter
- 84 -
item
Oxygen Engine: preheat (engine deceleration, thin Sudden deceleration from 200mV or lower
sensor mixing concentration, acceleration, thick 4000rpm
concentration) Sudden engine acceleration 600-1000mV
Engine: preheat (use heating oxygen sensor Idling speed 400mV or lower
signal to check air/fuel ratio and ECU (oscilation)
control 2000rpm 600-1000mV
Inspection
Note:
● Before inspection, preheat engine so that ECT is 80-95℃
● Use accurate digital voltmeter
1. Disconnect oxygen sensor connector and measure resistance between terminal 3 and terminal 4.
Standard value
Temperature ℃ 0Resistance (Ω)
Sensor is Sensor Sensor is Sensor
40 30 or above grounded signal grounded signal
2. In case of fault, replace oxygen sensor.

3. Dirctly supply battery voltage beween terminals 3 and 4.
Heater (-) Heater (+) Heater (-) Heater (+)

Front Rear
Connector at the wiring harness side of the
heating oxygen sensor
Note:
When supplying voltage, circuit will be damaged if terminals are connected wrong or there is short circuit.
4. Connect a digital voltmeter between terminals 1 and 2;
- 85 -
5. If engine accelerates repeatedly, measurement oxygen sensor is faulty.
Generator Oxygen sensor input voltage Resistance (Ω)

Acceleration Minimum 0.6V 30 or above
6. If there is a problem, oxygen sensor maybe faulty.

Sensor is Sensor
Tightening torque grounded signal
Heating oxygen sensor:
40-50Nm
Heater (+) Heater (-)

Connector at the heating oxygen sensor
side(front, rear)
Harness side Measure HO2S power supply voltage
connector
Abnormal
Check for open circuit, short circuit or

grounding beween PCM & OS Normal 3
●Oxygen sensor connector: disconnected
Abnormal
Harness side
connector
Harness side Check conductiohn of grounding circuit

connector
(H) ●Connector: disconnected Normal End
- 86 -
7. Camshaft position sensor
CMP (camshaft position) sensor detects camshaft position during compression stroke of NO.1 and NO.4 cylinders
and convert it to a pulse signal.
This signal is input to ECM. Then, ECM will calculate fuel injection sequence according to input signals.
Circuit diagram
Connector at the camshaft

Connector at the position (CMP) sensor side
camshaft position Output characteristic
sensor side
Turn the crankshaft

rotation angle sensor
Harness side connector for a circle
(H)

Harness side
connector

Harness side
(H)
- 87 -

●Connector: disconnected Normal End
●Voltage: 4.8-5.2V
Harness side
(H)

If CMP sensor does not operate correctly, fuel injection sequence will not right, resulting in stop or uneven idling
speed of engine, or abnormal acceleration.
8. Crankshaft position sensor

Crankshaft position sensor detects crankshaft angle (piston position) of each cylinder and convert it to a pulse
signal. Based on such input signals, ECM calculates engine speed and controls fuel injection timing and ignition
timing.
Circuit diagram
Connector at the camshaft

position sensor side
Connector at the Output characteristic
crankshaft position
sensor side
Time
Turn the crankshaft
rotation angle sensor
Harness side for a circle
connector
(H)
- 88 -
1. If shock is felt during driving or the engine suddenly stops, shake crankshaft position sensor harness. If this
causes engine stop, check sensor for poor contact.
2. In case tachometer reading is 0 rpm when starting the engine, check crankshaft position sensor for fault,
timing belt for damage, or ignition system for fault.
3. If engine can idle when crankshaft angle sensor reading is not in specified range, check the following:
● fault in ECT sensor
● fault of idling speed control motor (not adjusted according to reference idling speed)
Use GST
Inspection item Inspection conditions Inspection contents Normal status
Crankshft ● Engine: starting Compare starting speed with Displayed speed
position sensor ● Tachometer connected (to check reading on multi-purpose is the same
on/off of ignition coil) testing instrument
Inspection item Inspection conditions Coolant temperature Testing parameter

Crankshaft ● Engine: idling At -20℃ 1500-1700rpm
position sensor ● Idling speed position switch: On At 0℃ 1350-1550rpm
At 20℃ 1200-1400rpm
At 40℃ 1000-1200rpm
At 80℃ 650-850rpm

Harness side
connector ●Plug: disconnected Normal 2


connector
- 89 -

●Voltage: 4.8-5.2V

connector(H)
9. Fuel injector
Fuel injectors inject fuel according to signals input to ECM. Amount of fuel injected is determined by time of
solenoid valve excitation.
Connector
Connector at the
fuel injector side
Harness side
connector (ABCD)

Harness side
connector (ABCD) Abnormal Repair harness
- 90 -
Check for open/short circuit or grounding
between ECM/injector Normal End

Harness side ●Injector connector: disconnected
Harness side connector
(H)

1. When the engine is hot, if starting is difficult, check fuel pressure and leakage in fuel injectors;
2. When the engine starts, if fuel injectors do not work, check the following:
● faulty power supply circuit to ECM; faulty grounding circuit;
● faulty fuel injector control relay;
● faulty crankshaft position (CKP) sensor or camshaft position (CMP) sensor;
3. During idling speed, when fuel injection by injectors is cut off according to cylinder sequence, in case idling
speed remains unchanged upon cutting off fuel injection at one cylinder, perform the following inspections for this
cylinder:
● injector and harness;
● spark plug and HV cable
● cylinder compression pressure.
4. In case injection system is normal but injector driving time exceeds specified range, check the following:
●poor fuel in cylinder (spark plug, ignition coil and cylinder compression pressure etc.).
10. Evaporation exhaust carbon tank purification solenoid valve

This solenoid valve is of duty ratio type. It controls purifying air passing the evaporation exhaust carbon tank.
Circuit diagram
- 91 -
Evaporative emission
canister purge solenoid
Evaporative emission
canister purge solenoid
Harness side connector (H)
Engine: operating
Yes
Check for normal line harness & connection No Repair line
Yes
No Replace evaporation carbon
Check for normal electric parts of evaporation tank purification control
carbon tank purification control valve solenoid valve
Yes
Erase DTC from memory and test again for No Normal

the same code
Yes
Replace ECM

- 92 -
Inspection item Inspection conditions Instrument display Type

Evaporation exhaust carbon tank purifidcation Ignition switch: On PCSV Driving
solenoid valve (not starting)
● Testing of actuator

Harness side
connector (A) Abnormal Repair harness
Check for open/short circuit or grounding of

Harness side
connector evaporation exhaust carbon tank purification
solenoid valve & ECM
Normal End
Harness side ●PCSV connector: disconnected
connector (H)
11. Knockmeter
The knockmeter is installed on cylinder body to detect knocking of engine. Engine body vibration will apply
pressure on piezoelectric element and this vibration pressure will be converted to voltage signal for output. If
knocking occurs on the engine,ignition timing will be delayed to stop the knocking.
Knockmeter
- 93 -
Circuit diagram
Signal Ground
Engine: operating
Yes
Check for normal line connection between No Repair sensor
knockmeter and ECM
Yes
No
Check that knockmeter torque meets Retighten sensor bolts
specified value (20±5Nm)
Yes
Check (with new part) for normal No
Replace this sensor
knockmeter
Yes
Erase DTC from memory and test again for No Normal
the same code
Yes
Replace ECM

- 94 -
ECM
harness side Check for open/short circuit or grounding
connector
between ECM and knockmeter
Normal 2
●Knockmeter connector: disconnected
Harness side
connector Abnormal
Repair harness

Harness side
Inspection of sensor
1. Disconnect knockmeter connector

2. Measure resistance between terminals 1 and 2
Standard value: about 5MΩ (20 ℃)
3. If resistance is continuous, replace the sensor
Knockmeter
Sensor tightening torque: 16-28Nm side
4. Measure capacitance between terminals 1 and 2 connector
Standard: 800-1600pF
12. Power steering pressure (PSP) switch

The power steering pressure switch detects power steering load and convert it to low/high voltage signals for input
to ECM. ECM will use these signals to control idling speed control motor.
Power steering oil
pressure switch
- 95 -
Circuit diagram
Harness side
线束侧接头connector
Power steering switch

动力转向开关压力开关
pressure switch

Inspection item Data Inspection Steering wheel Normal display
display conditoins
Power steering oil Switch Engine: Steering wheel middle position (vertical) Off
pressure switch status idling speed Turn steering wheel for half a round On


connector
- 96 -
VI. Troubleshooting corresponding to DTCS (diagnosis test codes)

Diagnosis items
DTC (diagnosis test code) Diagnosis item
P0101 Air flow circuit range/performance problem
P0102 Air flow circuit low voltage
P0103 Air flow circuit high voltage
Testing procedure
● Start engine for idling to reach engine operating temperature
●Measure voltage between MAFS terminal 1 and ground
Check if voltage is in specified range (0.2-0.8V)
Yes No
●Turn to close ignition switch and disconnect MAFS connector

● Turn to open ignition switch and measure voltage between MAFS
harness terminal 2 and ground (in specified range 12-14V or not)
Yes No
Measure voltage beween MAFS harness Open/short circuit grounding between MAFS
terminals 2 and 3 (if in specified range 12-14V) and main relay; repair line if required
Yes No
●Turn to close ignition switch, connect MAFS connector Disconnect MAFS from ECM terminal
● Measure voltage between MAFS terminal 2 and ground Repair line and connector if required
(if in specified range 12-14V)
Yes No
●Turn to close ignition switch, connect MAFS connector Open/short circuit grounding between
● Turn to open ignition switch; measure voltage between MAFS and main relay; repair line or
ECM end C15-4 (11) and ground (if in specified range) connector if required
A
(Continued on the next page)
- 97 -
Yes No
Check for poor connection of MAFS line Open/short circuit grounding between
MAFS and ECM terminal C15-4 (11)
Yes No
Repair connection if required Provisionally install a good MAFS

to check for normal operation; if the
problem is solved, replace MAFS
Return the vehicle to initial status, clear all DTC’

s and
drive vehicle connected to detection tool to verify
uncertain codes
DTC Diagnosis item

P0112 Intake air temperature circuit low voltage
P0113 Intake air temperature circuit high voltage
Description
Intake air temperature (IAT) sensor is installed inside MAF sensor. IAT sensor is of rheostat type and its resistance
changes with changes with change of air flow temperature at air intake. ECM regulates fuel injector pulse width
according to signals input by IAT sensor. When detected temperature is low, PCM will thicken fuel mixed gas by
increasing fuel injector pulse width. When air temperature is high, fuel injection pulse width will be shortened.
- 98 -
DTC detection conditions Possible causes

● IAT sensor converts intake air temperature to voltage signals and ● MAF sensor fault
outputs them
● PCM module checks if the voltage is in specified range ● MAF sensor circuit broken or short
Inspection range circuit, or loose connector
● 60s or longer since start of engine ● ECM module fault
Judging standard
●Sensor output voltage at 46V or higher (corresponding IAT is -45℃
or lower) for continuous 4s
● Sensor output voltage is 0.2V or lower (corresponding IAT is 125℃
or higher) for continuous 4min.
Circuit diagram
IAT sensor Sensor MAF Power

supply signal ground
- 99 -
Testing procedure
●Turn to open ignition switch

●Connect detection tool to data connector
●Verify if DTC P0112 or P0113 and other DTC’
s have been set.
No Yes
●Engine under room temperature (cooling in garage at night recommended) A

●Measure garage air temperature
To next page
●Turn on ignition switch
● Connect detection tool and observe IAT sensor reading (if measured
temperature is very close to garage air temperature)
No; detected temp. is higher No; detected temp. is lower Yes; detected temp. is very
than garage air temperature than garage air temperature closeto garage air temp.
●Turn off ignition switch ●Turn off ignition switch No problem found at this
● Disconnect MAF/IAT ● Disconnect MAFS/IAT timd. Fault is intermittent or
sensors sensors repaired. ECM memory not
●Turn on ignition switch ●Turn of ignition switch erased. Clear codes and verify
● Observe if IAT sensor ● Measure voltage between if IAT sensor reading is in
reading (measured temp.) on ground and MAF/IAT harness normal range
detection tool is now -4.4℃ terminal 4 (if it is 4.5-5.0V)
No Yes Yes, display 4.5-5.0V No, display 0V No, 12V appears
Replace MAF & IAT sensors. Clear Repair short connecting batteries
codes and verify if IAT sensor is in between MAFS/IAT sensors and
normal parameter range ECM. Clear codes and verify if IAT
sensor is in normal parameter range
B C
(To next page) (To next page)
- 100 -
From previous page (A)
●Turn off ignition switch

●Disconnect MAF and IAT sensors
● Measure is resistance between ground and MAF/IAT sensor
harness connector terminal 4 is 1Ω or smaller
Yes No
Replace MAFS and IAT sensor; Repair open line between MAF/IAT
Clear codes & verify if IAT sensor is sensor harness terminal 5 and ECM.
in normal range Clear codes and verify if IAT sensor is in
normal parameter range
From previous page (B) From previous page (C)
B C
●Disconnect MAF and IAT sensor

●Disconnect MAF and IAT sensor ●Turn off ignition switch
●Turn off ignition switch ●Disconnect ECM connector C15-4
●Disconnect ECM connector C15-4 ● Grounding of terminal 5 of MAF/IAT sensor
● Measure resistance between ground and MAF/ harness connector
IAT sensor harness terminal 5; check if there is ● Measure resistance between ground and ECM
open circuit as indicated by the resistance connector C15-4 terminal 17 (if 1Ω or smaller)
No Yes Yes No
Repair short circuit between line Verify tightening of all ECM connectors Repair broken line between
from MAF/IAT sensor harness and if OK, replace MAF/IAT sensors. MAF/IAT sensor harness
terminal 4 to ECM and ground; Clear codes and verify if IAT sensor is in terminal 5 and ECM. Clear
clear codes & verify if IAT sensor normal parameter range. If problem still codes verify if IAT sensor is in
is in normal parameter range exists, replace ECM normal parameter range
- 101 -
DTC Diagnosis item

P0115 Engine coolant temperature circuirt fault
P0116 Drifting of engine coolant temperature sensor
Description
ECT sensor is installed in cylinder head coolant channel. ECT sensor is of rheostat type and its resistance changes
with change of temperature of coolant passing the sensor. When coolant temperature is low, sensor resistance is
high; when coolant temperature is high, sensor resistance is low. ECM checks ECT voltage 50 times per second
aend uses such information to adjust fuel injector pulse width and ignition timing. When detected temperature is
very low, ECM will thicken fuel mixed gas concentration.
DTC detection conditions Possible cauess

Background
● ECT sensor converts ECT to voltage for output. ● ECT sensor fault
● ECM checks if voltage is in specified range. Besides, it also ● Open circuit, short circuit or loose
checks that ECT (signal) does not fall during engine preheating. connector in ECT sensor circuit
● ECM fault
Inspection range and judging criteria
● Sensor output voltage is 4.6V or larger (corresponding to coolant
temperature of -45℃ or lower) for continuous 4s.
● Sensor output voltage is 0.1V or lower (corresponding to coolant
temperature 140℃ of or higher) for continuous 4s.
Inspection range and judging criteria

● Sensor output voltage rises from lower than 1.6V to higher than
1.6V (coolant temperature is lowered from higher than 40℃ to
lower than 40℃).
● Later, sensor output voltage is 1.6V or higher for continuous
5min.
Inspection range
●After starting procedure, ECT is about 40℃ or lower (judging
criterion)
●About 60-300s after completion of starting procedure, engine
coolant temperature rises to about 40℃.
- 102 -
Circuit diagram
Engine water temperature sensor
Output voltage
Resistance
- 103 -
Testing procedure
●Turn on ignition switch

●Connect detection tool to data connector
●Verify setting of DTC P0115 or P0116 and DTC P0112
or P0113
No Yes
●Cold engine status Reference chapters P0112/P0113

● Connect detection tool and observe ECT/IAT and execute testing procedure
sensor readings. Is measured temperature the same as
garage air temperature？
Yes No, IAT reading is different No, ECT reading is different
●Turn off ignition switch Reference DTC P0112/P0113 Replace ECT sensor; clear
●Disconnect ECT sensor and execute procedure for codes & verify ECT sensor in
●Turn off ignition switch testing of EAT sensor normal parameter range
● Measure voltage between
ECT sensor harness terminals
1 and 3 (if 4.5-5.0V)
Yes, reading is 4.5-5.0V No, reading is < 4.5V
Replace ECT sensor; clear ●Turn off ignition switch

codes & verify ECT sensor in ●Disconnect ECT sensor
normal parameter range ●Disconnect ECM connector C15-4
●Ground ECT harness connector terminal 3
● Measure resistance between ground and ECM
connector C15-4 terminal 22 (if 1Ω or smaller)
Yes No
Repair open circuit in line between ECT sensor harness connector

terminal 3 and ECM harness connector C15-4 terminal 22. Clear
A
codes and verify ECT sensor in normal parameter range.
To next page (A)
- 104 -
From previous page

A

●Disconnect ECT sensor
●Disconnect ECM connector C15-4
● Meaure resistance between ground & ECM harness
connector C15-4 terminal 22 (if open circuit is displayed)
Yes No
Repair short circuit grounding between ECT sensor harness

connector terminal 3 and ECM harness connector C15-4 terminal
22. Clear codes and verify ECT sensor in normal parameter range

●Disconnect ECT sensor
●Disconnect ECM connector C15-4
If resistance shows open circuit
Yes No
Verify tightening of ECM connectors. Repair open circuit in line between ECT sensor
Replace with a good ECM sensor; if harness connector terminal 1 and ECM harness
the problem remains, replace ECM. connector C15-4 terminal 22. Clear codes and
Clear codes & verify ECT sensor in verify ECT sensor in normal parameter range.
normal parameter range
- 105 -
DTC Diagnosis item

P0122 Throttle position sensor low voltage
P0123 Throttle position sensor high voltage
Description
TP sensor is installed beside throttle valve and connected to throttle blade shaft. TP sensor is of rheostat
(potentiometer) type and its resistance changes with throttle blade shaft position. During acceleration, TP sensor
resistance decrease and during deceleration, TP sensor resistance increases. TP sensor also includes an idling
position switch. At idling position, the switch closes. ECM provides TP sensor with a reference voltage and then
measure voltage at TP sensor signal circuit. ECM uses TP sensor signals to adjust timing and fuel injector pulse
width. TP sensor signals and MAP sensor signals are used by ECM together for calculation of engine load.
DTC detection conditions Fault causes
●TP sensor outputs a voltage proportional to throttle opening angle ●TP sensor faulty or incorrectly
●ECM checks if voltage output by TP sensor is in specified range. adjusted
Besides, it checks that output voltage will not be too high during engine ●Open/short circuit or loose connector
idling. in TP sensor circuit
Inspection range and judgment criteria
●With opening of closed TP switch, sensor output voltage will be 2V or ●Fault in opening of closed TP switch
higher in continuous 4s.
●Sensor output voltage is 0.2V or lower in continuous 4s ●Short circuit in closed TP switch
Inspection range signal line
●Engine rotation speed in 500 to 3000rpm ●ECM failed
●Low engine load
Judgment criterion
●Sensor output voltage is 4.6V or higher in continuous 4s
Circuit diagram
- 106 -
Testing procedure
 Turn the ignition switch to OFF.

 Connect the testing tool to the data connecting joint
 Verify if the DTC P0122 or P0123 and other codes have
been set.
No
 Turn the ignition switch to ON and the engine is running at idle speed.
 Use the testing tool to observe the output voltage of the throttle position sensor.
Is the output voltage of the throttle position sensor within the range of 0.3-0.9V.
No, the output is above 0.9V No, the output is above 0.9V Yes, the output is within the
or below 0.3V range of 0.3-0.9V
 Turn on the ignition switch and  Turn the ignition switch to It is an intermittent malfunction or
the engine is not running OFF. has been repaired. ECM memory
has not been cleared. Check the
 Throttle opens completely  Disconnect the TP sensor terminal connection between the
 Try to regulate the output  Turn on the ignition switch ECM and the TP sensor. Clear the
voltage of the TP sensor to 0.4-0.5V and the engine is not running DTCs and verify if the reading of
Can the voltage of the TP sensor be  Use the testing tool to the TP sensor is within the
measure the voltage and see if it allowable range.
regulated to the required value?
is 0V.
Yes No
Replace the TP sensor. Clear the DTCs Repair the short circuit voltage
and verify if the reading of the TP sensor between the TP sensor wiring
is within the allowable range. harness connector terminal No.2
and ECM wiring connector C15-4
terminal No.14. Clear the DTCs
and verify if the reading of the TP
No Yes sensor is within the allowable
range.
 Turn on the ignition switch and the engine is not running

 Keep the throttle valve in full open position.
 Measure the voltage of the TP sensor and see if it is around
4.8V.
B C
Go to next page
转下一页转下一页
Go to next page
- 107 -
接一页Continued from previous page

B

 Disconnect the TP sensor
 Turn the ignition switch to ON
 Use the voltmeter to measure the voltage between the
ground and the TP sensor wiring harness connector terminal
No. 2 and see if it is 5V.
Yes No
否
 Turn on the ignition switch the engine is not running

Repair the open circuit between the TP sensor
 ●点火开关开，发动机不转
Disconnect the TP sensor wiring harness connector terminal No.2 and ECM
 ●断开
MeasureTPand observe if the resistance between the
传感器 wiring connector C15-4 terminal No.22. Clear the
DTCs and verify if the reading of the TP sensor is
ground and the TP sensor
●测量地线和 wiring harness connector
TP 传感器线束接头端子 1 间的 within the allowable range.
terminal No. 1 is 1 or1Ω
电阻是否大约为 less.
或更小
Yes
是 No
否
 Turn on the ignition switch the engine is not Repair the传感器线束接头端子

poor ground and open1 和 circuit
●点火开关开，发动机不转修理 TP ECMbetween
线束
running
the TP sensor wiring harness
接头 C15-4 端子 11 间线路的接地不良或断路 connector terminal
 ●断开 TP 传感器
Disconnect the TP sensor
●跨过 TP 传感器线束接头端子 1 和 2，
 Measure and observe if the resistance 连接保the
between No.1 and ECM wiring connector
问题，清除代码并验证 C15-4 terminal
TP 传感器在正常参
险丝跨接线
ground and the TP sensor wiring harness connector No.11.
数范围内 Clear the DTCs and verify if the reading of
●使用检测工具观察
terminal TP 传感器的输出电压是
No. 1 is 1 or less. the TP sensor is within the allowable range.
否大于 4.8V
No
否 Yes
是
 Turn the ignition switch to OFF. Replace the TP sensor. Clear the DTCs and verify
●点火开关关闭更换 TP 传感器，清除代码并验证 TP 传感器
 Disconnect the TP sensor if the reading of the TP sensor is within the
 ●断开ConnectTP the
传感器 fuse jumper 在正常参数范围内
 ●保险丝跨接线连接好
Connect ECM allowable range.
 ●ECM
Measure
连接好 the voltage between the ground and the
ECM connector C15-4
●测量地线和 terminal
ECM 接头 No.22
C15-4 端子(anode probe)
22 间的电
and压（反探针)
see if it is 5V.是否为 5V
转下一页
Go to next page
- 108 -
Continued from previous page Continued from previous page

接上一页接上一页
D
C
No
否 Yes
是
The malfunction is caused by incorrect Replace the TP sensor. Clear the

故障已修理，问题是错调 TP 更换 TP 传感器，清除代码并
regulating of the TP sensor and has been DTCs and verify if the reading of the
Clear the DTCs and verify TP
repaired. 传感器。清除代码并验证 if the TP验证 TP is
sensor 传感器在正常参数范
within the allowable
reading 传感器在正常参数范围内
of the TP sensor is within the range.
围内
allowable range.
Yes
是 No
否
 Turn the ignition switch to ON and the engine is running Repair the open circuit or short circuit to ground
●点火开关开，发动机怠速
at idle speed. 修理 TPthe传感器线束和
between ECMharness
TP sensor wiring 线束间线路 and the
 ●使用检测工具观察怠速开关输出
Use the testing tool to observe if the output throttle of the ECM wiring harness. Clear the DTCs and verify
的开路或接地短路。清除代码并验证 TP
idle speed position switch is fully closed. if the reading of the TP sensor is within the
节气门是否完全关闭传感器在正常参数范围
allowable range.
Yes
是 No
否
 Turn the ignition switch to OFF Replace the throttle position sensor Clear the
●点火开关关更换节气门位置传感器。清除代码并验
 Disconnect the TP sensor connector
DTCs
证 TPand传感器在正常参数范围内
verify if the reading of the TP sensor
●TP 传感器接头断开
When the throttle valve moving from the idle speed position
to●当节气门从怠速位置移至开启位置时，测量
the open position, measure the resistance between TP 传感the TP is within the allowable range.
sensor
器接头端子 connector
1和 terminal No.1 and 3the
TP 传感器端子 TP sensor terminal No.3.
间的电阻
The resistance shows that there is a short circuit when the
电阻显示在怠速位置时短路，节气门在开启位置时开
throttle valve at the idle speed position and an open circuit when
it 路。电阻测量是否正常
at the open position. Is the measured resistance normal
Yes
是 No
否
Verify if the ECM connector is fastened. If yes, replace the Replace the TP sensor. Clear the DTCs and
确认 ECM 接头是紧固的。如果正常，更换节气门位置更换节气门位置传感器，清除代码并验
throttle position sensor If the problem remains, replace ECM. verify if the reading of the TP sensor is within
传感器。如问题仍存在，更换 ECM。清除代码并验证证 TP 传感器在正常参数范围内
Clear the DTCs and verify if the reading of the TP sensor is the allowable range.
TP 传感器在正常参数范围内
within the allowable range.
- 109 -
DTC Diagnosis item
P0125 Coolant temperature for closed loop fuel control is not enough
Description
To obtain full high purification rate of CO, HC and NOx in exhaust gas, 3-element catalytic converter is used. To
obtain highest efficiency in using the 3-element catalytic converter, air/fuel ratio must be accurately controlled so
that it is always near theoretical air/fuel ratio. Oxygen sensor is characterized by sudden change of output voltage
at theoretical air/fuel ratio. This characteristics is used to detect oxygen concentration in exhaust gas and feed
back to control system for control of air/fuel ratio. When AFR is thinner, O2 concentration in exhaust gas
increases and O2 sensor prompts ECM thin status (low emf: 0V). When AFR is thicker than theoretical value, this
concentration decreases and O2 sensor notify ECM thick status (high emf: 1V). ECM determines thick or thin
AFR by sensor voltage and control injection time accordingly. But if this sensor fails and has abnormal voltage
output, ECM cannot perform accurate AFR control. Heating type O2 sensor has a zirconia heater controlled by
ECM. When IAT (or exhaust temperature) is low, the sensor will be electrically heated to accurately detect O2
concentration.
●MFI system reduces emission by means of closed loop fuel control ●Heating type O2
●ECM checks time required for start of closed loop fuel control sensor faulty
Inspection range ●Fuel injector faulty
●Engine coolant temperature higher than 80℃ ●Fuel pressure
●Intake air temperature is -10℃ or higher regulator faulty
●Atmospheric pressure is 76kPa or higher ●Fuel pump faulty
●Engine rotation speed is about 2400-3500rpm ●Fuel filter clogged
●Engine load is 26-60% ●Air in exhaust
●Operating in air/fuel ratio feedback zone system
●Monitoring time: 128s ●Exhaust leakage
Judgment criteria ●ECM faulty
●MFI system cannot perform closed loop control within about 30s after startup
●Each stroke is monitored only once
- 110 -
Circuit diagram
Engine water temperature sensor
Output voltage
Resistance
- 111 -
Detection procedure
 Turn the ignition switch to ON position
 Make sure the DTC P0125 has been set and verify if only
the P0123 has been set.
Yes No
否
 The engine is running at idle speed under the normal Refer to the appropriate section and identify
running temperature.
other codes.
 Connect the testing tool and observe if the measured
temperature of the ECT sensor is within the range of 77-88℃.
No, the measured temperature Yes, the measured temperature is within the
否，测量的温度低于是 77℃ is below 77℃. 是，测量的温度在规定的范围内
specified range.
 Turn the ignition switch to OFF. If there is no problem this time, it is an

●关闭点火开并此次没有发现问题，问题是间歇性的或
 Disconnect the ECT sensor. intermittent malfunction or has been repaired.
 ●断开Turn ECT 传感器 switch to ON
the ignition 已修理好，ECM 存储器没有清除，清除
ECM memory has not been cleared. Clear the
 ●打开点火开关
Measure and observe if the voltage between the ECT sensor 代码并验证 ECT 传感器在正常参数范
DTCs and verify if the reading of the ECT
●测量
wiring ECT connector
harness 传感器线束接头端子terminal No.11and
和 No.3
3 间电压是否在
is within the 围内
sensor is within the allowable range.
4.5-5.0V
range 之间
of 4.5-5.0V.
Yes,
是，在 the voltage
4.5-5.0Vis within
之间 the range of 4.5-5.0V No, the否，所测电压低于
measured voltage is4.5V
below 4.5V.
Replace the ECT sensor. Clear the DTCs and  Turn the ignition switch to OFF.
更换 ECT 传感器，清除代码并验证 ECTverify
传感if the ●关闭点火开关
 Disconnect the ECT sensor.
reading of the ECT sensor is within the allowable range.
器在正常参数范围内 ●断开 ECT 传感器
Disconnect the ECM connector C15-4
●断开 The ECM
ECT接头 wiring harness connector terminal
C15-4
No.2 is grounded
●ECT 线束接头端子 2 接地
 Measure and observe if the resistance
●测量地线和
between ECMand
the ground 线束接头
the ECMC15-4 端子 13
connector 间
C15-4
的电阻是否为大约
terminal No.13 is 1 or1Ω 或更小
less
Yes
是 No
否
Verify if the ECM connector is fastened. Replace with

Repair the open circuit between the ECT sensor
确认and
a new ECM 接头坚固，
good 用已知好的部件更换
ECM sensor. ECT
If the problem remains, wiring harness connector terminal No.2 and ECM
replace ECM sensor. Clear the DTCsECM，清除代
传感器，如果问题仍存在，更换 and verify if the wiring harness connector C15-4 terminal No.13
码并验证 ECT 传感器在正常参数范围内
reading of the ECT sensor is within the allowable Clear the DTCs and verify if the reading of the ECT
sensor is within the allowable range.
range.
- 112 -
DTC Diagnosis item
P0132 Oxygen sensor circuit short circuit (group 1, sensor 1)
P0134 Time to enter closed loop control is too long
Description
In order to obtain full and high purification rate of CO, HC and NOx in exhaust gas, 3-element catalytic converter
is used. To obtain highest efficiency in using the 3-element catalytic converter, air/fuel ratio must be accurately
controlled so that it is always near theoretical air/fuel ratio. Oxygen sensor is characterized by sudden change of
output voltage at theoretical air/fuel ratio. This characteristics is used to detect oxygen concentration in exhaust
gas and feed back to control system for control of air/fuel ratio. When AFR is thinner, O 2 concentration in exhaust
gas increases and O2 sensor prompts ECM thin status (low emf: 0V). When AFR is thicker than theoretical value,
this concentration decreases and O2 sensor notify ECM thick status (high emf: 1V). ECM determines thick or thin
concentration.
●When aging of heating type sensor starts, sensor signal reaction deteriorates. ●Aging of heating type
●ECM forces change of AFR so that it is thinner or thicker, and checks reaction oxygen sensor
speed of heating type oxygen sensor. Besides, ECM also checks for open circuit in ●Open circuit in heating
heating type oxygen sensor output line. type oxygen sensor
Inspection range output line
●Coolant temperature sensor: normal ●ECM fault
●After completion of startut procedure, heating type oxygen sensor voltage signal is
0.1V or lower for continuous 3min or longer.
●ECT is higher than 80℃
●Engine rotation speed is higher than 1200rpm
●Engine load is 25% or higher
Judgment criterion
●When 5V is supplied to heating O2 sensor output line via resistor, input voltage
supplied to ECM interface circuit is 4.5V or higher
Inspection range
●Coolant temperature sensor: normal
●ECT: 50℃ or higher
●Engine rotation speed: 1500-3000rpm or 1100-3000rpm
●Engine load is 25-60%
●Intake air temperature is -10℃ or higher
●Under closed loop air/fuel ratio control
●Monitoring time: 8s
Judgment criteria
●In case of forced change of AFR (thinner or thicker), heating O2 sensor signal
cannot response in 1.28s
- 113 -
Circuit diagram
Front oxygen sensor

Rear oxygen sensor
- 114 -
Detection procedure
 Connect the testing tool to the data
connecting joint
 Verify if the DTC P0132 or P0133 have
been set as well as other DTCs
No Yes
是
 Start the engine and warm up the engine to the normal Regulate the conditions affecting the
●起动发动机并暖机至正常工作温度调整影响其它 DTC 设定的条件，
operating temperature.
setting
参照 of DTCother DTCs. Refer to the DTC
 ●打开空调（如果配备)
Turn on the A/C (if equipped) 测试程序
 ●增加发动机转速至
Increase the engine speed to 4000rpm.
4000rpm， Use the testing tool to testing procedure.
使用检测工具监视氧传感
observe if the voltage of
器电压是否在 0 到 900mv 之间变化 the oxygen sensor changes within the
range of 0- 900mv.
No, the reading is No, the reading is No, the No, the voltage No, the voltage Yes, the voltage
否，电压是恒否，电压是恒否，电压为否，电压变否，电压变
is changing in 是is ，电压在
changing
a constant voltage a constant voltage reading is 0V is changing in the range below
定的，读数大定的，大约为 0V 但在 500mV 但在 500mV within 100-900mV
the range
of about 450mV. of about 5V or the range below 500mV
约为 450mV 5 或 12V 以下（稀) 以上（浓)
(frequent) of 100-900mV
之间变化
12V 500mV (rare)
Repair the short circuit

voltage in the wiring harness B C D
and verify if the reading of
the oxygen sensor is within
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the allowable range
● When the engine is running, ●· Disconnect the oxygen sensor connector.

measure and observe if the voltage Observe if the voltage reading on the testing tool is
between the front oxygen sensor
changing within the range of 19-58mV.
connector terminal No.1 and No.2 is
changing around 500mV.
No
否 Yes
是
A Repair the short circuit to ground between the Replace the oxygen sensor.
修理氧传感器线束接头端子 1 和 ECM Clear the DTCs and verify if
oxygen sensor wiring harness connector terminal
No.1 and线束接头 C15-4harness
ECM wiring 端子 6 间线路接地短路
connector C15-4 the reading of the oxygen
Go to next page
转下一页 sensor is within the allowable
terminal 的问题，
No.6. Clear the DTCs and verify if the
清除代码并验证氧传感器在正 range.
reading 常参数范围内
of the oxygen sensor is within the
allowable range.
- 115 -
接上一页
Continued from previous page
Yes
是 No
否

 Disconnect the front oxygen sensor Replace the oxygen sensor. Clear the DTCs and
 Disconnect the ECM connector C15-3 verify if the reading of the oxygen sensor is within
 The front oxygen sensor wiring harness connector
the allowable range.
terminal No.2 is grounded.
 Measure the resistance between the ground and
the ECM connector C15-4 terminal No.22 and see if it
is 1 or less
Yes
是 No
否
Verify if the ECM connector is fastened. If yes, replace

Repair the open circuit or high resistance caused
with a new and good oxygen sensor. Clear the DTCs by other reasons. Clear the DTCs and verify if the
and verify if the reading of the ECT sensor is within reading of the oxygen sensor is within the
the allowable range. allowable range.

接上一页 Continued from previous page
接上一页
B C
The voltage is changing in the range

The voltage is changing in the range 电压变化但在 500mV 以上（浓)
below 500mV (frequent)
below 500mV (rare)
 Check if there is leakage or damage on the lower

end of intake port of the mass air flow sensor.
 Check if there is any crack, leakage or damage
occurred on the exhaust manifold
Yes
是 No
否
Repair or replace the exhaust manifold. ●According to some descriptions in the service manual,
Clear the DTCs and verify if the reading verify if the testing fuel pressure after completing tests is
of the sensor is within the allowable within the specified range and there is no pressure leakage.
range.
Go转下一页
to next page
- 116 -
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Continued from previous page 接上一页
D E
The voltage is changing within the

range of 0-900mV
Yes No
否
According to the diagnostic procedure,

Clear the DTCs and verify if the reading
 Disconnect the connector on the ignition coil.
of the oxygen sensor is within the
 After starting the engine, connect a voltmeter between the allowable range.
battery negative(-) pole post and the contact point lead of the
generator to measure and observe the voltage drop passing the
battery negative pole(-) is below 0.5V.
Yes
是
No
否
Replace the negative battery cable.

 Disconnect negative (-) battery terminal.
 Measure and observe if the resistance between the generator Clear the DTCs and verify if the
cover and the grounding point is around 1 or less. reading of the oxygen sensor is within
Yes
是 No
否
 If the malfunction light indicator (MLI) flashes Clean the contact surface of the
intermittently and the DTCP0133 has been set, it may be generator cover and the engine
caused by poor grounding circuit. Clean the negative battery
body. Clear the DTCs and verify if
terminal and engine ground wire as well as the contact surface
of the generator cover and the engine body. the reading of the oxygen sensor is
 If the MLI lights and DTCP0133 has been set, replace in the allowable range.
the oxygen sensor.
 Clear the DTCs and verify if the reading of the oxygen
sensor is in the allowable range.
- 117 -
DTC Diagnosis item
Description
concentration.

●When the heater is excited, ECM checks if heater current is in specified ●Open or short circuit of oxygen
range. sensor heater circuit
Inspection range: ●Open circuit of oxygen sensor
●Battery voltage is 12-16V. heater
Judgment criteria: ●ECM fault
●Current of heater of heating oxygen sensor (group 1, sensor) is 0.2A or
lower, or 3.5A or higher for continuous 6s;
●Each stroke is monitored only once.
- 118 -
Circuit diagram
Front oxygen sensor

Rear oxygen sensor

- 119 -
Measurement procedure
 Connect the testing tool to the data connecting
joint
 Verify if the DTC P0135 has been set
 Disconnect the front oxygen sensor

 Start the engine.
 Measure and observe if the voltage between the
oxygen sensor wiring harness connector terminal No.1
and the ground wire is within the range of 12-16V.
Yes No
 Turn the ignition switch to OFF. Repair the open circuit or short circuit to ground
 Disconnect the front oxygen sensor
 Disconnect the ECM connector C15-3 between the connector terminal and the oxygen
 The front oxygen sensor wiring harness connector sensor wiring harness connector terminal No.3.
terminal No.4 is grounded. Clear the DTCs and verify if the reading of the
 Measure and observe if the resistance between the
oxygen sensor is within the allowable range.
ground wire and the ECM wiring harness connector
C15-3 terminal No.10 is around 1 or less
Yes
是 No
否
● Turn the ignition switch to OFF. Repair the short circuit to ground or other short
● Disconnect the front oxygen sensor circuits between the oxygen sensor wiring harness
● Disconnect the ECM connector C15-3 connector terminal No.4 and ECM wiring harness
● The front oxygen sensor wiring harness connector connector C15-3 terminal No.10. Clear the DTCs
terminal No.4 is grounded. and verify if the reading of the oxygen sensor is
● Measure and observe if the resistance between the
ground wire and the ECM wiring harness connector
Yes
是 No
否
● Turn the ignition switch to OFF. Repair the short circuit to ground or other short
● Disconnect the front oxygen sensor circuits between the oxygen sensor wiring harness
● Measure and observe if the resistance between connector terminal No.4 and ECM wiring harness
connector C15-3 terminal No.10. Clear the DTCs
the oxygen sensor terminal No.3 and No.4 is within and verify if the reading of the oxygen sensor is
the allowable range(11-14). within the allowable range.
Yes
是 No
否
Verify if the ECM connector is fastened. If yes, replace Replace the oxygen sensor. Clear the DTCs and
with a new and good oxygen sensor. Clear the DTCs and verify if the reading of the oxygen sensor is within
verify if the reading of the oxygen sensor is within the the allowable range.
allowable range. If the problem remains, replace ECM .
- 120 -
DTC Diagnosis item

P0136 Oxygen sensor circuit open circuit (group 1, sensor 2)
P0140 Oxygen sensor circuit short circuit (group 1, sensor 2)
Description
gas and feed back to control system for control of air/fuel ratio. When AFR is thinner, O2 concentration in exhaust
concentration.

●ECM checks for open circuit in heating oxygen sensor output line ●Heating type oxygen
Inspection range sensor fault
●Coolant temperature sensor: normal ●Open circuit in heating
●After completion of startup procedure, heating oxygen sensor voltage is 0.1V or oxygen sensor output line
lower for continuous 3min or longer ●ECM fault
●ECT is 80℃ or higher
●Engine rotation speed is higher than 1200rpm
●Engine load is 25% or higher
●Monitoring time: 7-10s
Judgment criteria
●When 5V is supplied to heating oxygen sensor output line via a resistor, input
voltage supplied to ECM interface circuit is 4.5V or higher
●Thickening of air/fuel ratio by 15% will not cause rise of heating oxygen sensor
output voltage exceeding 0.1V
- 121 -
Circuit diagram
Front oxygen sensor

Rear oxygen sensor

- 122 -
Detection procedure
● Turn the ignition switch to ON
● Connect the testing tool to the data
connecting joint
● Verify if the DTC P0136 or P0140 have
been set as well as other DTCs
No Yes
Start the engine and warm up the engine to the normal Regulate the conditions affecting the
operating temperature.
Turn on the A/C (if equipped) setting of other DTCs. Refer to the DTC
Increase the engine speed to 4000rpm. Use the testing tool to testing procedure.
observe if the voltage of the oxygen sensor changes within the
range of 0- 900mv.
No, the reading is No, the reading is No, the No, the voltage No, the voltage Yes, the voltage
a constant 否，电压变 is否，电压变
changing in 是is，电压在
changing
a constant voltage voltage of about reading is 0V. is changing in
但在 500mV the 但在 range above within
500mV the range
100-900mV
of about 450mV 5V or 12V. the range below 500mV of 100-900mV.
以下（稀) 以上（浓) 之间变化
500mV (rare) (frequent)
Repair the short circuit

修正线路线束
voltage in the wiring
harness
中的短 and接verify
电 if B C D
the reading of the
压，并验证氧
oxygen sensor is 转下一页
Go to next 转下一页转下一页
Go to next
传感器在正常 Go to next
range.
的参数范围内 page page page
● When the engine is running, ●Disconnect the oxygen sensor connector.

measure and observe if the voltage Observe if the voltage reading on the testing tool is
changing within the range of 19-58mV.
between the front oxygen sensor
connector terminal No.1 and No.2 is
changing around 500mV.
No
否 Yes
是
A Repair the short circuit to ground between Replace the oxygen sensor.
the oxygen sensor wiring harness connector Clear the DTCs and verify if
terminal No.2 and ECM wiring harness the reading of the oxygen
转下一页
Go to next page connector C15-4 terminal No.22. Clear the sensor is within the allowable
DTCs and verify if the reading of the range.
- 123 -
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Continued
Yes
是 No
否
● Turn the ignition switch to OFF.

Replace the oxygen sensor. Clear the DTCs and
● Disconnect the rear oxygen sensor
● Disconnect the ECM connector C15-4 verify if the reading of the oxygen sensor is within
● The rear oxygen sensor wiring harness connector the allowable range.
● Measure and observe if the resistance between
the ground wire and the ECM wiring harness
connector terminal No.2 and the ECM connector
Yes
是 No
否
Verify if the ECM connector is fastened. If yes, replace Repair the open circuit or high resistance caused
by other reasons. Clear the DTCs and verify if the
with a new and good oxygen sensor. Clear the DTCs reading of the oxygen sensor is within the
and verify if the reading of the ECT sensor is within allowable range.
Continued
接上一页 from previous page Continued
B C
The voltage is changing in the range

The电压变化但在
voltage is changing in the range
500mV 以下（稀) 电压变化但在 500mV 以上（浓)
below 500mV (frequent)
below 500mV (rare)
● Check if there is leakage or damage on the lower

end of intake port of the mass air flow sensor.
● Check if there is any crack, leakage or damage
occurred on the exhaust manifold
Yes
是 No
否
Repair or replace the exhaust manifold. ●According to some descriptions in the service manual,
Clear the DTCs and verify if the reading verify if the testing fuel pressure after completing tests is
of the sensor is within the allowable within the specified range and there is no pressure leakage.
range.
E
Go to next page
转下一页
- 124 -
接上一页
Continued from previous page 接上一页
D E
The voltage is changing within the

range of 0-900mV.
Yes No
According to the diagnostic

● Turn the ignition switch to OFF.
procedure, Clear the DTCs and
● Disconnect the connector on the ignition coil.
verify if the reading of the oxygen
● After starting the engine, connect a voltmeter between the sensor is within the allowable
battery negative(-) pole post and the contact point lead of the range.
generator to measure and observe the voltage drop passing the
battery negative pole(-) is below 0.5V.
Yes
是
No
否
Replace the negative battery cable.

● Disconnect negative (-) battery terminal. Clear the DTCs and verify if the
● Measure and observe if the resistance between the generator reading of the oxygen sensor is
cover and the grounding point is around 1 or less. within the allowable range.
Yes
是 No
否
● If the malfunction light indicator (MLI) flashes Clean the contact surface of the
intermittently and the DTCP0136 has been set, it may be caused
generator cover and the engine
by poor grounding circuit. Clean the negative battery terminal and
engine ground wire as well as the contact surface of the generator body. Clear the DTCs and verify if
cover and the engine body. the reading of the oxygen sensor is
● If the MLI lights and DTCP0136 has been set, replace the in the allowable range.
oxygen sensor.
● Clear the DTCs and verify if the reading of the oxygen
sensor is in the allowable range.
- 125 -
DTC Diagnosis fault

P0141 Oxygen sensor heating circuit fault (group 1, sensor 2)
Description
concentration.

Background ●Open or short circuit in oxygen
●When heater is excited, ECM checks if heater current is in specified sensor heater circuit
range. ●Open circuit of oxygen sensor
heater
Inspection range ●ECM fault
●Battery voltage is 12-16V.
Judgment criteria
●Heater current of heating oxygen sensor (group 1, sensor 2) is 0.2A or
lower, or 3.5A or higher for continuous 6s
- 126 -
Circuit diagram
Front oxygen sensor

Rear oxygen sensor

- 127 -
Detection procedure
● Turn the ignition switch to ON
● Connect the testing tool to the data connecting joint
● Verify if the DTC P0141 has been set
● Disconnect the rear oxygen sensor

● Start the engine.
● Measure and observe if the voltage between the
oxygen sensor wiring harness connector terminal No.3 and
the ground wire is within the range of 12-16V.
Yes No
● Turn the ignition switch to OFF. Repair the open circuit between the connector
● Disconnect the rear oxygen sensor terminal and the oxygen sensor wiring harness
connector terminal No.3. Clear the DTCs and
● Disconnect the ECM connector C15-3. verify if the reading of the oxygen sensor is within
Measure and observe if the resistance between the the allowable range.
ground wire and the oxygen sensor wiring harness
connector terminal No.4 shows any open circuit in
the circuit.
Yes
是 No
否
 Turn the ignition switch to OFF. Repair the open circuit between the ECM wiring
 Disconnect the rear oxygen sensor harness connector C15-3 terminal No.4 and the
 Disconnect the ECM connector C15-3. oxygen sensor wiring harness connector terminal
Measure and observe if the resistance between No.4. Clear the DTCs and verify if the reading of
the ground wire and the oxygen sensor wiring
harness connector terminal No.4 shows any the oxygen sensor is within the allowable range.
open circuit in the circuit.
Yes
是 No
否
 Turn the ignition switch to OFF. Repair the short circuit to ground or other short
 Disconnect the rear oxygen sensor circuits between the ECM wiring harness
connector C15-3 terminal No.4 and the oxygen
 Measure and observe if the resistance between sensor wiring harness connector terminal No.4.
the oxygen sensor terminal No.3 and No.4 is within Clear the DTCs and verify if the reading of the
the allowable range(7-9).
Yes
是 No
否
Verify if the ECM connector is fastened. If yes, Replace the oxygen sensor. Clear the DTCs and
replace the rear oxygen sensor. Clear the DTCs and
verify if the reading of the oxygen sensor is within verify if the reading of the oxygen sensor is within
the allowable range. If the problem remains, replace the allowable range.
ECM.
- 128 -
DTC Diagonosis item
P0171 Fuel mixed gas too thin (group 1)
P0172 Fuel mixed gas too thick (group 1)
Testing procedure
●Use the testing tool to check if there are DTCS stored。

Is there any DTC stored in the ECM memory?
No
否 Yes
是
●Check if there is any air leakage between the air filter and Repair other relevant malfunctions first.
the throttle valve body and any loosened part on the hose and
the pipeline.
No
否 Yes
是
● Check if the vacuum hoses in the engine power

Repair as necessary
compartment (especially the PSV, ISC hoses and the vacuum
booster) are connected correctly.
No
否 Yes
是
●When the engine is running in the idle speed, disconnect

the hoses between the EVAP valve and the carbon canister. Repair as necessary
Check if there is a vacuum in the purifying valve when the
EVAP valve is not working
No
否 Yes
是
●After installing the fuel pressure gauge on the repairing point There is a malfunction in the EVAP carbon
of the fuel pipeline, connect the DLC F/P and B（B+） with a canister purifying valve or the circuit.
jumper. Repair in accordance with DTC P0443
Turn the ignition switch to ON, measure and observe if the fuel repairing procedure.
pipeline pressure is correct.
Idle speed Fuel pressure: 46-49psi
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Yes
是 No
否
Test the front oxygen sensor output wire reversely. Start the Low pressure: clamp the oil return pipe the
engine and warm up the engine to the operating temperature. check if the pressure rises.
When spraying the carburetor cleaning agent in the following  If the pressure rises, replace the pressure
areas within a short time, the voltage on the front oxygen regulator
sensor output terminal is found rising for a quite long time(the  If the pressure does not rise, check the
voltage will rise if the spraying indicator shows that the filter screen in the fuel pump
carburetor cleaning agent has entered into air intake chamber High pressure: disconnect the oil return pipe
and there is a fuel-air mixed gas leakage) Make sure there is at the fuel filter side and blow air to the
enough time to measure the quantity of the carburetor cleaning canister through the pipeline.
agent diffused in those areas.  If the pipeline is clean, replace the fuel
Warning supply module.
Don’t spray the carburetor cleaning agent near the coil or the  If the pipeline is blocked, check the
spark plug lead, or a fire will be caused on the lead or the coil. reasons for it and clean or replace as
 Gasket of the throttle valve body necessary.
 Gasket between the intake manifold and the purifying
If all the above are OK, check the fuel
canister
 Sealing member between the intake manifold and the fuel
injector
 Sealing member between the purifying canister and the
PCV valve.
Is there any gas leakeage?
No
否 Yes
是
● Check if there is any air leakage in the exhaust

system(especially the parts around the exhaust manifold and the Repair as necessary.
oxygen sensor or at the back of the catalyzer)
No
否 Yes
是
 Start the engine; check the reduced engine speed when Repair as necessary
pulling off the joints of the fuel injector one by one.
 Measure the reduced engine speed of all 4 cylinders
Is there no change or just a little chan
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Continued
B
No
否 Yes
是
●Check if the MAFS output signal between the MAFS

Repair as necessary.
output terminal No.2 and the receiving and sending
terminal No.3 is within the allowable range (0.2-0.8V)
when the engine is running at idle speed.
Yes
是 No
否
●Remove the spark plug and check if the color of the Check and repair according to the MAFS
spark plug end is different from that in other cylinders. diagnosis.
No
否 Yes
是
●Check if the input signals of the MAFS, oxygen sensor, Check if there is malfunction in the engine
TPS, ECM and other parts are within the allowable range. mechanism. If no, replace the spark plug.
Yes
是 No
否
Make the vehicle recover to its initial condition and clear Replace all damaged parts
all DTCs. Verify and monitor the unidentified codes by
driving a vehicle equipped with testing tools.
DTC Diagnosis item

P0201，P0202
Fuel injector circuit fault (cylinder-1, cylinder-2, cylinder-3, cylinder-4)
P0203，P0204
Description
Fuel injectors are of solenoid valve type and normally closed. When fuel injector coil is excited (subject to pulse),
injector needle valve will move so that compressed fuel passes the injector and mixes with air entering the engine.
Each fuel injector (one for each cylinder) is fitted inside intake air manifold to facilitate fuel injection into
cylinder head gas inlet.
- 131 -
ECM controls fuel injection timing and pulse width (how long injectors will open). Based on information
provided by engine sensor network, ECM sends pulses to fuel injectors. ECM makes use of crankshaft position
sensor to determine when to send pulse to injectors. ECM uses data such as engine coolant temperature, intake air
temperature, air flow and throttle position etc. to calculate fuel injector pulse width.
ECM also uses sensor network to determine if a pulse will be provided to all injectors (synchronous injection) or
an individual injector (sequential injection). During normal operation of engine, sequential injection is always
used and during engine starting, synchronous injection will be used.

●When an injector is driven, current flows into closed injector coil to ●Injector fault
generate impulse voltage ●Open or short circuit or loose
●ECM checks this impulse voltage. connector in injector circuit
Inspection range ●ECM fault
●Engine rotation speed is 50-1000rpm
●TP sensor output voltage is 1.16V or smaller
Judgment criterion
●Impulse voltage in injector coil is not detected for 4s (system voltage
of +2V)
Circuit diagram
Connect the connector.
#1 fuel #2 fuel #3 fuel #4 fuel

injector injector injector injector
#1 fuel #2 fuel #3 fuel #4 fuel

control device control device control device control device
Detection procedure
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 Verify if the DTC P0201, P0202, P0203 or P0204 have been set.
 The engine is running at idle speed under the normal running temperature.
 Check the reduced engine speed when pulling off the joints of the fuel injectors one by
one. Is the reduced speed the same for all fuel injectors?
No Yes
 Turn the ignition switch to OFF. It is an intermittent malfunction or has been

 Disconnect the joints of fuel injectors repaired. ECM memory has not been cleared.
 Measure and observe if the voltage between the Clear the DTCs and verify if the reading of the
ground wire and the fuel injector wiring harness terminal fuel injector is within the allowable range.
No.2 is the same as the battery voltage.
Yes
是 No
否
●断开燃油喷油器
Disconnect the fuel injector Repair the open circuit between the connector
修理接头端子和燃油喷油器线束接头端
 Turn the ignition switch to OFF. terminal and the fuel injector wiring harness
●关闭点火开关子 2 间开路情况。清除代码并确认燃油
connector terminal No.2. Clear the DTCs and
 Disconnect the ECM connector C15-1. The fuel injector
●断开harness
wiring ECM 接头 C15-1，
connector 燃油喷油器线束接头端子
terminal No.1 is grounded. 1Measure
接地， verify if the reading of the fuel injector is within
喷油器在正常参数范围内
and observe if the resistance
测量地线和 ECM 接头 C15-1 线束端子间的电阻是否约为 between the ground wire and the the allowable range.
ECM
1Ω 或更小wiring harness connector C15-1 terminal is around 1
or less

Yes
是 No
否

●关闭点火开关 Repair the open circuit between the ECM
 Disconnect the fuel injector wiring harness connector C15-1 terminal
●断开燃油喷油器
 Disconnect the ECM connector C15-1
●断开 ECM 接头 and the fuel injector terminal No.1. Clear
 Measure andC15-1
observe if the resistance between the
ground wire and the
●测量地线和燃油喷油器线束接头端子 fuel injector wiring harness terminal No.1
1 间的电阻阻值 the DTCs and verify if the reading of the
shows any open circuit occurred. fuel injector is within the allowable range.
是否显示为开路
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Continued
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Yes
是 No
否
 Turn the ignition switch to OFF. Repair the short circuit to ground or other
修理 ECM 线束接头
malfunctions C15-1
in the circuit 端子和燃油喷油器
between the ECM wiring
 Disconnect the fuel injector
Measure and observe if the resistance between the fuel harness
线束接头端子connector1C15-1 terminal and the fuel injector
间的接地短路或短接其它电路
connector terminal No.1. Clear the DTCs and verify if
中的故障，清除故障代码并确认燃油喷油器正
injector connector terminal No.1 and No.2 is around the reading of the fuel injector is within the allowable
14.5 under the temperature of 20℃. 常参数范围内
range.
Yes
是 No
否
Verify if the ECM connector is fastened. If yes, replace Replace the fuel injector. Clear the DTCs and verify
with a new and good fuel injector. Clear the DTCs and if the reading of the oxygen sensor is within the
verify if the reading of the fuel injector is within the allowable range.
allowable range. If the problem remains, replace ECM.
DTC Diagnosis item

P0300 Random fire accident detected
Description
When ignition switch is at “On”or “Start”, voltage is supplied to ignition coil. Ignition coil consists of two coils
and is connected to each cylinder by HV wire. In each expansion stroke (cylinder in compression stroke and
exhaust stroke), ignition coil will light two spark plugs. Coil No.1 will ignite cylinder 1 and cylinder 4, while coil
No.2 will ignite cylinder 2 and cylinder 3.
Ignition power transistor is controlled by ECM and provides a switching circuit ground to excite primary ignition
coil. When primary coil is excited or deexcited, this coil generates a HV peak to pass connected spark plug. At the
same time, rotation speed interface (ignition power transistor part) will supply a rotation speed signal to ECM and
transmission control module (TCM).
- 134 -
DTC detetion conditions Fault causes

●Sudden change of engine rotation speed in case of fire accident during ●Fault of relevant ignition system
engine operation parts
●ECM checks change of engine rotation speed ●Poor crankshaft position sensor
Inspection range signal
●5s or longer after start of engine ●Incorrect air/fuel ratio
●Engine rotation speed is 500 to 6000rpm ●Low cylinder compression pressure
●Engine coolant temperature is higher than -10℃ ●ECT sensor fault
●Intake air temperature is higher than -10℃ ●Missing tooth in timing belt
●No sudden acceleration/deceleration during operation, e.g. gear shift ●Fuel injector fault
Judgment criteria (change of crankshaft angular acceleration is used for ●Engine control module fault
detection of fire accident)
●Frequency of ignition failure in recent 200 revolutions is higher than
permitted value. [When catalyst temperature is higher than 950℃]
●During 1000 revolutions of electric motor, fire accident frequency is
higher than permitted value (2%)
Circuit diagram
Ignition switch
To spark plug No.1 To spark plug No.1

#2 Ignition
#1
ignition failure
ignition
coil sensor
coil
Ignition detecting Speed

Ignition coil Ignition coil signal controller
control device control device
- 135 -
Detection procedure
 Inspect the fuel quality
joint
Is the DTC P0300 the only code that has been set? Is
the octane number of the fuel above 87.
Yes No
否
 Turn the ignition switch to ON Refer to the appropriate section and in accordance
 Disconnect the connector on the ignition coil.
with the testing procedure of other setting codes,
Measure and observe if the voltage between the ground
wire and the ignition coil connector terminal No.1 is refill the vehicle with the fuel whose octane number
the same as the battery voltage. is or above 87. Clear the DTCs and verify if the DTC
P0300 has not been set.
Yes
是 No
否
 Turn the ignition switch to OFF. Repair the circuits between the connectors of the
 Disconnect the ECM connector C15-1 engine parts and the ignition coil connector terminal
 Ignition coil wiring harness connector terminal
No.1. Clear the DTC and verify that the DTC will
No.3 is grounded. Measure and observe if the
resistance between the ground wire and the ECM not present again.
wiring harness connector C15-1 terminal No.10 and
No.23 is around 1 or less.
Yes
是 No
否
 Turn the ignition switch to OFF. Repair the open circuit between the ignition coil
 Measure and observe if the resistance connector terminal No.3 and ECM connector C15-1
between the ignition failure sensor wiring harness
terminal No.10 and No.23. Clear the DTC and verify
connector terminal No.2 and the ignition coil
wiring harness connector terminal No.1 is around that the DTC will not present again.
1 or less.
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Yes No
否

 Ignition failure sensor Repair the open circuit between the ignition failure
 Measure and observe if the resistance between the sensor wiring harness connector terminal No.3 and
ground wire and the ignition failure sensor wiring the ignition coil connector terminal No.2. Clear the
harness connector terminal No.1 and the ignition coil DTC and verify that the DTC will not present again.
wiring harness connector terminal No.1 is around 1
or less.
Yes No
是否
 Disconnect the ignition coil Repair the open circuit between the ignition switch
●断开点火线圈
Connect the ECM connector again. 修理点火开关和点火线圈接头端子 1 间的断路
and the ignition coil connector terminal No.1. Clear
●再连接
Turn theECM 接头 switch to START.
ignition 线路，清除代码并确认代码不再出现。
●点火开关转至起动
Measure and observe if the voltage between the the DTC and verify that the DTC will not present
ground wire and the ignition coil wiring harness again.
●测量地线和点火线圈线束接头端子 3 间的电
connector terminal No.1 is within the range of 4-5V.
压，电压应在 4V 和 5V 之间。
Yes No
是否
Verify  Turn the ignition switch to OFF.

确认ifECMthe ECM connector is fastened. If yes, replace
接头是紧固的，如果一切正常，用已知
with a new and good power transistor. Clear the DTC  Disconnect the ignition coil connector.
好的部件更换功率晶体管。清除代码和验证代码不  Measure the resistance between the ignition coil
and再出现。如果问题仍存在，更换
verify that the DTC will not present
ECM。 again. If the connector terminal No.1 and No.2. Pay attention to
problem remains, replace ECM. the resistance of the primary coil.
 Measure the resistances between the ignition
coil spark plug lead terminal No.1 and No.4, and
terminal 2 and No.3. Pay attention to the resistance
of the secondary coil.
 The resistance of the primary coil should be
about 1.3 and resistance of the secondary coil
should be within the range of 10.3K-13.9K. The
measured resistance should be within the
specification.
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No No
否

Replace the ignition coil. Clear the DTC and
 Inspect the spark plug, cables, the fuel injector
verify that the DTC will not present again
and the vacuum hose and make sure that all of these
are not damaged and within the specifications.
Yes
是
No
否
Repair or replace the parts damaged or out of the Replace the power transistor. Clear the DTC and
specifications. Clear the DTC and verify that the verify that the DTC will not present again.
DTC will not present again.
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DTC Diagnosis item

P0301，P0302
Fire accident detection (cylinder-1, cylinder-2, cylinder-3, cylinder-4)
P0303，P0304
Description
Reference random detection of ignition failure (P0300)

●Sudden change of engine rotation speed in case of fire accident during engine ●Fault of relevant ignition
operation system parts
●ECM checks change of engine rotation speed ●Poor crankshaft position
Inspection range sensor signal
●5s or longer after start of engine ●Incorrect air/fuel ratio
●Engine rotation speed is 500 to 6000rpm ●Low cylinder compression
●Engine coolant temperature is higher than -10℃ pressure
●Intake air temperature is higher than -10℃ ●ECT sensor fault
●No sudden acceleration/deceleration during operation, e.g. gear shift ●Missing tooth in timing belt
Judgment criteria (change of crankshaft angular acceleration is used for ●Fuel injector fault
detection of fire accident) ●EGR valve fault
●Frequency of ignition failure in recent 200 revolutions is higher than ●ECM fault
permitted value. [When catalyst temperature is higher than 950℃]
●During 1000 revolutions of electric motor, fire accident frequency is higher
than permitted value (2%)
Circuit diagram
Ignition switch
To spark plug To spark plug

#1 #2 Ignition
ignition ignition failure
coil coil sensor
Ignition Speed
Ignition coil Ignition coil detecting signal controller
control device control device
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Detection procedure
 Make sure that the fuel whose octane number is or above
87 is used on the vehicle.
 Verify if the DTC P0301, P0302, P0303 or P0304 as well
as DTC P0201, P0202, P0203 or P0204 have been set or if the
fuel whose octane number below 87 is used.
Yes No
否
 Turn the ignition switch to OFF. Complete relevant testing procedures. If

 ●关闭点火开关
Disconnect the ignition coil connector. necessary, refill with the fuel whose
 ●断开点火线圈接头
Measure the resistance between the ignition coil connector octane number is or above 87. Clear the
terminal No.1 and No.2. Pay 1attention
●测量点火线圈接头端子 to the resistance of the
和 2 间的电阻，注意初级线 DTC and verify that the DTC will not
primary coil.
present again.
 圈电阻值Measure the resistance between the ignition coil spark plug
lead terminal No.1 and No.4.
●测量点火线圈火花塞引线端子 1 和 4 间的电阻
 Measure the resistance between the ignition coil spark plug
●测量点火线圈火花塞引线端子
lead 2 和 to
terminal No.2 and No.3. Pay attention 3 间的电阻，注意
the resistance of the
primary coil.
次级线圈电阻值
The resistance of the primary coil should be about 1.3 and
resistance of the secondary coil1．
初级线圈电阻值是否大约为 3Ω,次级线圈电阻是否在
should be within the range of
10.3-13.9kΩ 之间
10.3K-13.9K.
Yes
是 No
否
 Turn the ignition switch to OFF. Replace the ignition coil. Clear the DTC
and verify that the DTC will not present
 Check if the spark plug, cables, the vacuum hose and again.
the connector are not damaged.
Yes
是 No
否
 Turn the ignition switch to OFF. Repair or replace the parts. Clear the DTC
●关闭点火开关
Check if the fuel injector is blocked or if it is in normal and verify that the DTC will not present
●检查燃油喷油器是否堵塞，燃油喷油器是否正常 again.
condition.
Yes
是 No
否
Clean or replace the fuel injector. Clear

Verify if the ECM connector is fastened. If yes, replace ECM. the DTC and verify that the DTC will not
Clear the DTC and verify that the DTC will not present again. present again.
- 140 -
DTC Diagnosis item
P0325 Knock-meter circuit fault (group 1)
Detection procedure
 Turn the ignition switch to OFF and disconnect the connectors of the
knock sensor and the ECM.
 Measure and observe if the resistance between the knock sensor
terminal No.2 (to ECM) and the ECM is less than 1.
Yes No
●Measure and observe if the resistance between the knock Disconnect the knock sensor terminal No.2
sensor terminal No.3 (to ECM) and the ECM is less than 1. from the ECM and repair as necessary.
Yes No
否
●Measure and observe if the resistance between the knock Disconnect the knock sensor terminal
断开爆震传感器端子 3 和 ECM No.3
间的连from
sensor terminal No.1 (to ECM) and the ECM is less than
the 接，按需要修理
ECM and repair as necessary.
1.
Yes No
是否
 Connect the knock sensor connector and the ECM Disconnect the knock sensor
●再连接爆震传感器接头和 ECM 接头断开爆震传感器端子 1 和terminal No.1 from
ECM 间的连
connector again. the接，按需要修理
ECM and repair as necessary.
●测量爆震传感器端子
Measure and observe3（至 if theECM) 和地线间的电阻
resistance between the
knock
是否小于 sensor1Ω
terminal No.3 (to ECM) and the ground wire
is less than 1.
Yes No
是否
knock sensor terminal and 3the terminal No.2 is（在
within the The knock sensor terminal No.3 and the ECM
●测量爆震传感器端子
specified range ( 4.87M10% 和端子 2 间的电阻
under 20℃
the temperature of 爆震传感器端子 3 和 ECM 端子 3 接地短
terminal No.3 is short circuit to the ground.
20时 ).
℃4.87MΩ±10%) 是否在规定范围内路，按需要修理
Yes No
是否
The terminals are bad connected because of oxidation, Replace with a new and good knock sensor and
由于氧化、弯曲或端子错位造成端子接触不良，按需先用已知好的爆震传感器部件安装上并
bending and terminal misplacement. Repair as necessary. check if it is working correctly. If yes, replace
要进行修理检查是否运行正常，如果问题解决，更
knock sensor.
换爆震传感器
Make the vehicle recover to its initial condition and clear all DTCs,
返回车辆至原始状态，清除所有故障诊断代码，通过行
and then verify and monitor the unidentified DTCs by driving a
驶连接有检测工具的车辆来验证和监控悬而未决的代码
vehicle equipped with testing tools.
- 141 -
DTC Diagnosis item
Description
Crankshaft position (CKP) sensor consists of a magnet and a coil near flywheel. This sensor sends a voltage signal
to ECM to determine engine rotation speed and crankshaft position.

●During engine operation, crankshaft position sensor outputs a pulse signal ●Crankshaft position sensor
●ECM checks for pulse signal input during engine startup fault
Inspection range ●Open circuit or short circuit in
●Engine already started crankshaft position sensor circuit
Judgment criteria ●ECM fault
●Sensor output voltage not changing (no pulse signal input) for 4s
●No normal signal input from crankshaft position sensor and camshaft
position sensor for 4s
Circuit diagram
Connect the connector.
Camshaft Crankshaft
position position
sensor. sensor
Camshaft position signal Crankshaft position signal

- 142 -
Detection procedure

joint
 Ignition switch at ON position

●点火开关打开
 Disconnect the crankshaft position (CKP) sensor.
●断开曲轴位置（CKP)
Measure and observe 传感器if the voltage between the
●测量地线和 CKP 传感器线束接头端子
ground wire and the CKP sensor wiring 3 间的电
harness
压是否为蓄电池电压，
terminal No.3 is the same as the battery voltage.
Yes No
否
 Turn the ignition switch to OFF. Repair the open circuit between the CKP sensor
●点火开关关闭
 Disconnect the CKP sensor wiring harness connector terminal No.3 and the
 ●断开 CKP 传感器
Disconnect the ECM connector C15-2
●断开 ECM 接头
 CKP sensor wiring C15-2
harness connector terminal No.2 engine part connector terminal No.D10. Clear the
●CKP 传感器线束接头端子
is grounded. Measure and observe 2 接地，测量地线和
if the resistance DTCs and verify if the reading of the CKP sensor
ECM 线束接头
between C15-4
the ground wire端子
and 5the
间的电阻是否大约为
ECM connector C15-4 is within the allowable range.
1Ω 或者更
terminal is 1 or less.
Yes
是 No
否
 Turn the ignition switch to OFF. Repair the open circuit between the CKP sensor
 Disconnect the CKP sensor 修理 CKP 传感器线束接头端子 2 和 ECM 线束
 Disconnect the ECM connector C15-4. Measure wiring harness connector terminal No.2 and the
接头 C15-4 端子 19 间的开路现象，清除代码
and observe if the resistance between the ground wire ECM wiring harness connector C15-4 terminal
并确认 CKP 传感器在正常参数范围内
and the CKP sensor wiring harness connector terminal No.19. Clear the DTCs and verify if the reading of
No.2 shows any open circuit in the circuit.
the CKP sensor is within the allowable range.
Yes
是 No
否
Repair the short circuit to ground or other short circuits

修理 CKP 传感器线束接头端子 2 和 ECM
between the CKP sensor wiring harness connector
线束接头 C15-4 端子 19 间的接地短路或短
terminal No.2 and the ECM wiring harness connector
接其它回路中的问题，清除代码并确认
C15-4 terminal No.19. Clear the DTCs and verify if
CKP 传感器在正常参数范围内
the reading of the CKP sensor is within the allowable
range.
A
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 Disconnect the CKP sensor
 Measure and observe if the resistance between the ground wire and the CKP sensor
wiring harness connector terminal No. 1 is 1 or less.
Yes No
否
●Check if there are damaged parts or fragments Repair the open circuit or short circuit to ground in the
修理接地线路中的开路或接地不良现象,清除
in the CKP sensor and if the CKP is in the normal ground wire. Clear the DTCs and verify if the reading
conditions. of 代码并确认 CKP
the CKP sensor 传感器在正常参数范围内
is within the allowable range.
Yes
是 No
否
Turn the ignition switch to ON Repair
修理或更换or replace
CKPthe传感器,清除代码并确认
CKP sensor. Clear the DTCs
CKPand
 Disconnect the CKP sensor
verify if the reading of the CKP sensor is within the
 ●断开 CKPthe
Connect 传感器PCM connector. 传感器在正常参数范围内
 ●接上Measure
PCMand
接头 observe if the voltage between the allowable range.
ground wire and CKP
●测量地线和 the 传感器线束接头端子
CKP sensor wiring harness
2间
terminal No.2 is around 5V.
的电压是否大约为 5V
No
否 Yes
是
Verify
确认ifPCM ECM connector is fastened. If yes, Repair
the 接头已紧固,如果一切正常,用一个修理或更换or replace
CKPthe传感器,清除代码并确认
CKP sensor. Clear the DTCs
CKPand
replace with a new andCKP
已知好的部件更换 CKP sensor. Clear the verify
good传感器,清除代码并 if the reading of the CKP sensor is within the
传感器在正常参数范围内
DTCs
确认and verify
CKP if the reading of the CKP sensor is allowable range.
传感器在正常参数范围内.如果问
题仍存在,更换 ECM range. If the problem remains,
replace ECM.
DTC Diagnosis item

Description
Camshaft position (CMP) sensor monitors #1 cylinder top dead center (TDC) in compression stroke. Signals of
CMP sensors are provided to ECM for determination of fuel injector sequential starting point.
- 144 -

●Camshaft position sensor outputs pulse signal during engine operation ●Camshaft position sensor fault
●ECM checks for input of pulse signal ●Open circuit, short circuit or
Inspection range and judgment criteria loose connector in camshaft
●No change of sensor output voltage (no pulse signal input) for 4s position sensor circuit
●No normal signal input from crankshaft position sensor and camshaft ●ECM fault
position sensor for identification of cylinder for 4s
Circuit diagram
Camshaft Crankshaft
position position
sensor sensor
Camshaft position signal Crankshaft position signal
- 145 -
Detection procedure
 Connect the testing tool to the data
connecting joint
 Verify if the DTC P0340 has been identified.
 Ignition switch at ON position

●点火开关打开
 Disconnect the camshaft position (CMP) sensor
 ●断开凸轮轴位置(CMP)传感器
Measure and observe if the voltage between the
●测量地线和 CMPCMP
ground wire and the 传感器线束接头端子 3 间的
sensor wiring harness terminal
电压是否为蓄电池电压
Yes No
否
 Turn the ignition switch to OFF. Repair the open circuit between the CMP sensor wiring
●点火开关关闭修理 CMP 传感器线束接头端子 3 和发动机
 Disconnect the CMP sensor harness connector terminal No.3 and the engine part
 ●断开 CMP 传感器
Disconnect the ECM connector C15-4 部件连接体端子间的开路,清除代码并确认
connector terminal. Clear the DTCs and verify if the
 ●断开The ECM
CMP 接头 sensor
C15-4 wiring harness connector reading
CMP of the CMP sensor signal is within the allowable
传感器的信号在正常参数范围内
●CMP 传感器线束接头端子 2 接地 range.
●测量地线和
ground wire and ECM 线束接头端子
the ECM 18 间的电阻
wiring harness connector
terminal
是否大约等于No.18 is 1Ω
around
或更小1 or less.
Yes
是 No
否
 ●点火开关关闭
Disconnect the CMP sensor Repair the open circuit between the CMP sensor wiring
修理 CMP 传感器线束接头端子 2 和 ECM
 Disconnect the ECM connector C15-4 harness connector terminal No.2 and the ECM wiring
●断开 CMP 传感器线束接头端子间的开路问题,清除代码并确
harness connector terminal. Clear the DTCs and verify if
●断开
ground ECM and
wire 接头 theC15-4
CMP sensor wiring harness the认reading of the CMP sensor signal is within the
CMP 传感器的信号在正常参数范围内
connector
●测量地线和 terminalCMP
No.2 shows any open circuit
传感器线束接头端子 2 间的 in the allowable range.
circuit.
电阻是否显示为回路开路
Yes
是 No
否
 Turn the ignition switch to OFF. Repair the short circuit to ground between the CMP
●点火开关关闭修理 CMP 传感器线束接头端子 2 和 ECM 线
 Disconnect the CMP sensor sensor wiring harness connector terminal No.2 and the
 ●断开 CMPand
Measure 传感器 observe if the resistance between the ECM束接头端子间的接地短路问题,清除代码并
wiring harness connector terminal. Clear the DTCs
and确认verify
CMP if 传感器的信号在正常参数范围内
the reading of the CMP sensor signal is
ground wire and the传感器线束接头端子
●测量地线和 CMP CMP sensor wiring1 间的 harness
电阻大小是否为大约等于或小于 1Ω within the allowable range.
connector terminal No. 1 is 1 or less.
Yes
是 No
否
 ●检查CheckCMP
if 传感器是否破损或失调,同时确认
the CMP sensor is damaged or Repair
修理the CMPopen circuit between the1 CMP
传感器线束接头端子和地线间的 sensor wiring
maladjusted
正时已是否调整正确 and verify if the timing is adjusted harness connector terminal CMP
开路问题,清除代码确认 No.1 and the ground wire.
传感器信号在
correctly. Clear the DTCs and verify if the reading of the CMP
正常参数范围内
sensor signal is within the allowable range.
- 146 -
DTC Diagnosis item
P0350 Fault fo ignition coil primary/secondary circuit
Testing procedure
●Turn the ignition switch to ON and disconnect the
ignition coil connector.
 Turn the ignition switch to ON. Measure and
observe if the voltage between the ignition switch
terminal No.4 and the ground wire is within the
specified range.
Yes No
否
●Turn the ignition switch to OFF and measure the There is a short circuit between the ignition coil
●关闭点火开关并测量初级线圈电阻[在 20℃时
resistance of the primary coil [0.66-0.88 under the
0.66-0.88Ω] terminal No.4 and the ignition switch. Repair as
temperature of 20℃]
●测量次级线圈电阻[在
Measure and observe20℃时 if the 11.3-15.3kΩ].
resistance of the necessary.
primary coil is within the specified range[11.3-15.3k
电阻是否在规定值范围内
under the temperature of 20℃].
Yes
是 No
否
The terminals are bad connected because of oxidation, Install with an ignition coil in good condition
由于氧化,弯曲或错位,端子接触不良,按需要进行
bending temporarily and check if it is working correctly.
修理 and terminal misplacement. Repair as necessary. If yes, replace the ignition coil.
 Turn the ignition switch to ON. Measure and observe if

●打开点火开关并测量 ECM 端子(气缸 1 和 4)和
the voltage between the ECM terminal (cylinder No.1 and
地线间的电压是否在规定值范围内
No.4) and the ground wire is within the specified range.
Yes
是 No
否
 Measure and observe if the voltage between the There is an open or short circuit between the
●测量 ECM 端子(气缸 2 和 3)和地线间电压是否点火线圈端子 3 和 ECM 端子间开路或短路,
ECM terminal (cylinder No.2 and No.3) and the ignition coil terminal No.3 and the ECM terminal.
在规定值范围内
ground wire is within the specified range. 按需要进行修理
Yes
是 No
否
Make the vehicle recover to its initial condition and clear There is an open or short circuit between the ignition
将车辆返回至原始状态,清除所有故障诊断代码, 点火线圈端子 1 和 ECM 端子间开路或短路,
all DTCs, and then verify and monitor the unidentified
通过行驶连接有检测工具的车辆来确认和监控 coil terminal No.1 and the ECM terminal. Repair as
按需要进行修理
DTCs by driving a vehicle equipped with testing tools.
悬而未决的代码 necessary.
- 147 -
DTC Diagnosis item

P0421 Heating catalyst efficiency lower than limit value (group)
Description
ECM compares wave forms of oxygen sensors in front of and behind catalyst to determine if catalyst performance
has deteriorated. Air/fuel ratio feedback compensation maintains cyclic change (thick to thin and thin to thick) of
wave form of oxygen sensor in front of catalyst.
If catalyst function is normal, wave form of oxygen sensor behind catalyst will change (cyclicly between thick and
thin) slower than that of the oxygen sensor in front of catalyst. However, when these wave forms change at similar
speed, catalyst performance has deteriorated.

●Signal of heating oxygen sensor behind catalytic converter is different from ●Aging of catalytic converter
that of the sensor in front of the converter. This is because catalystic converter ●Heating oxygen sensor fault
purifies exhaust gas. After aging of catalytic converter, these signals become ●ECM fault
similar.
●ECM checks output of heating oxygen sensor
Inspection range
●Engine rotation speed is greater than or equal to 3000rpm
●Close throttle position switch: off
●Under closed loop air/fuel ratio control
Judgment criterion
●Abnormal signal of front or rear heating oxygen sensro
- 148 -
Detection procedure

joint
 Verify if the DTC P0421 as well as other DTCs
relevant to the oxygen sensor have been set.
No Yes
是
 Turn the ignition switch to ON and the engine is In accordance with the DTC testing procedure,
●点火开关打开,发动机运行
running.
 ●检查在催化剂前后是否有泄漏
Check if there is a leakage at the front or back of the check P0133, P0135, P0136 or P0141 first.
catalyzer.
 ●检查前,后氧传感器周围是否有泄漏
Check if there is a leakage around the front or rear
oxygen sensor. Is the exhaust system near to the catalyzer
催化剂和氧传感器周围的排气系统是否都正常
and the oxygen sensor in the normal condition.
Yes
是 No
否
 In accordance with the DTC P0136 testing Tighten the parts on the leaking parts. Clear the
●按照 DTC P0136 测试程序检查后氧传感器是否拧紧泄漏部位的零件,清除代码并确认氧传
procedure, check if the oxygen sensor is in the normal DTCs and verify if the reading of the oxygen
正常
condition. 感器信号在正常参数范围内
sensor signal is within the allowable range.
Yes
是 No
否
 Turn the ignition switch to OFF. Repair or replace the rear oxygen sensor. Clear the
●点火开关关闭修理或更换后氧传感器,清除代码并确认氧
 Replace the catalyzer.
 ●更换催化剂
Clear the DTC P0421 from the memory. DTCs and verify if the reading of the oxygen
传感器的信号在正常参数范围内
 ●从存储器中抹去
Make the vehicle DTC to the road test and verify sensor signal is within the allowable range.
P0421
subject
●对车辆进行路试并确认
if the DTC P0421 是否再出现
DTC P0421 presents again.
Yes
是 No
否
Verify
确认 ifECM the 接头是紧固的,如果一切正常,更换
ECM connector is fastened. If yes, The problem is resolved and other tests are
问题已解决,不需要其他的测试
replace the ECM. Clear the DTCs and verify if the
ECM,清除代码并确认氧传感器信号在正常参数 unnecessary.
reading
范围内of the oxygen sensor signal is within the
allowable range.
- 149 -
DTC Diagnosis item
P0443 Fault of evaporation exhaust control system purification control valve circuit
Description
This evaporation system absorbs vapor in fuel tank and burns it as part of fuel storage, so as to lower COx
emission. Evaporated fuel will be stored in active carbon tank till absorbed into air intake manifold.

●When solenoid valve is turned on and off, ECM checks current in ●Fault of evaporation exhaust
evaporation exhaust purification solenoid valve driving circuit purification solenoid valve
Inspection range ●Open circuit, short circuit or
●Battery voltage greater than or equal to 10V loose connector in evaporation
Judgment criterion exhaust purification solenoid
●When EVAP exhaust solenoid valve is turned on/off, EM coil purification valve circuit
voltage (system voltage of +2V) is not detected. ●ECM fault
Circuit diagram
Connect the
connector
Purge control solenoid

valve (PCSV)
PCSV control device

Engine Control Module
(ECM)
Testing procedure
- 150 -

joint

●关闭点火开关
 Disconnect the PCSV connector.
 ●断开 PCSV
Turn the 净化控制电磁阀接头
ignition switch to ON
Measure and observe if the voltage between the
●测量地线和
ground wire and PCSV 线束接头端子
the PCSV 2 间的电压
wiring harness terminal
是否为蓄电池电压
Yes No
否
 Turn the ignition switch to OFF. Repair the open circuit or short PCSV
circuit接头端
to ground
●关闭点火开关修理发动机部件连接体端子和
 Disconnect PCSV.
between the engine part
子 2 间线路的开路或接地短路的情况，清除 connector terminal and the
 ●断开 PCSV the ECM connector C15-1. the PCSV
Disconnect
wiring
●断开 harness
ECM connector terminal No.1
接头 C15-1，PCSV is grounded.
线束接头端子 1 PCSV connector
代码并确认 terminal
PCSV No.2. Clear the DTCs and
在正常参数范围内
 接地 Measure and observe if the resistance between the verify if the reading of the PCSV is within the
ground
●测量地线和wire and ECM
the 线束接头
ECM wiring harness
C15-1 端子 connector
9 间电 allowable range.
C15-1 terminal No.9
阻是否大约为 1Ωis或更小
1 or less
Yes
是 No
否
 Turn the ignition switch to OFF. Repair

●点火开关关闭修理 theECM open
接头 circuit
C15-1between
端子 9 the ECM 线束
和 PCSV connector
 Disconnect ECM.
C15-1 terminal No.9 and the PCSV wiring harness
1 之间的开路线路清除代码并确认
●ECM 断开 PCSV.
Disconnect 接头端子
●PCSV
Measure
断开and observe if the resistance between connector terminal
PCSV 在正常参数范围内 No.1. Clear the DTCs and verify if
the ground
●测量地线和 wirePCSV
and 线束接头端子
the PCSV wiring
1 间的电阻harness the reading of the PCSV is within the allowable range.
connector terminal No.1 shows any open circuit in
显示是否为开路
the circuit.
Yes
是 No
否

●关闭点火开关修理the PCMshort circuit to9ground
接头端子和 PCSV or other
接头端子 short circuits
1
 Disconnect PCSV.
between
间的接地短路或短接其它回路等问题，清除 the
the PCM connector terminal No.9 and
●断开 PCSVand observe if the resistance between
Measure
PCSV connector terminal No.1. Clear the DTC and
the●测量
PCSVPCSV 接头端子
connector 1 和 2 No.1
terminal 间电阻是否大约and No.2 is 代码并确认代码不再出现
为 27Ω verify that the DTC will not present again.
around 27
Yes
是 No
否
Verify
确认if PCM
the PCM connector is fastened. If yes, replace Replace
接头是紧固的，如果一切正常，用 PCSV. Clear the DTCs PCSV
更换 PCSV，清除代码并确认 and verify
在正常if the
with a PCSV in good condition.
一个已知好的部件更换 Clear the DTCs and reading
PCSV，清除代码并确参数范围内 of the PCSV is within the allowable range.
verify if the在正常参数范围内，
认 PCSV reading of the PCSV如果问题仍存在，is within the
allowable
更换 PCM range. If the problem remains, replace PCM.
- 151 -
DTC Diagnosis item
Description
When the vehicle runs, vehicle sensor will output a pulse signal and ECM will check for pulse signal output.

●When the vehicle is running, speed sensor will output a pulse signal ●Fault of speed sensor
●Check ECM for output of pulse signal ●Open circuit, short circuit or loose
Inspection range connector in speed sensor circuit
●Close throttle position switch: off ●Fault of ECM
●Engine rotation speed greater than or equal to 3000 rpm
●Engine load greater than or equal to 70%
Judgment criterion
●No change of sensor output voltage (no pulse sigal input) for 4s
Circuit diagram
Junction box in the

passenger compartment
Vehicle speed
sensor
Vehicle speed input
Testing procedure
- 152 -
joint
 Driving the vehicle and observe if the
speedometer is working.
是否
 Turn the ignition switch to OFF. Repair the speedometer cable and/or driving
●关闭点火开关修理有缺陷的速度表电缆和/或驱动齿
 Check if the connector between the VSS and the gear parts with defects. Clear the DTCs and
●检查 VSS 和变速箱齿轮间接口是否正常 verify if the reading of theVSS
轮部件，清除代码并确认 VSS信号在
signal is
transmission gear.
正常参数范围内
是否

●关闭点火开关修理the VSSconnector between the VSS and the
和变变速箱齿轮间的接口，
 Disconnect the VSS connector.
transmission gear. Clear
VSSthe DTCs and verify
 ●VSS 接头断开
Disconnect the ECM connector C15-4. 清除代码并确认信号在正常参数
 ●断开The VSS wiring
ECM 接头 harness connector terminal No.3 is
C15-4 if the
范围内 reading of the VSS signal is within the
grounded.
●VSS 接头线束端子 3 接地 allowable range.
●测量地线和
ground ECMECM
wire and the 线束接头wiringC15-4 端子
harness 16 间的电
connector C15-4
terminal
阻是否大约为No.16 is 1
1Ωor less
或更小
是否
 Turn the ignition switch to OFF. Repair the circuit between the VSS wiring
 ●点火开关关闭
Disconnect the VSS connector. 修理 VSS 线束接头端子 3 和 ECM 线束
harness connector terminal No.3 and the ECM
 ●VSS 接头断开
Disconnect the ECM. 接头 C15-4
wiring harness端子 16 间的线路，清除代码
connector C15-4 terminal
 ●ECM
Measure
断开 and observe if the resistance between the No.16.
并确认 Clear
VSS the DTCs and verify if the
信号在正常参数范围内
VSS wiring
●测量 VSSconnector
线束接头端子 terminal No.3 and the ground wire
3 和地线间的电阻是否显 reading of the VSS signal is within the
allowable range.
shows any open circuit in the circuit.
示是一个开路
是否
Verify if the ECM connector is fastened. If yes, replace Repair the short circuit to ground and other short
确认
with ECMin接头是紧固的，如果一切正常，用已知
a VSS good condition. Clear the DTCs and verify 修理 VSS
circuits 线束接头端子
between the VSS3 和 ECM 线束
wiring harness
the reading of VSS，清除代码并确认
if 好的部件更换 the VSS signal is within VSS 信号在
the allowable connector terminal No.3
接头 C15-4 端子 16 间的接地短路或短接 and the ECM wiring
range. If the problem remains,
正常参数范围内，如果问题仍存在，更换 ECM replace ECM. harness connector C15-4 terminal No.16.
其它电路问题，清除代码并确认 Clear
VSS 信
the DTCs and verify if the reading of the VSS
号在正常参数范围内
signal is within the allowable range.
DTC Diagnosis item
- 153 -
P0507 Idling control-high rotation speed
Description
Amount of air intake during idling is controlled by opening or closing the idling control valve on throttle air
bypass. In case of fault in ISC system, actual engine rotation speed will be different from target engine rotation
speed. ECM will check this difference.

●In case of fault in ISC system, actual engine rotation speed will be ●Fault of idling speed control motor
different from target engine rotation speed. ●Open circuit, short circuit or loose
●ECM checks this difference. connector in idling speed control motor
Inspection range ●Fault of ECM
●Under closed loop idling speed control
Judgment criteria
●Actual idling speed higher than target idling speed by 300rpm or
more for continuous 10s
Inspection range
●During idling speed closed loop control
●During recent running, highest air temperature is smaller than or
equal to 45℃
●Fuel tuning is -8% to +8% for a long time
●Engine coolant temperature higher than or equal to 80℃
●Battery voltage higher than or equal to 10V
●Intake air temperature greater than or equal to -10℃
Judgment criterion
●Actual idling speed higher than target idling speed by 200rpm or
more for 10s
Inspection range
●During idling speed closed loop control
●Power steering pressure switch closed
●Engine load smaller than or equal to 40%
●Intake air temperature greater than or equal to -10℃
Judgment criterion
●Actual idling speed lower than target idling speed by 120rpm or
more for 10s
Circuit diagram
- 154 -

Switch on Switch off
VII. Ignition system (DOHC)

Ignition timing is controlled by ECM. Engine operation ignition
timing data are programmed and stored in ECM. Engine
operation conditions (speed, load, warming etc.) are detected by
various sensors. Based on such sensing signals and data stored
in ECM, signal to cut off primary current is sent to power
transistor. Igntion coil will be energized and timing controlled
at optimum point.
*CKP: crankshat position; *CMP: camshaft position
Ignition
2.4 14
Type
Primary coil resistance 0.86±10%(Ώ)
Secondary coil resistance 12.1±15%(Ώ)
- 155 -
Spark plug
2.4 14
Type
Champion RNIOPYP4
NGK PGR5C-11
Spark plug clearance 1.0-1.1 mm
Ignition system
Fault phenomena Fault causes Correction
Engine cannot start or Ignition lock switch fault Replace ignition lock switch
start with difficulty Ignition coil fault Check ignition coil
(rotation of crankshaft is Power transistor fault Check power transistor
normal) High voltage line broken or damaged Check HV line
Spark plug fault Replace spark plug
Poor idling or engine stop High voltage line fault Check HV line
Ignition coil fault Check ignition coil
Spark plug wire fault Check spark plug wire
Slow or failed engine Spark plug fault Replace spark plug
acceleration High voltage line fault Check HV line
Small operation mileage Spark plug fault Replace spark plug
Ignition coil
1. Measurement of primary coil resistance

Connect 3V power supply negative pole (-) terminal to
terminal 2 of power transistor. Then check conduction of
terminals 3 and 2 with terminal 1 connected and disconnected
to positive pole (+) terminal.
Terminals 1 and (+) Terminals 3 and 2
Connected Conduction (about 0.86Ώ)
Disconnected No conduction
In case of fault found, replace power transistor.
2. Measurement of secondary coil resistance

Measure resistance between ignition coil HV terminals.
Standard value: about 12.1KΩ
- 156 -
Dismantling and installation

1. Disconnect battery negative pole terminal.
2. Remove air bag module.
Warning:
SRS is designed such that within about 30s after
disconnecting batteries, there will be enough power to
expand air bag. Therefore, if SRS system maintenance is
carried out immediately after disconnecting batteries, air
bag may suddenly expand to seriously hurt people.
3. After loosening taper screw, lift and remove horn gasket.
4. Loosen lock nut and gasket.
5. Pull out damper from front, lift and remove the damper.
6. Install special tool (09562-11001) to remove steering wheel.
Caution:
Do not hammer steering wheel when removing it.
7. Remove upper and lower sheathes of steering column.
8. Remove lower cover.
- 157 -
9. Disconnect connector and remove multi-function switch.
10. Remove mounting bolts and separate ignition switch from steering column.
Inspection
1. Separate the connector under steering column.
2. Check conduction among switch terminals.
3. If conduction does not meet specification, replace the switch.
Terminal Door alarm switch and

Ignition switch Lock
key illumination
Position Key 1 2 3 4 5 6 1 2 3 4 RO RE
Pull out ○ ○ L L
Lock
L F
Accessories ○ ○ F F
Insert
On ○ ○ ○ ○ F F
Start ○ ○ ○ F F
Note
○— ○indicates conduction among terminals
RO: rotate locking bar
RE: return locking bar
L: lock Ignition switch
F: free
Door warning switch
Ignition switch Door warning switch
- 158 -
Prompt:
If engine does not rotate, check if driving axle shifting switch is at “Parking”or “Neutral”.
If “no rotation”only occurs at a certain shift position (not at other positions), the cause is mostly problem with
driving axle shifting switch.
Testing of spark plug Incorrect insulation Incorrect insulation

不正确的绝缘不正确的绝缘
1. Remove spark plug and connecting wire.

2. Ground spark plug external pole and start engine.
3. Check and confirm discharging among poles at this time.
Correct
正确的
Note: Incorrect insulation
不正确的绝缘
To replace spark plug, use original manufacturer part.
Testing of spark plug wire
1. With engine idling, disconnect wire of a spark plug each time to check change of engine operation
performance.
Note:
Wear rubber gloves during operation.
2. If engine performance does not change, check resistance of spark plug and the spark plug proper.
3. Check for crack in cover and housing.
4. Measure resistance.
- 159 -
VIII. Circuit diagrams
Engine control system (gasoline engine 1)
Keep power on Keep power on

Ignition switch junction box
Refer to the power supply distribution
Engine
control
relay
Connect to the
ignition coil
Multifunction
inspection port
connection lug
Fuel
pump
motor
8 (without
theft-deterrent device)
22 (with theft-deterrent
device)
Control Engine Memory
Input of fuel relay Battery
power power
pump control
supply
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Connect to the engine control relay
Connector
Crankshaft
Idle speed Camshaft Pulse
control position position solenoid
relay valve
sensor sensor
CMP CKP PCSV

Open close Ground sensor
sensor sensor
signal wire signal signal
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Connector
Connect to ECM
Front
sensor ground oxygen
Rear
wire sensor
oxygen Sensor
Heater sensor
Heater
Sensor
Fuel Fuel Fuel Fuel

1 2 3 4
Variohm
Leaded
gasoline Unleaded
gasoline
Signal Heating Fuel Fuel Fuel Fuel

Heating Signal injector 2 injector 3 injector 4
input input injector 1
control control control control
Torque
control Engine RPM
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Connect to the
engine control relay
Adjustable
resistance
Throttle Intake Air flow
position pressure sensor
sensor sensor
Air
temperature
sensor
Connect to
variohm
Water
temperature
sensor and
transmitter
Sensor Throttle Sensor MAP signal AFS signal

power position ground
supply sensor wire
input
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Connect to the ignition switch
Connect to the spark plug Connect to the spark plug

Ignition Ignition Ignition
coil 1 coil 2 failure
sensor
Condenser
Ignition detecting signal

Ignition coil control Speed Instrument
Indicator
cluster
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With current at the ON or START

shift
Fuse block
Refer to the fuse block in the passenger compartment
Instrument
cluster
Refer to the A/C control system

Multifunction diagnostic connector Vehicle speed sensor
(with theft-deterrent device)
(without theft-deterrent device)
8 (with theft-deterrent device)
22 (without theft-deterrent device)
A/C relay A/C signal A/C pressure Ignition timing Vehicle

Indicator control input switch input adjustment speed input
control
Generator
Power steering
Starting signal Ground wire Knock sensor signal switch input
Knock
sensor
Refer to the starting Charging system

system
Power steering
pressure
switch
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Refine MPV Workshop Manual Delphi Control System
Section IV Engine control system (Delphi)
Refine MPV gasoline engines adopt two different modes of control system: Hyundri engine control system for
imported engines and Delphi control system for domestic engine.
I. General
Delphi MT20 engine control system uses MT20 and MT20U engine control module (ECM) as its core and is
characterized by computer closed loop control, multi-point sequential fuel injection, grouped direct ignition
without distributor, and 3-element catalyzer post-treatment.
MT20U engine control module (ECM) is an ECM specially developed by Delphi for Chinese electronic injection
market. This ECM adopts latest electronic hardware technology and features relatively high performance-price
ratio. The hardware adopts 16-bit microprocessor and has ample RAM and powerful operational speed. I/O ports
of flexible definitions are provided. Second generation software developed by Delphi modular C language is used.
All technical specification required for Europe-III emission regulation can be provided.
System functions include:
 Complete vehicle main power supply relay control;
 Speed density air metering method;
 Closed loop control multi-point sequential fuel injection (including cylinder judgment by MAP CID
pressure);
 Closed loop control multi-point sequential fuel injection;
 Fuel supply modes with fuel return, without fuel return and with half fuel return can be provided;
 Fuel pump operation control;
 Direct ignition without using distributor; built-in (in ECM) ignition module driving grouped ignition
(4-cylinder sequential ignition can also be supported);
 Linear EGR control;
 Step motor idling speed control;
 Knocking control;
 Air conditioning/cooling water tank fan control;
 Memory of mileage;
 Overvoltage protection;
 Electronic anti-theft;
 CAN-BUS communication interface capable of communication with automatic transmission control module
or ABS system;
 System self-diagnosis function;
 Open and modular C language programming.
ECM control structure

MT20（U）Engine
MT20（U）Engine Control
- 166 Module
Control -Module (ECM)
(ECM) function
function
System
supply
power
5V sensor reference voltage

12V battery power supply
Main power supply relay control
ntrol
wer
12V ignition power supply

System functions:
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According to 58X tooth signal, the system determines crankshaft position and measure engine rotation speed, for
accurate control of engine ignition and fuel injection timing.
2. Speed density type air flow meter
ECM calculates amount of air entering cylinders by means of IAT sensor and intake air manifold pressure sensor
and controls amount of fuel supply so that air/fuel ratio meets requirements by various operating conditions.
3. Cylinder judgment sequential control
To realize sequence control of engine by the system, two modes of cylinder judgment can be adopted: one is
conventional camshaft cylinder judgment technology; the other is unique Delphi manifold pressure cylinder
judgment technology. This vehicle adopts conventional camshaft cylinder judgment technology.
4. Closed loop control
This system adopts closed loop control for engine fuel supply and idling speed. The advantage of closed loop
control is system capability to eliminate deviations in the system and relevant mechanic parts due to manufacture
and wear in use, so as to improve comprehensive conformability of the whole vehicle and reduce emission.
5. Grouped control
In the system, engine cylinders are organized in two groups: 1-4 and 2-3, for control of ignition. Grouped control
optimizes and simplifies system structure so as to reduce costs of parts, manufacture and processing.
6. Fuel injection functions
The system adopts speed density method and multi-point sequential injection. Each engine cycle implements
accurate fuel supply by means of main pulse width and trimming of pulse width. In addition, the functions of
closed loop control and self-learning are provided. Hardware will be Delphi third generation fuel injectors and
latest fuel pressure regulator.
7. Fuel pump control
After the ignition switch is turned, the fuel pump will operate for 1.5s. If effective 58X signal (crankshaft signal)
is not detected, the fuel pump will stop and the engine will start to rotate. After ECM detects 2 effective 58X
signals, the fuel pump will start to operate.
0.8s after loss of rotation speed signal or when the anti-theft device requests closing of fuel pump, this pump will
stop.
8. Idling speed control function
Idling speed control function refers to system control of engine rotation speed with throttle valve closed. System
control of idling speed performs adjustment of the following parameters so that actual rotation speed conforms to
target idling speed:
- control of amount of air at idling speed;
- control of fuel injection amount;
- control of ignition timing.
Designed control opportunities for idling speed
- calibration of idling stability
- calibration of acceleration operating conditions
- calibration of deceleration operating conditions
- speed reduction and fuel supply interruption
- calibration of fuel supply under engine instantaneous transition operating conditions
- calibration of uniform speed running
- calibration of mechanic and electric load increase/decrease
Target idling speed is determined according to many input signals:
- When engine water temperature is relatively low, the system will provide relatively high target idling speed for
quicker warming of vehicle. For engine that uses mechanic fan, when engine coolant temperature is too high, the
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system will adopt relatively high idling speed so as to increase amount of intake air to cooling water tank.
- When external load (e.g. load of air conditioning, power steering and various electric appliances) changes, the
system will increase idling speed to compensate increased load and maintain stable idling speed.
9. Correction of engine mixed gas
With engine at normal operating temperature, part of load control is closed loop fuel control. At this time, the
system will perform realtime correction of amount of fuel injection by means of engine electronic control module
according to voltage signal feedback by oxygen sensor, so as to adjust concentration of mixed gas near theoretical
air/fuel ratio and hence ensure optimum efficiency of 3-element catalyzer for conversion of harmful gases in
exhaust gas, and good fuel economy.
In normal operating temperature range of engine, open loop fuel control will be used for full load operation. At
this time, to ensure optimum engine power output, the system will control amount of fuel injection with thicker
air/fuel ratio and provided that no knocking of engine will occur, suitably increase ignition advance angle. The
system will also control exhaust temperature using exhaust temperature mathematical model established by
calibration, so as to ensure engine proper and 3-element catalytic converter.
The system determines engine full load condition according to signal provided by throttle valve position sensor.
Normally, when throttle opening reaches above 80%～90%, the system will deem engine in full load status.
When driver steps down throttle pedal for acceleration, the system will suitably increase amount of fuel injection
so to ensure engine demand for power during acceleration. Amount of fuel injection increased is proportional to
speed of changing of throttle opening.
During acceleration, the system will first suitably postpone ignition advance angle and then gradually restore it so
as to avoid too fast increase of torque during rapid acceleration resulting in impinge on power train.
When acceleration operating condition approaches engine full load, the system will temporarily and automatically
disconnect vehicle air conditioning system to ensure power output during acceleration.
No matter in what condition, when engine rotation speed exceeds highest rotation speed set in the system, the
system will cut off fuel supply to suppress unlimited rise of rotation speed and protect the engine (preventing
“galloping”. When rotation speed falls back to below highest rotation speed (the limit) specified by the system,
fuel supply will be restored immediately.
During normal operation of engine, if driver releases throttle pedal, the vehicle will start to slide and haul the
engine. At this time, the vehicle does not require power from the engine. In addition, after full closing of throttle
valve, air intake is very small and the engine will discharge more harmful substances due to poor combustion.
Therefore, the system will stop fuel supply at this time, so as to greatly reduce generation of harmful substances in
the engine and improve fuel economy.
After a number of failed starts of the engine, unfired gasoline will accumulate inside cylinders, referred to as
“flooding of cylinder”. At this time, driver can step down throttle pedal to bottom to start the engine; the system
will automatically use extreme thin air/fuel ratio so that excessive gasoline in cylinders will be discharged during
engine rotation.
10. Self-diagnosis of faults
System fault self-diagnosis is an indispensable function of engine control system. In case of abnormal operation of
one or more parts in the system, the system will timely notify this condition by means of fault indicators to prompt
necessary inspections and maintenance.
In case of above faults, the system can also adopt temporary emergency scheme to control engine operation, so as
to ensure that user can drive the vehicle to a maintenance station (not stopped at road side).
11. 3-element catalytic converter overheat system protection function
The system will, according to actual operating conditions of engine and forecast trend of rise of engine exhaust
gas temperature, adopt the method of control of fuel/air mixing ratio in good time to reduce engine combustion
temperature and protect 3-element catalytic converter.
3-element catalyzer fast aging technology
- Unique Delphi 3-element catalytic converter fast aging technology is used for project development and can
forecast end gas emission after 80,000km road test.
- After turning on the air conditioning switch, the system will receive a signal called air conditioning request,
carry out preparations before loading the air conditioner according to operating conditions at that time, and then
turn of air conditioning compressor. The system will control on or off of air conditioner according to the need to
protect the air conditioner.
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12. Control of air conditioner compressor
To ensure power output and protect the engine, the system will interrupt air conditioner operation under specific
operating conditions:
Air conditioner operating conditions:
- Coolant temperature Air conditioner status
108℃ Stopped
105℃ Restore operation
- Air conditioner can only be started 5s after start of engine or later;
- Air conditioner can only be started with engine rotation speed higher than 600rpm and lower than 6200rpm;
- After start of AC and evaporator, engine target idling speed will be increased by 150rpm.
The air conditioning system will be PnP type and the system will automatically determine configuration of
automobile AC, to facilitate user selection of AC or not at any time.
13. Control of radiating fans
This system provides control of electric dual-speed engine cooling fans and an AC condenser fan for complete
vehicle.
For cooling water tank, the system can provide two cooling schemes: one or two functional schemes can be
selected and decision shall be made before design and development:
Mechanic cooling: In case normal idling speed cannot cool the water tank, the system will increase idling speed to
increase amount of intake of cooling air.
Electric fan control function: The system can control dual-speed cooling fans according to water temperature
(turning on different fans) to reduce internal power consumption of engine.
30 87
BAT
ACFAN
E
86 85
ACFAN
30 87
BAT
C EngineFANLO 85 86
U
EngineFANHI
30 87
85 86
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II. Operating principle of electronic injection control and actuator assembly

l. Pressure and intake air temperature sensors
MT20U electronic injection system adopts speed density air metering method to detect amount of air entering the
engine, so as to control fuel injection pulse width and accurately control engine power output. At the same time,
this system adopts intake air pressure cylinder judgment technology. Intake air pressure sensor is installed near
cylinder #1 air intake manifold air intake. In the instant when this air intake opens, an instantaneous pressure drop
will occur at the sensor (about 1kpa). ECU will detect this instantaneous pressure drop. After receiving this signal,
ECU will use software to analyze and process it to determine compression top dead center signal.
Internal pressure diaphragm of intake air pressure sensor is connected to a magnet core placed in the coil. When
intake air pressure inside intake air pipe changes, the diaphragm will drive the magnet core to move, changing
sensor output voltage. ECU can convert sensor output voltage to amount of engine air intake. Based on this signal
and referencing other signals, amount of fuel injection of engine can be controlled.
Intake air temperature sensor assembly is a negative temperature coefficient (NTC) resistor. With rise of IAT, this
resistance will decrease and engine ECU will use an internal comparison circuit to monitor change of intake air
temperature.
Fault diagnosis:
Short circuit (to ground or to power supply) of sensor
line;
Sensor line broken;
Intake air pressure detected by sensor exceeds upper
limit;
Intake air pressure detected by sensor exceeds lower
limit.
Installation:
Installed on cylinder 1# air intake manifold; cylinder Intake manifold absolute pressure/air
judgment will be carried out according to pressure drop intake temperature sensor
generated in the instant of opening of air intake.
Fault correction:
Main inspections are for:
Short/broken circuit in connection between 4 sensor
wires and ECU;
Clogging of sensor detection hole;
Short/broken circuit and grounding among sensor
harnesses;
Sensor failure due to being hit.
Range of pressure detection: 10kPa-110kPa
Range of operating temperature: -40～125℃
Air intake manifold absolute pressure/IAT sensor
Pins:
No.1 (A): intake air pressure sensor signal (connected
to ECU 42#);
No.2 (B): standard 5V power supply (connected to
ECU4#);
No.3 (C): IAT sensor signal (connected to ECU 27#);
No.4 (D): sensor ground (connected to ECU 21#).
Intake
Operating voltage: 5.0V±0.1 V pressure/temperature
sensor
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2. Throttle position sensor (TPS)

Purpose:
MT20U TPS (throttle position) sensor is used to provide ECU with information such as throttle turning angle,
rotation angular speed and engine idling speed position. According to such information, ECU can obtain engine
load information, operating conditions information (e.g. startup, idling, back hauling, partial load and full load),
and acceleration/deceleration information. This sensor is of 3-wire type and ECU detects throttle opening by
monitoring of change of voltage.
Composition and principle:

This sensor has a structure of sliding resistance plate (i.e. linear rheostat). ECU monitors voltage at signal output
end and use comparison circuit inside computer to obtain throttle opening signal. Inside ECU, voltage signal is not
received directly; instead, ratio of output and input signals is detected. This can avoid signal fluctuation due to
voltage fluctuation.
Fault diagnosis:
TPS signal higher than measurement range;
TPS signal lower than measurement range;
TPS signal line short circuit;
TPS signal line open circuit.
Warning:
Outline drawing for throttle position sensor
Normally, removal of TPS is strictly prohibited. Upon
ex-factory, this sensor had been adjusted to optimum
position.
Installation:
Permitted tightening torque for fastening screws:
1.5Nm-2.5Nm.
Fault correction:
Main inspections:
Short circuit or open circuit in connection between 3
sensor wires and ECU;
Short circuit, open circuit and grounding among sensor
harnesses;
Use multimeter to detect bouncing between sensor
signal end and ground wire when throttle is turned on
or off;
Check if sensor resistance exceeds standard value very
much (possibly due to fouling inside sensor).
Operating voltage: 5+0.1V
Range of openness: 7％～93％
Sensor resistance: 3k～12kΩ
Output signal when throttle closes: 0.612～0.588V
Output signal when throttle is fully open: 4.15～4.65V
Pins
No.1 (A): standard 5v power supply (connected to
ECU 20#)
No.2 (B): sensor ground (connected to ECU 5#)
No.3 (c): sensor signal (connected to ECU 24#) Throttle position sensor
Circuit Diagram of Throttle Position Sensor
3. Coolant temperature sensor
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Purpose:
This sensor is used to provide coolant temperature information. ECU will be provided with water temperature
signal for control of startup, idling, ignition timing during normal running and injection pulse width. This signal is
also provided to instrument for water temperature display. This signal is the most important one for engine cold
start. During cold start, amount of fuel injection is determined by water temperature sensor signal.
This sensor is a negative temperature coefficient
thermistor. Its resistance decreases with rise of coolant
temperature and increases with drop of coolant
temperature, but not linearly. According to sensor
output signal, ECU will monitor change of water
temperature by means of internal comparison circuit.
Fault diagnosis:
Water temperature signal higher than limit value;
Water temperature signal lower than limit value;
Water temperature sensor line short circuit or open
circuit.
Normal temperature resistance data: 2.5±5％KΩ
Mounting prompt: Max. tightening torque is 20Nm.
Description:
This vehicle is fitted with 3-wire water temperature
sensor. Advantages of this type of sensor: saving of
costs and maintaining system consistency.
The 3 wires of the sensor:
To
5v standard power supply;
instrument
Sensor signal line (to ECU);
Sensor signal line (to instrument).
Fault correction:
Main inspections:
Short circuit or open circuit on connection between 3
sensors wires and ECU or instrument;
Short circuit, open circuit or grounding among sensor
harnesses;
Poor earthing of line that may easily cause too high
temperature indication on engine water temperature
gauge.
Operating voltage: 5V (DC power)
Operating temperature range: -40— 135℃ Water temperature sensor
Pins:
This sensor has 3 pins that may be exchanged. Circuit Diagram of Coolant
No.1 (A): sensor ground wire (connected to ECU 5#); Temperature Sensor
No.2 (B): water temperature sensor signal (connected
to ECU 43＃)
No.3 (C): to water temperature gauge.
Characteristic parameters (standard values):
－10℃ 16120Ω
0℃ 9399Ω
60℃ 671Ω
90℃ 241Ω
4. Knock-meter
Purpose: The knock-meter is used to send engine knocking information to ECU for control of knocking.
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Composition and principle: The knock-meter is a vibration acceleration sensor fitted on engine cylinder body
(normally between cylinders 2 and 3 to favor engine knocking balance). ECU makes use of vibration frequency
signal output by the knock-meter (and perform ECU internal filtering) to judge if engine knocking has occurred.
When knocking signal is detected, ECU will gradually decrease it till no knocking, and then gradually restore to
edge of knocking. This process will be repeated.
Fault diagnosis:
ECU monitors knock-meter, power amplification
circuit and detection circuit. In case of any of the
following found, knock-meter fault mark bit will be
set:
Fault of knock-meter;
Fault of knocking control data processing circuit;
Cylinder judgment signal cannot be trusted;
Fault of sensor line;
After the knock-meter fault mark bit is set, knocking
infinite loop control will be closed and software will be
used to fix the ignition advance angle stored in ECU at
a safe angle. When error frequency falls below set
value, fault mark bit will be reset.
Description of installation:
Tightening torque: 20+5Nm.
Fault correction:
Main inspections:
Short circuit or open circuit on connection between 2
sensor wires and corresponding pins of ECU;
Sensor installation torque and if gasket is fitted;
Poor press-fit between sensor and cylinder body, or
foreign matter between sensor and cylinder body.
Operating temperature interval: -40~150℃
Resistance: greater than 1MΩ
Pins:
No.1 (A): knock-meter signal 1 (ECU 5#) Knock sensor
No.2 (B): knock-meter signal 2 (ECU 69#) Circuit diagram of knock
sensor
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5. Front oxygen sensor (FO2S)

Purpose:
This sensor is used to provide information on whether oxygen is surplus after complete combustion of fuel
injected into engine cylinder in air absorbed. ECU makes use of this information for quantitative infinite loop
control of fuel, so that the 3 main toxic contents in engine exhaust gas (HC, CO and NOx) can be converted and
purified in 3-element catalytic converter to the maximum extent.
Oxygen sensor sensing assembly is a type of ceramic tube with pores. External side of tube walls is surrounded by
engine exhaust gas and internal of the tube is connected to atmosphere. This sensor indirectly calculates fuel
injection pulse width according to difference of oxygen concentration inside and outside the tube and sends it to
ECU, which will then control fuel injection. At the same time, rear oxygen sensor also outputs data to the ECU, so
that data from front and rear oxygen sensors are compared inside ECU to monitor if operation of 3-element
catalysis is good.
Oxygen sensor operating voltage fluctuates in 0.1～0.9V and shall change 5～8 times within 10s. If this
frequency is lower, this indicates aging of sensor and replacement shall be made. This sensor cannot be repaired.
Fault diagnosis:
ECU monitors oxygen sensor, line, and power
amplification circuit and detection circuit inside ECU.
Once any of the following is found, oxygen sensor
fault mark bit will be set:
Battery voltage cannot be trusted;
Air intake manifold absolute pressure signal cannot be
trusted;
Engine coolant temperature signal cannot be trusted;
Fault of fuel injector driving level.
After the oxygen sensor fault mark bit is set,
quantitative infinite loop control of fuel will be closed
and fuel quantification will adopt basic fuel injection Oxygen sensor
time stored in ECU.
Installation:
Oxygen sensor tightening torque shall be 50 to 60Nm.
After replacement of oxygen sensor, a layer of antirust
paint shall be applied on the sensor to prevent rusting
and hence difficult removal. Main relay
Fault correction:
Main inspections are for good connection (insertion) of
sensor wires and open/short circuit.
Normally, sensor damage results from poisoning by
lead and phosphor etc. Therefore, attention shall be
paid to fuel quality. Also, over consumption of engine
oil will cause sensor failure.
Number of changes of oxygen sensor within certain
time shall be not less than a limit.
All oxygen sensors have cable. The other end of such
cable is electric connector. These sensors are wrapped Oxygen sensor
with asbestos fire sleeve.

Circuit diagram of the front
oxygen sensor
All connectors have 4 pins:
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No.1 (A): oxygen sensor signal low level (connected to

ECU 6#);
No.2 (B): oxygen sensor signal high level (connected
to ECU62#);
No.3 (C): connected to main relay power supply;
No.4 (D): sensor heating line control (connected to
ECU61#).
Rear oxygen sensor (RO2S)
Basically, structure and detection of rear oxygen sensor
are not different from those of front oxygen sensor.
However, the purposes of these sensors are very
different.
Purpose:
The purpose of front oxygen sensor is to detect oxygen
content in exhaust gas so as to determine if amount of
injected fuel is excessive. This sensor converts oxygen
content in exhaust gas to an electric signal and sends it
to ECU, which will control fuel injection pulse width
according and adjust air/fuel ratio, thereby indirectly
controlling engine exhaust emission.
The purpose of rear oxygen sensor is to detect oxygen
content in exhaust gas after 3-element catalytic
conversion. The sensor will convert this signal to point
signal and send it to ECU, which will compare signals
from front and rear oxygen sensors to determine if
3-element catalysis is operating well.
Fault diagnosis, fault correction and signal detection
etc. are the same for front and rear oxygen sensors.
Rear oxygen sensor
No.1 (A): oxygen sensor signal low level (connected to
ECU 6#);
No.2 (B): oxygen sensor signal high level (connected Circuit diagram of the rear
to ECU 38#); oxygen sensor
No.3 (C): connected to main relay power supply;
No.4 (D): sensor heating line control (connected to
ECU 64#).
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6. Electronic control unit (ECU)

Purpose:
ECU is an electrically controlled engine control center with microprocessor as core and integrating sensor signal
input interface and actuator driving circuit. ECU receives and processes engine status signals input by each sensor
and sends control signal to actuator, so that engine will operate according to preset program and at optimum status,
thus ensuring good power, fuel economy and emission.
Normal operating voltage: 9-16V
Overvoltage protection: +24V/-12V<60s
Composition:
Housing with screen and PCB on which many electronic control units for control of electronic injection system.
Functions:
Multi-point sequential fuel injection system
Grouped ignition system
Idling speed control
Automatic knocking infinite loop control
Provision of sensor power supply: 5V/l00mA
Infinite loop control, with self-adaptive
Dual oxygen sensor
Discharge carbon tank control
Air conditioning ECU control
Engine fault indicator
Engine rotation speed signal output
Self-diagnosis of fault (with flashing code function)
Receiving engine load signal.
Fault correction:
Since fault rate of electronic control unit (ECU) is very low, replacement of ECU for resolving all problems is not
recommended. First check for fault in peripheral line, sensors and other assemblies; only replace ECU when it is
confirmed that there is no fault in peripheral parts.
ECU terminals definitions
Pin Connection point Type Pin Connection point Type
1 Ignition switch control hot wire Input 2 Unused
(power supply)
3 Vehicle speed signal sensor Input 4 5V standard power supply Output
5 5v standard power supply ground wire Ground 6 Front O2 sensor signal (low level) Input
7 Unused 8 Unused
9 Unused 10 Unused
11 Diagnosis communication Output 12 Rotation speed sensor signal (high Input
Level)
13 Unused 14 Unused
15 Unused 16 Unused
17 Battery power supply (+12v) Input 18 Battery power supply (+12v) Input
19 Unused 20 5v standard power supply Output
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21 5v standard power supply ground wire Ground 22 Unused

23 Unused 24 TPS signal Input
25 Unused 26 AC evaporator temperature sensor Input
27 Air intake manifold temp sensor Input 28 Rotation speed sensor signal (low Input
Level)
29 Unused 30 Diagnosis request Input

31 Engine fault indicator Input 32 Ignition coil (1, 4) Input
33 Idling step motor driving coil B Output 34 Idling step motor driving coil A Output
35 Unused 36 Unused
37 Unused 38 Rear O2 sensor signal (low level) Input
39 Air conditioning request signal Input 40 Unused
41 Unused 42 Air intake pressure sensor signal Input
43 Coolant temp. sensor signal Input 44 Unused
45 Engine rotation speed signal Output 46 Air conditioning relay control Output
47 Fuel pump relay control Output 48 Unused
49 Unused 50 Control of high speed fans Input
Pin Connection point Type Pin Connection point Type

51 Unused 52 Ignition coil 2, 3 Input
53 Idling step motor driving coil C Output 54 Idling step motor driving coil D Output
55 Fuel injector 1# Input 56 Fuel injector 2# Input
57 Unused 58 Unused
59 Unused 60 Unused
61 Front O2 sensor heating control Input 62 Front O2 sensor signal (high level) Input
63 Carbon tank solenoid valve control Input 64 Rear O2 sensor heating control Input
65 Unused 66 Unused
67 Fan low speed control Input 68 Unused
69 Knock-meter signal Input 70 Fuel injector 3# Input
71 Fuel injector 4# Input 72 Unused
73 Power grounding Ground None
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7. Purpose:
Deliver fuel from fuel tank to engine fuel supply
header at certain pressure and flow, and maintain stable
fuel pressure (by means of fuel pressure regulator).
Composition and principle: The electric fuel pump
consists of DC motor, impeller pump and end cover
(integrating check valve, pressure relief valve and
anti-EM interference assembly etc.) The pump is
installed on the same axis with motor and enclosed in
the same housing. Max. pressure at electric fuel pump
outlet is determined by pressure relief valve (between
450 and 650kPa). However, pressure of the whole fuel
system is determined by fuel pressure regulator
Electric fuel pump sketch
(normally 300kPa for MT20U electronic injection
system.
Description:
If vehicle fuel tank is at low fuel status for a long time,
fuel pump lubrication will be poor, resulting in fritting
and burnout of fuel pump.
Main power
Fuel temperature substantially affects fuel pump
supply
performance. When operating at high temperature for a
long time, fuel pump pumping pressure will fall
sharply if fuel temperature is higher than certain value. Power relay
Therefore, if hot engine will not start, please carefully
check if fuel pump high temperature operation
Fuel pump control
performance is not good.
Fuel pump lubrication and cooling rely on gasoline in
Electric fuel pump
fuel tank.
circuit diagram
Fuel tank of this vehicle is of saddle type and fitted with two ports.
Relief pressure: <900 kPa
Operating pressure: 8～16V
Fuel pump resistance: <130Ω
Injection pump inside auxiliary fuel tank will be responsible to pump return fuel back to main fuel tank.
Pins:
The electric fuel pump has two pins connected to fuel pump relay. On fuel pump housing near these 2 pins,
symbols “+”and “－”are inscribed respectively to indicate positive and negative pole. ECU pin 47# controls
fuel pump relay.
Fault correction:
Normally, fuel pump faults include low fuel pressure and no pumping of fuel etc. To correct faults, check if
system fuel pressure is in specified range and for leakage in pipeline. Besides, fuel tank positive pressure
negative pressure will affect fuel system.
8. Electromagnetic fuel injector
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Purpose:
MT20U adopts sequential fuel injection technology.
Sequential injection signals are provided by air intake
pressure sensor. If air intake pressure sensor is
damaged, according to ignition sequence, grouped
injection mode will be used for control. According to
ECU commands, fuel injectors will inject fuel at
specified times, thereby supplying fuel to engine and
Electromagnetic fuel injector
atomizing it.
illustration
ECU sends electric pulses to fuel injector coil, generating magnetic field force. When this force increases to
overcome the resultant force of return spring pressure, needle valve gravity and friction, the needle valve will
start to rise and fuel injection will start. When fuel injection pulse ends, pressure of return spring will close
needle valve once more.
Installation:
For certain fuel injectors, specified plugs must be used (no mixing). To facilitate installation, it is recommended to
apply silicon-free clean engine oil on surface of upper O-ring connected to fuel distribution pipe. Note not to
pollute inside of fuel injectors or injection holes by engine oil. For installation, make sure to maintain sealing of
fuel injector lower ports; otherwise air intake system may leak. Fit fuel injector in the injector seat vertically (to
the seat) and use the clamp to fix injector on the injector seat.
Description:
For vehicles not used for a long time, starting may not be normal due to sticking of gasoline inside fuel injectors.
Please carefully check for such fault.
Fault diagnosis:
MT20U electronic injection system performs fault diagnosis not for fuel injector proper but for injector driving
stage. In case of injector driving stage short circuit to battery voltage, overload, short circuit to ground, or open
circuit, fault mark bit will be set. At this time, oxygen sensor infinite loop control and self-learning pre-control
will be closed. Last self-learning data will be valid. After correction of fault, fault mark bit will be reset.
Operating pressure: 350 kPa
Fuel injector resistance: 11-16Ω
Operating temperature: -40～130℃
Circuit diagram of EM fuel injector

Pins:
No.1: cylinder 1 injector control pole (connected to
ECU55#) Main relay
ECU 70#)
ECU 56#)
ECU71#)
The other wires of the 4 injectors are connected
Fuel injector group
together, engine main relay will supply power and
ECU will control injector earth. Circuit diagram of the
electromagnetic injector
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Fault correction:
Normally, injection not free and poor atomization at injection nozzles are due to extended use of engine. You can
perform periodic cleaning of nozzle.
Short circuit and open circuit of nozzle internal coils can also cause injection system fault. Check system line for
short circuit and open circuit.
Extended use of disqualified fuel will result in sticking of fuel at nozzle injector holes, easily causing unstable
idling speed.
9. Idling speed actuator step motor
Functions:
Control air circulation area in the bypass in throttle valve,
and hence amount of engine air intake. According to signals
from each sensor, ECU can control engine rotation speed
within target range (to be calibrated according to coolant temperature).
The step motor is essentially a mini-motor. Since currents of
different directions pass motor coil, this motor will rotate in
different directions and its rotating shaft will drive screw rod, Air Idle speed
indirectly controlling valve openness. MT20U sends digital control
valve
square wave signals to control motor rotation in positive and
negative directions, and further controls step motor stroke.
Fault diagnosis:
ECU can monitor short circuit and open circuit of the two
coils of idling speed step motor. In case of such fault, ECU
Throttle body
will light up engine fault indicator and the engine will enter fault mode.
Short circuit and open circuit between the 4 sensor wires and ECU
Circuit diagram of the idle speed
will be monitored.
ECU cannot monitor faults due to mechanic part of the motor. actuator step motor
Fault correction:
Check for short circuit and open circuit in the 4 wires
connecting step motor and ECU.
Check step motor for stagnation.
Check for short circuit, open circuit in step motor;
Remove step motor, turn on power and check step
motor for free extension and contraction.
Accumulated carbon and dirt in air intake system may
affect step motor operation performance.
Motor coil resistance: 58.3～47.7Ω
Operating voltage: 7.5~12V
Pins:
No.1 (B): idling speed step motor control (connected to
ECU 33#)
No.2 (A): idling speed step motor control (connected to
ECU 34#)
No.3 (D): idling speed step motor control (connected to
ECU 54#) Idle speed step motor
Circuit diagram of the idle speed
No.4 (D): idling speed step motor control (connected to actuator step motor
ECU 53#)
10. Ignition coil
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Functions:
Ignition coil converts primary winding low voltage power to secondary winding high voltage power. The spark
plug will generate sparks by discharge to ignite fuel/air mixed gas inside cylinder.
MT20U adopts grouped ignition technology and uses the principle of high energy generation by mutual
inductance of EM coils to control primary coil power-on time. At the instant of primary coil power-off, high
voltage will be generated at the secondary coil to breakdown spark plug gap and generate strong sparks to ignite
mixed gas. Since during engine exhaust stroke, air ionization is very high and resistance is very low, only very
low voltage is required to breakdown spark plug gap. Therefore, the system adopts grouped ignition technology
thereby saving energy and cost.
Fault diagnosis:
ECU does not have the function of fault diagnosis for ignition coil. Therefore, in case of problem with the ignition
coil, there will be no fault code; only inspection of ignition coil resistance can determine if ignition coil is
operating normally. Under normal conditions, operation of ignition coil will generate high heat. Too high ignition
coil temperature will cause increased ignition coil resistance, resulting in unstable engine operation and auto stop
of engine. However, ECU can monitor control line of ignition coil:
Control line short circuit to ground;
Control line short circuit to power supply;
Control line open circuit.
Counter-fault strategy:
When fault of an ignition coil is detected, fuel injector Main
of corresponding cylinder will be closed. relay
Description: High
If ignition coil temperature is too high, operation of pressure
engine ignition system may be poor. coil
Ignition coil primary resistance: O.55～0.4 5 KΩ
Ignition coil secondary resistance: 5.6～4.8 KΩ
Pins:
No.1 (c): coil primary winding (connected to
ECU32#);
No.2 (A): coil secondary winding (connected to
ECU52#); Ignition coil subassembly
No.3 (B): coil power supply (connected to system main Circuit diagram for
relay). ignition coil
High voltage side:
Pins 1, 2, 3 and 4 are connected to spark plugs of homonymic engine cylinders via distributor wire.
Fault correction:
Short circuit, open circuit inside coil;
Coil electric leakage, cracking of housing;
Aging of coil causing low ignition electric quantity.
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11. Steel fuel distributing pipe assembly

Purpose:
Storage and distribution of fuel from fuel pump; provide fuel injection system with a relatively stable pressure
environment so as to achieve balance of fuel supply pressure and amount for each cylinder and smooth engine
operation.
Composition:
Fuel distributing pipe assembly consists of fuel distributing pipes and fuel injectors.
Installation requirements:
Reliable connection must be ensured for fuel inlet/outlet pipes and fuel supply pipe quick couplers. After fuel
system maintenance, first carry out test run at the maintenance site to ensure no leakage in fuel system.
Fault diagnosis:
Normally, probability of fuel supply header fault is extremely low. Most such faults are improper assembling,
resulting in fuel system leakage. Therefore, during assembling, make sure to note that used oil seal must not be
used again and some lubricating oil can be suitably applied during assembling.
Description:
For fuel system maintenance, first relieve pressure and ensure that fuel pipeline is free of pressurized fuel.
Remove fuel pump plug and then stop the vehicle (然后着车?) till the engine goes out. At this time, there is no
pressurized fuel in the system. For first start after maintenance, first pump fuel to the system.
Method:
Turn on ignition key and turn it off after self-test. Repeat for 3～4 times.
12. Camshaft position sensor

Functions:
Camshaft position sensor is a Hall effect sensor
installed near camshaft and operating along with signal
wheel on camshaft (corresponding to specific position
on engine). ECM uses digital voltage signals from this
sensor to determine operating cylinders of engine and
perform one-to-one control.
Performance:
Operating temperature: -40150℃
Operating voltage: 4.513V
Operating clearance: 0.32mm
Wiring terminals:
A— signal; B— ground; C— +5V
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Purpose:
This sensor is used to send engine rotation speed, rotation angle and top dead center signals to ECU for engine
ignition, fuel injection and timing systems.

MT20U electronic injection system adopts magnetic induction coil type rotation speed sensor, which generates AC
current and voltage signals by rotation cutting magnetic lines of force. ECU uses such signals and (after
rectification) converts them to digital signals that can be recognized by ECU for engine system control. Flywheel
tooth ring and signal wheel are installed together. The signal wheel adopts the form of 58X teeth and provides
rotation speed, rotation angle and top dead center signals for ECU. At the notch is a top dead center of a cylinder.
Fault diagnosis:
ECU monitors sensors and lines in a realtime manner:
Sensor no signal output;
Sensor output signal distortion;
Sensor signal line short circuit;
Sensor signal line open circuit.
Fault correction:
Check for normal sensor line (if there is earth short
circuit);
Main relay
Use T to connect sensor and harness connectors to
check for normal power supply, ground wire and signal
wire connections.
Operating temperature: -40— 150℃
Gap between sensor and tooth ring: 0.3— 1.5 mm
Sensor resistance: 616~504Ω
Pins:
No.l (A): sensor signal line high level (connected to
Carbon canister
ECUl2#);
solenoid valve
No.2 (B): sensor signal line low level (connected to
ECU28#);
No.3 (c): sensor ground wire (connected to ECU 73#)
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13. Carbon tank solenoid valve
Purpose:
Control of cleaning air flow from carbon tank to air
intake header. Carbon tank absorption is subject to
certain limit. If gasoline vapor absorbed in carbon tank
is not consumed, gasoline will volatize to outside,
polluting atmosphere and bringing in unsafe factor.
Outline drawing of the carbon canister
solenoid valve
Inside carbon tank solenoid valve is a solenoid valve
mechanism. Solenoid valve openness is controlled by
digital pulse square wave sent by ECU. According to
different engine operating conditions, carbon tank
solenoid valve openness will be different. At engine
high load and idling speed, to ensure engine output
power, carbon tank solenoid valve will not be put into
operation.
Fault diagnosis:
Sensor line short circuit to ground;
Sensor line short circuit to power supply;
Sensor line short circuit.
Main relay
Fault correction:
Check for short/open circuit in sensor line;
Check for (wrong) cross connection among harnesses;
Check for sensor line short circuit to power supply;
Check for clogging in carbon tank solenoid valve and
free ventilation.
Operating temperature: -40/120℃
Coil resistance: 19~22Ω
Operating voltage: 8~16V Carbon canister
Rated operating voltage: +12V solenoid valve
Pins:
No.l (A): magnetic valve coil control (connected to ECU63#)
No.2 (B): connected to main relay power supply.
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14. Air conditioning control system

Control principles:
Turn on AC switch. If AC pressure is normal and data detected by evaporator temperature sensor are normal, AC
request signal will be sent to ECU via these switches. After ECU detects this signal, AC relay will be controlled to
close, with signal to increase rotation speed sent to step motor. Electronic fans will be turned on and the AC system
put into operation.
AC cutoff conditions:
Fault of throttle position sensor;
Fault of vehicle speed sensor;
High engine load;
Fault of evaporator temperature sensor;
Power supply
Evaporator temperature less than 1.5℃;
Engine overspeed;
Coolant temperature higher than 108℃: emergency oil filling. Air conditioning
request signal
Fault diagnosis:
AC relay line short circuit to ground;
AC relay line short circuit to power supply;
AC relay line open circuit;
Evaporator temperature sensor temperature too low;
Evaporator temperature sensor temperature too high. A/C compressor clutch
Fault correction:
Check AC system line; Circuit diagram for A/C
Check for damage of AC evaporator temperature sensor; controlling
Check for (wrong) cross connection inside harnesses.
Pins:
No.l: AC request signal (connected to ECU39#);
No.2: AC relay control (connected to ECU46#).
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15. Fan control (FAN)
MT20U controls fan speed. The control system controls fan speed (high or low) according to signals such as water
temperature and AC. When conditions are suitable, fan system delay can be controlled.
Control modes:
Gear 1: On at 98℃ and Off at 94℃
Gear 2: On at 105℃ and Off at 101℃
After engine shutdown, if water temperature exceeds Main power
101℃, fans will continue to run for 1min; supply
After engine shutdown, if water temperature exceeds
94℃, fans will continue to run for 0.5min;
After engine shutdown, if water temperature is lower
than 85℃, fans will stop. High-speed
fan relay
Fault diagnosis:
Short circuit of high speed relay line to power supply;
Short circuit of high speed relay line to ground; Low-speed fan Dual speed fan
relay
High speed relay line open circuit;
Short circuit of low speed relay line to power supply;
Short circuit of low speed relay line to ground;
Low speed relay line open circuit;
Circuit diagram for fan controlling
Fault correction:
At ECU side, check line for short circuit and open circuit according to pins shown in the left figure.
Fan control circuit diagram
In the figure on the right, pins for high and low speeds are the same as actual. However, actual circuit diagram is
different. The circuit diagram shown is for reference only.
III. Basic principles for fault diagnosis for electronic injection system
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1. Fault information record

MT20U electronic control unit constantly monitors sensors, actuators, relevant circuits, fault indicators and
battery voltage etc., as well as ECU itself, and performs credibility detection of sensor output signals, actuator
driving signals and internal signals (e.g. oxygen closed loop control, knocking control, idling speed control and
battery voltage control etc.). Once a fault is discovered at some node, or a signal value cannot be trusted, the ECU
will immediately set fault information record in RAM fault memory. This record will be stored in the form of a
fault code and displayed according to sequence of occurrence.
According to occurrence frequency, a fault can be “stable state fault”or “accidental fault”(e.g. due to temporary
harness open circuit or poor contact of a card).
2. Fault state
If duration of first occurrence of an identified fault exceeds set stable time, ECU will deem it a stable fault and
store it as “stable state fault”. If a fault disappears, it will be saved as “accidental fault”and “non-existing”. If 。如
this fault is again identified later, it will still be an “accidental fault”but “existing”historical fault will not affect
engine operation.
3. Type of fault
Short circuit to power supply positive pole;
Short circuit to ground;
Open circuit;
Signal cannot be trusted.
4. 4 types of fault
Maximum fault: signal exceeding upper limit of normal range;
Minimum fault: signal exceeding lower limit of normal range;
Signal fault: no signal;
Unreasonable fault: signal is present but not reasonable.
5. Limping home
For some important identified faults, if their duration exceeds set stable time, ECU will take suitable software
strategy to maintain engine operation, so that the vehicle will not break down in midway.
6. Fault alarm
MT20U electronic injection system is provided with fault indicators. When some important parts (such as ECU,
air intake manifold absolute pressure sensor, throttle position sensor, coolant temperature sensor, knock-meter,
oxygen sensor, fuel injector, 2 driving stages of idling speed actuator step motor, air conditioning relay, and fan
relay etc.) fail, and corresponding fault bit is set, ECU will warn the driver by means of fault indicators that the
vehicle has entered fault mode, till reset of this fault bit.
7. Reading of fault
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Engine fault indicator

During engine operation, in of fault in system or parts, engine fault indicator will automatically light up to prompt
driver for timely inspection and maintenance.
For emergency fault handling, special operation can be carried out so that engine fault indicators will flash to allow
reading of engine fault codes. This is the most economic method to obtain fault codes. Method of operation is as
follows:
diagnose plug interface definition
Inspect to determine:
8 None +12V
That battery voltage can ensure engine starting rotation speed;
That engine and complete vehicle accessories are 7 communication None
closed: 6 None None
Throttle valve is completely closed; 5 earthing wire None
Transmission is at neutral; 4 earthing wire None
Ignition switch is turned off; 3 None None
Use wire to short connect diagnosis request terminal 1 2 None None
in fault diagnosis plug to ground wire 4 or 5; 1 diagnose request None
Turn ignition switch to ON but do not start engine;
At this time, if a fault presently exists in the system or
after correction of a fault, there is a historical fault code
not cleared, engine fault indicators will flash according
to certain rule to output faults codes detected by the
system (while reading a fault code, idling speed control
valve will perform reset action);
After reading fault codes, turn off ignition switch and
remove diagnosis request short connection wire.
Rules of indicator flashing to report faults:
·display faults according to sequence of fault codes memory;
·pause 3.2s between 2 consecutive fault codes; digits will flash 0.4s On and 0.4s Off; pause 1.2s between 2 digits;
·digit 0 will flash 10 times while other digits will flash the same number of times;
·take fault codes 0110 and 0443 as examples:
The diagnosis requests for Turn the ignition The indicator flashes once Pauses for 3.2 seconds
short to ground switch to ON first
10 Pauses for 1.2 1 Pauses for 1.2 1 Pauses for 1.2 10

seconds seconds second seconds second seconds seconds
Pauses for 3.2

seconds
10 Pauses for 1.2 1 Pauses for 1.2 1 Pauses for 1.2 3

seconds seconds second seconds second seconds second
Pauses for 3.2

seconds
If the diagnosis request is not stopped, the DTC 0110 will be reported again…
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Note: After fault correction, you are recommended to use fault diagnosis meter to clear fault codes to avoid
affecting judgment on faults in next maintenance.
8. Clearing of fault information records

When a fault is corrected, corresponding fault information record in memory shall be cleared.
Information of faults that appears upon ignition but not maintained to end of set stable time will not be recorded.
Fault codes will be automatically cleared after certain number of successful starts of engine.
By means of fault diagnosis meter, “zero fault memory”command can be used to clear fault information records.
Unplug ECU connector or remove battery wire to clear fault information records in external RAM.
Diagnosis access
Main power supply
9. Locating of faults:
After obtaining fault information records by aforesaid means, we only know rough locations of the faults and not
exactly. This is because, for example, cause of a fault record can be damaged electric element (e.g. sensor, actuator
or ECU etc.), broken wire, wire positive pole short circuit to ground or battery, or even a mechanic fault.
Faults are intrinsic and only various symptoms can be seen. After finding a symptom, first use fault diagnosis meter
to check for fault information record, or do so according to flashing codes. Correct relevant faults according to
fault information. Later, locate the faults according to engine symptoms.
- 190 -
List of engine fault code

List of fault code of Delphi MT20(u) engine management system
Fault Fault
Fault description Fault description
code code
P0105-1 Intake manifold absolute pressure P0443-1 Canister solenoid valve line short-circuited to
sensor signal too high power positive pole
P0105-2 Intake manifold absolute pressure P0443-2 Canister solenoid valve line open-circuited or
sensor signal too low short-circuited to ground
P0110-1 Intake temperature sensor signal too P0480-1 Water tank low speed fan relay drive circuit
low short-circuited to power positive pole
P0110-2 Intake temperature sensor signal too P0480-2 Water tank low speed fan relay drive circuit
high open-circuited or short-circuited to ground
P0115-1 Coolant temperature sensor signal too P0481-1 Water tank high speed fan relay drive circuit
low short-circuited to power positive pole
P0115-2 Coolant temperature sensor signal too P0481-2 Water tank high speed fan relay drive circuit
high open-circuited or short-circuited to ground
P0120-1 Throttle position sensor signal too P0482-1 Air conditioning cooling fan relay drive circuit
high short-circuited to power positive pole
P0120-2 Throttle position sensor signal too low P0482-2 Air conditioning cooling fan relay drive circuit
open-circuited or short-circuited to ground
P0130-4 No oxygen sensor signal P0500-0 No speed sensor signal
P0135-1 Oxygen sensor heating circuit P0505-0 Idle speed control error
short-circuited to power positive pole
P0135-2 Oxygen sensor heating circuit P0560-1 System voltage too high
open-circuited or short-circuited to
ground
P0170-1 Time indicating oxygen sensor air-fuel P0607-0 Knock control system failure
ratio concentrated too long
P0170-2 Time indicating oxygen sensor air-fuel P0650-1 Fault-indicating lamp line short-circuited to
ratio thinned too long power positive pole
P0201-0 Injector A (1-cylinder) circuit fault P0650-2 Fault-indicating lamp line open-circuited or
short-circuited to ground
P0202-0 Injector B (3-cylinder) circuit fault P1230-1 Main relay line short-circuited to power
positive pole
P0203-0 Injector C (4-cylinder) circuit fault P1230-2 Main relay line open-circuited or
P0204-0 Injector D (2-cylinder) circuit fault P1530-1 Air conditioning relay line short-circuited to
power positive pole
P0230-0 Fuel pump relay short-circuited to P1530-2 Air conditioning relay line open-circuited or
power positive pole short-circuited to ground
P0230-2 Fuel pump relay open-circuited or P1604-0 EEPROM error
P0325-0 Poor connection of knock sensor P1610-0 Anti-theft controller error
P0335-0 No 58x crankshaft position sensor P1610-8 ECM and anti-theft controller communication
signal error
P0335-8 58x crankshaft position sensor signal P2000-1 Front air conditioning evaporator temperature
error too high
P0342-0 Camshaft position signal low P2000-2 Front air conditioning evaporator temperature
too low
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P0343-2 Camshaft position signal high P2001-1 Rear air conditioning evaporator
temperature too high
P0351-1 Ignition coil 1-4 cylinders drive line short-circuited P2001-2 Rear air conditioning evaporator
temperature too low
to power positive pole
P0351-2 Ignition coil 1-4 cylinder line open-circuited or P2100-2
short-circuited to ground wire
P0352-1 Ignition coil 2-3 cylinders drive line short-circuited P2100-8
P0352-2 Ignition coil 2-3 cylinders drive line open-circuited
or short-circuited to grounding wire
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IV. Maintenance flow according to fault codes
intake pressure/temperature
sensor
Intake pressure/temperature sensor
Fault
P0105-1 Intake manifold absolute pressure sensor signifying too high
code:
To set up emergency ● Light-up the fault-indicating lamp until the fault disappeared
control scheme: ● When engine stops: 90kPa
● When engine is at idle: =45kPa
● When engine is running: manifold pressure changes as the throttle opening
changes
● If cylinder pressure cylinder-judgment technique is used, the injection sequence
will have 50% probability of dislocation by 3600.
Connection terminal: MT20U Pressure/temperature Normal measuring
sensor signal
5V reference voltage: 04 B 5V
Manifold pressure 42 A 0.5～4.5V
signal:
Sensor signal ground: 21 D 0V
Judgment conditions Possible cause Refer to trouble
shooting scheme
Engine running 1） Wiring harness pressure signal is 1） Repair the harness
No TPS fault short-circuited to 5V reference voltage or power
MAP＞98.117kpa positive pole
TPS＜19.141% 2） Sensor damaged 2） Replace the sensor
Fault duration＞2.5s 3） ECM pressure signal input interface fault 3）Replace ECM
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Fault
P0105-2 Intake manifold absolute pressure sensor signal too low
code:
To set up emergency ● Light-up the fault-indicating lamp until the fault is disappeared
control scheme: ● When engine stops: 90kPa
● When engine is at idle: =45kPa
● When engine is running: manifold pressure changes as the throttle opening
changes
● If cylinder pressure cylinder-judgment technique is used, the injection sequence
will have 50% probability of dislocation by 3600.
Connection terminal: MT20U Pressure/temperature Normal measuring signal
sensor
5V reference voltage: 04 B 5V
Manifold pressure signal: 42 A 0.5～4.5V
Sensor signal ground: 21 D 0V
Judgment conditions Possible causes Refer to trouble shooting
scheme
No TPS fault 1） Connector not secured 1） Connect again
MAP＜14.017kpa 2） Wiring harness pressure signal line 2） Repair the harness
PRM＜1050rpm open-circuited
TPS＞18.75% 3） Wiring harness pressure signal line 3） Repair the harness
Fault duration ＞2.5s short-circuited to ground
4） 5V reference voltage line open-circuited 4） Repair the harness
5） Sensor signal grounding wire open-circuited 5） Repair the harness
6） Wiring harness 5V reference voltage reversed 6） Repair the harness
with reference grounding wire (this fault may lead
to sensor damage)
7） Sensor damaged 7） Replace the sensor
8） MAP signal interface fault on ECM 8）Replace ECM
Fault
P0110-1 Intake temperature sensor signal too low
code:
To set up emergency ● Lightup the fault-indicating lamp until the fault is disappeared
control scheme: ● Intake temperature is equal to coolant temperature, but not exceeding 44.25℃
Connection MT20U Pressure/temperature Normal measuring
terminal: sensor signal
Intake 27 C 0.5～4.5V
temperature
signal:
Sensor signal 21 D 0V
ground:
Judgment conditions Possible causes Refer to trouble
shooting scheme
Engine running time ＞120s 1） Connectors not connected securely 1）Re-connect
MAT＜-38.25℃ 2） Temperature signal line open-circuited 2）Repair harness
Fault duration ＞2s 3）Sensor signal open-circuited to ground 3） Repair harness
4）Temperature signal line short-circuited to power 4） Repair harness
positive pole
5）Sensor damaged 5） Replace sensor
6）ECM signal input interface fault 6）Replace ECM
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Fault
P0110-2 Intake temperature sensor too high
code:
To set up emergency Lightup the fault-indicating lamp until the fault is disappeared
control scheme: Intake temperature is equal to coolant temperature but not exceeding 44.25℃
Connection Intake temperature Pressure/temperature Normal measuring
MT20U
terminal: sensor sensor signal
Intake 27 B C 0.5～4.5V
temperature
sensor:
Sensor signal 21 A D 0V
ground:
shooting scheme
Engine running time＞60s 1）Temperature signal line short-circuited to ground 1） Repair harness
MAT＞148.5℃ 2）Sensor damaged 2） Replace sensor
Fault duration ＞2s 3）ECM signal input interface fault 3）Replace ECM
to instrument
Water temperature sensor
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Fault code: P0115-1 Coolant temperature sensor too low
control scheme: ● Use intake temperature when starting, and fix after increasing to 79.5℃ with
the time
Connection terminal: MT20U Coolant temperature sensor Normal measuring
signal
Coolant temperature 43 B 0.5～4.5V
signal:
Sensor signal 05 A 0V
ground:：
shooting scheme
Engine running time＞10s 1）Connectors not connected securely 1) Re-connect
CTS＜-38.25℃ 2) Temperature signal line open-circuited 2) Repair harness
Fault Duration＞2s 3）Sensor signal open-circuited to ground 3) Repair harness
4）Temperature signal line short-circuited to 4) Repair harness
power positive pole
5）Sensor damaged 5) Replace sensor
6）ECM signal input interface fault 6) Replace ECM
Fault code: P0115-2 Coolant temperature sensor too high

control scheme: Use intake temperature when starting, and fix after increasing to 79.5℃ with the
time
Connection terminal: MT20U Coolant temperature sensor Normal measuring
signal
Coolant temperature 43 B 0.5～4.5V
signal:
Sensor signal ground: 05 A 0V
shooting scheme
Engine running time＞2s 1）Temperature signal line short-circuited to 1) Repair harness
CTS＞135℃ ground
Fault duration ＞2s 2）Sensor damaged 2) Replace the sensor
Throttle position sensor
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Fault code: P0120-1 Throttle position sensor signal too high

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

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

control scheme: ● Air-fuel ratio cannot be controlled in closed-loop
Connection terminal: MT20U Heated oxygen Normal measuring
sensor signal
System main power \ C 12V
supply:
Heating drive: 61 D 0V
Oxygen sensor high 62 B 0～1000mV
signal: fluctuation
Oxygen sensor low 06 A 0V
signal:
shooting scheme
360.24mV＜oxygen sensor signal ＜538.19 1）Connectors not connected securely 1) Re-connect
mV 2）Sensor signal line open-circuited 2) Repair harness
Engine running time＞40s 3）Sensor poisoned or failed due to 3) Replace sensor
No TPS and MAP fault Coolant temperature overheat
＞72℃ 4）ECM signal input interface fault 4) Replace ECM
Entering closed-loop fuel control status
TPS＞10.156%
Fault duration＞15s
-198-
Fault code: P0135-1 Oxygen sensor heating circuit short-circuited to power positive pole
To set up emergency ● Lightup the fault-indicating lamp until the fault is disappeared and turn off the
control scheme: ignition switch
● Postpone the system closed-loop operation time
sensor signal
supply:
Oxygen sensor high 62 B 0～1000mV fluctuation
signal:
signal:
shooting scheme
Fault duration＞1s 1）Heating drive line short-circuited to power 1) Repair harness
positive pole
Fault code: P0135-2 Oxygen sensor heating circuit open-circuited or short-circuited to ground
To set up emergency ● Lightup the fault-indicating lamp until the fault is disappeared and turn off the
control scheme: ignition switch
● Postpone the system closed-loop operation time
Connection terminal: MT20U Heated Normal measuring
oxygen sensor signal
supply:
signal:
signal:
shooting scheme
1）Connectors not connected securely 1) Re-connect
No main relay fault
2 ） Wiring harness heating drive line 2) Repair harness
Duration ＞1s
open-circuited
3 ） Wiring harness heating drive line 3) Repair harness
-199-
Fault code: P0170-1 Time indicating oxygen sensor air-fuel ratio concentrated too long
sensor signal
supply:
signal:
signal:
shooting scheme
Oxygen sensor signal ＞998.26 mV 1）Sensor signal line short-circuited to 5V 1) Repair harness
Engine running time ＞40s or 12V
No TPS and MAP fault 2）Sensor damaged 2) Replace sensor
Coolant temperature ＞72℃ 3）ECM signal input interface fault 3) Replace ECM
Entering closed-loop fuel control
status
TPS＞10.156%
Duration＞15s
Fault code: P0170-2 Time indicating oxygen sensor air-fuel ratio thinned too long
Connection terminal: MT20U Heated Normal measuring
oxygen signal
sensor
supply:
signal:
signal:
shooting scheme
Oxygen sensor signal ＜52.083 mV 1 ） Sensor signal line ground 1) Repair harness
Engine running time ＞40s short-circuited
No TPS and MAP fault 2）Sensor high low signal lines reversed 2) Repair harness
Coolant temperature ＞72℃ 3）Sensor damaged 3) Replace sensor
Entering closed-loop fuel control status 4）ECM signal input interface fault 4) Replace ECM
TPS＞10.156%
Fault duration＞15s
-200-
main relay
B AB AB AB
Injector
Fault code: P0201-0 Injector A (1-cylinder) circuit fault

P0202-0 Injector B (3-cylinder) circuit fault
P0203-0 Injector C (4-cylinder) circuit fault
P0204-0 Injector D (2-cylinder) circuit fault
To set up emergency control scheme: ● Lightup the fault-indicating lamp until the fault is disappeared
● None
Connection terminal: MT20U Injection nozzle Normal measuring signal
System main power \ A 12V
supply:
Injector A (1-cylinder): 55 B 0-12V approximate square wave
Injector B (3-cylinder): 56 B 0-12V approximate square wave
Injector C (4-cylinder): 71 B 0-12V approximate square wave
Injector D (2-cylinder): 70 B 0-12V approximate square wave
Judgment conditions Possible causes Refer to trouble shooting scheme
Ignition switch 1） Corresponding nozzle line short-circuited 1） Repair harness
switched on to power positive pole or ground 2） Repair harness
Fuel pump operation 2） Corresponding nozzle circuit switch 3） Re-connect
normal 3） Connectors not connected securely 4） Replace damaged nozzle
Ignition voltage＞10V 4） Nozzle circuit damaged 5） Replace ECM
5） ECM signal output control interface fault
-201-
main power
power relay
fuel control pump
Fuel control pump
Fault code: P0230-1 Fuel pump relay short-circuited to power positive pole
control scheme: ● None
Connection terminal: MT20U Fuel pump relay Normal measuring signal
System main power \ Refer to electrical 12V
supply: system instructions
Relay drive: 47 Refer to electrical 0V(running), 12V(stopped)
system instructions
scheme
Duration＞1.5625s 1 ） Relay drive line short-circuited to 1) Repair harness
system power positive pole
2）Relay damaged 2) Replace relay
Fault code: P0230-2 Fuel pump relay open-circuited or short-circuited to ground
-202-
Connection terminal: MT20U Fuel pump relay Normal measuring signal
System main power \ Refer to electrical 12V
supply: system instructions
Relay drive: 47 Refer to electrical 0V(running), 12V(stopped)
system instructions
scheme
Duration＞1.5625s 1） Connectors not connected securely 1） Re-connect
2） Circuit connecting the system main 2） Repair harness
power open-circuited
3） Relay drive line short-circuited to 3） Repair harness
system power negative pole
4） Relay drive line open-circuited 4） Repair harness
5） Relay damaged 5） Replace relay
6） ECM signal input interface fault 6) Replace ECM
2 1
Knock sensor
-203-
Fault code: P0325-0 Poor connection of knock sensor

control scheme: ● Adopt safety ignition advance angle table
Connection terminal: MT20U Knock sensor Normal measuring signal
Knock signal: 69 0～1V
Sensor signal ground: 05 0V
scheme
Engine running speed＞2000rpm 1） Connectors not connected securely 1） Re-connect
MAP＞50kPa 2） Knock signal line open-circuited 2） Repair harness
Duration＞5s 3） Sensor signal short-circuited to ground 3） Repair harness
4） Knock signal line and other lines 4） Repair harness
short-circuited
5） Sensor damaged 5） Replace sensor
6） ECM signal input interface fault 6) Replace ECM
A B C
Crankshaft position sensor
-204-
Fault code: P0335-0 No 58x crankshaft position sensor signal

●Engine unable to start
Connection terminal: MT20U Crankshaft position sensor Normal measuring
signal
Crankshaft signal 12 A ＞400mV sine wave
high: (and sensor B)
Crankshaft signal 28 B ＞400mV sine wave
low: (and sensor A)
System grounding 73 C 0V
wire:
shooting scheme
Start engine 1）Connectors not connected securely 1) Re-connect
No engine speed signal 2）Signal high low connected in reverse 2) Repair harness
MAP dropped to 2.9509kPa 3）Signal line open-circuited 3) Repair harness
System voltage drops 0.8V 4）Signal line and other line short-circuited 4) Repair harness
Speed ＜4km/h 5）Sensor damaged 5) Replace sensor
Duration ＞2s 6）ECM signal input interface fault 6) Replace ECM
Fault code: P0335-8 58x crankshaft position sensor signal error

Connection terminal: MT20U Crankshaft position sensor Normal measuring
signal
Crankshaft signal 12 A ＞400mV sine wave
high: (and sensor B)
Crankshaft signal 28 B ＞400mV sine wave
low: (and sensor A)
System grounding 73 C 0V
wire:
shooting scheme
Number of teeth entering ECM not equal 1）Poor signal line screen 1）Adopt screened line
to 58 after engine running for 5 cycles in 2 ） 58x gear ring has metal foreign 2）Clear 58x gear ring
succession matters
-205-
main relay
B A A B
HV coil
Ignition coil
Fault code: P0351-1 Ignition coil 1-4 cylinders drive line short-circuited to power positive pole
control scheme: ● Stop fuel injection to 1- 4 cylinders
● Increase the target idle speed to 1200rpm
Connection terminal: MT20U Ignition coil Normal measuring signal
supply:
1-4 cylinder drive: 32 B 0-12V approximate square
wave signal induction
peak value＞300V
peak value＞300V
scheme
Duration: 1.25s 1）1-4 cylinder drive circuit and power 1) Repair harness
positive pole short-circuited
2）Ignition coil damaged 2) Replace ignition coil
3）ECM fault 3) Replace ECM
-206-
Fault code: P0351-2 Ignition coil 1-4 cylinder line open-circuited or short-circuited to ground wire
control scheme: ● Stop fuel injection to 1-4 cylinders
supply:
peak value＞300V
peak value＞300V
scheme
Duration: 1.25s 1）Connectors not connected securely 1) Re-connect
2）1-4 cylinders drive line short-circuited to 2) Repair harness
3）1-4 cylinders drive line open-circuited 3) Repair harness
Fault code: P0352-1 Ignition coil 2-3 cylinders drive line short-circuited to power positive pole
● Increase the target idle speed to 1200rpm
System main power \ B 12V
supply:
1-4 cylinders drive: 32 C 0-12V approximate square
peak value＞300V
2-3 cylinders drive: 52 A 0-12V approximate square
peak value＞300V
scheme
Duration: 1.25s 1）2-3 cylinders drive circuit short-circuited 1) Repair harness
-207-
main relay
B A
Canister solenoid valve
Fault code: P0352-2 Ignition coil 2-3 cylinders drive line open-circuited or short-circuited to
grounding wire
supply:
1-4 cylinders drive: 32 B 0-12V approximate square
peak value＞300V
peak value＞300V
scheme
Duration: 1.25s 1）Connectors not connected securely 1) Re-connect
2）2-3 cylinders drive circuit short-circuited to 2) Repair harness
the system power negative pole
3）2-3 cylinders drive circuit open-circuited 3) Repair harness
-208-
Fault code: P0443－1 Canister solenoid valve line short-circuited to power positive pole
To set up emergency control scheme: Lightup the fault-indicating lamp until the fault is disappeared
Turn off the canister solenoid valve
Canister Normal measuring
Connection terminal: MT20U
solenoid valve signal
System main power supply: \ B 12V
63 A 0~12V square wave
shooting scheme
Duration >2s 1) Solenoid valve drive circuit short-circuited 1) Repair harness
to power positive pole 2) Replace solenoid
2) Solenoid valve damaged valve
3) ECM fault 3) Replace ECU
Fault code: P0443-2 Canister solenoid valve line short-circuited to power positive pole
control scheme: ● Turn off the canister solenoid valve
Connection terminal: MT20U Canister solenoid valve Normal measuring signal
System main power \ B 12V
supply:
Solenoid valve drive: 63 A 0-12V square wave
scheme
Duration ＞5s 1）Connectors not connected securely 1) Re-connect
2）Solenoid valve drive circuit short-circuited to 2) Repair harness
3）Solenoid valve drive circuit open-circuited 3) Repair harness
4）Circuit connected with the system main power 4) Repair harness
open-circuited
5）Solenoid valve damaged 5) Replace ignition coil
-209-
Fault code: P0480-1 Water tank low speed fan relay drive circuit short-circuited to power positive
pole
● Fan does not run until water temperature rises to 98℃, then it turns On
Connection terminal: MT20U Low speed fan relay Normal measuring signal
Battery: \ Refer to electrical system 12V
instructions
Relay drive: 67 Refer to electrical system Running=0V,
instructions Stopped=12V
scheme
Duration ＞3s 1 ） Relay drive circuit short-circuited to power 1) Repair harness
positive pole
-210-
Fault code: P0480-2 Condenser fan relay drive circuit open-circuited or short-circuited to
ground
To set up emergency control ● Lightup the fault-indicating lamp until the fault is disappeared
scheme: ● None
● Fan does not run (open-circuited), until water temperature rises to 98℃,
then it turns On
● Fan running constantly (short-circuited to ground)
Battery: \ Refer to electrical 12V
system instructions
Relay drive: 67 Refer to electrical Running=0V,
system instructions Stopped=12V
scheme
Duration＞3s 1）Connectors not connected securely 1) Re-connect
2）Relay drive circuit short-circuited to system 2) Repair harness
power negative pole
3）Relay drive circuit open-circuited 3) Repair harness
4）Open-circuited to battery connection circuit 4) Repair harness
Fault code: P0480-2 Condenser fan relay drive circuit open-circuited or short-circuited to
ground
To set up emergency control ● Lightup the fault-indicating lamp until the fault is disappeared
scheme: ● None
● Fan does not run (open-circuited), until water temperature rises to 98℃,
then it turns On
● Fan running constantly (short-circuited to ground)
Battery: \ Refer to electrical 12V
system instructions
Relay drive: 67 Refer to electrical Running=0V,
system instructions Stopped=12V
scheme
Duration＞3s 1）Connectors not connected securely 1) Re-connect
2）Relay drive circuit short-circuited to system 2) Repair harness
power negative pole
3）Relay drive circuit open-circuited 3) Repair harness
4）Open-circuited to battery connection circuit 4) Repair harness
-211-
Speed sensor
Fault code: P0500-0 No speed sensor signal

● May adopt driving limit measures
Connection MT20U Speed sensor Normal measuring signal
terminal:
Sensor signal 03 / 0-12V square wave
ground:
scheme
Engine running 1）Connectors not connected securely 1）Re-connect
Speed ＜2kph 2 ） Signal line from gearbox to 2 ） Replace flexible shaft or
MAP＜25.82Kpa instrument interrupted signal wire
1200rpm ＜ engine speed ＜ 3）Wiring harness from instrument to 3）Repair harness
5000rpm ECM interrupted
Throttle closed 4）Speed sensor damaged 4）Replace speed sensor
fault Duration ＞5s 5）Instrument fault 5）Tidy up or replace instrument
6）ECM fault 6）Replace ECM
-212-
C D
B A
Idle speed stepping motor
Fault code: P0505-0 Idle speed control error

control scheme: ● Pause idle adjustment
Connection terminal: MT20U Idle control valve Normal measuring signal
Idle valve A-Hi: 54 D 0-12V square wave
(and idle valve C)
Idle valve A-Lo: 53 C 0-12V square wave
(and idle valve D)
Idle valve B-Hi: 33 B 0-12V square wave
(and idle valve A)
Idle valve B-Hi 34 A 0-12V square wave
(and idle valve B)
scheme
Engine idle running 1） Connectors not connected securely 1） Re-connect
Water temperature reached normal 2） Any one of lines of idle valve 2） Repair harness
value open-circuited
No TPS and VSS fault 3） Corresponding relationship of the 3） Repair harness
Deviation from the target speed idle valve connector and ECM
＞180rpm connector wrong
Duration ＞15s 4） Intake manifold leaking 4） Clear the leaking
5） Idle control valve damaged 5） Replace idle control valve
6） ECM fault 6） Replace ECM
-213-
Fault code: P0560-1 System voltage too high

control scheme: ● Stop system fuel injection
Connection terminal: MT20U Ignition switch Normal measuring
signal
Ignition switch: 01 Refer to electrical system 12V
instructions
shooting scheme
Switch on the ignition switch 1）Generator regulator damaged 1）Replace the damaged
System voltage ＞17.2V voltage regulator
Duration ＞5s 2）HV battery is used by mistake 2）Use correct battery
Fault code: P0607-0 Knock control system failure

control scheme: ●Ignition advance angle will be postponed (adopt safety ignition advance control)
Connection terminal: 69# MT20U ECM Normal measuring signal
ECM： ESM internal fault \
scheme
Fault code: P0607-0 Knock control system failure

control scheme: ●Ignition advance angle will be postponed (adopt safety ignition advance control)
Connection terminal: 69# MT20U ECM Normal measuring signal
ECM： ESM internal fault \
scheme
-214-
fault-indicating lamp
Fault code: P0650-1 Fault-indicating lamp line short-circuited to power positive pole
To set up emergency ● Not lit
control scheme:
Connection terminal: MT20U System fault-indicating lamp Normal measuring
signal
Ignition switch: \ Refer to electrical system 12V
instructions
Indicating lamp 31 Refer to electrical system Off=12V, On=0V
drive: instructions
shooting scheme
Duration ＞2s 1）Wiring harness J1 –31 line short-circuited to 1）Repair harness
system power positive pole
Fault code: P0650-2 Fault-indicating lamp line open-circuited or short-circuited to ground

To set up emergency ● Not lit (open-circuited)
control scheme: ● Constantly lit (short-circuited to ground)
Connection terminal: MT20U System fault-indicating lamp Normal measuring
signal
instructions
Indicating lamp 31 Refer to electrical system Not lit=12V, lit=0V
drive: instructions
shooting scheme
Duration ＞2s 1）Poor installation of the fault bulb 1）Re-install the bulb
2）Line to ignition switch fault 2）Repair harness
3）Drive circuit line short-circuited to power 3）Repair harness
negative pole
4）Fault bulb damaged 4）Replace the bulb
-215-
Fault code: P1230-1 Main relay line short-circuited to power positive pole
control scheme: ● Unable to start
Connection terminal: MT20U Main power relay Normal measuring signal
instructions
Relay drive: 58 Refer to electrical system Operating=0V,
scheme
Duration ＞1s 1）Relay drive line short-circuited to power 1）Repair harness
positive pole
Fault code: P1230-2 Main relay line open-circuited or short-circuited to ground

control scheme: ● Unable to start (open-circuited)
● Able to start normally (short-circuited to ground)
Connection terminal: MT20U Main power relay Normal measuring signal
instructions
Relay drive: 58 Refer to electrical system Operating =0V,
scheme
Duration ＞1s 1）Poor installation of relay 1）Re-install the relay
2）Line to ignition switch open-circuited 2）Repair harness
3）Relay drive line open-circuited 3）Repair harness
4 ） Relay drive line short-circuit to power 4）Repair harness
negative pole
5）Relay damaged 5）Replace the relay
-216-
power
air conditioning
request signal
air conditioning
compressor clutch
Air conditioning compressor relay
Fault code: P1530-1 Air conditioning compressor relay line short-circuited to power positive pole
control scheme: ● Air conditioning not operating
Connection terminal: MT20U Compressor relay Normal measuring signal
instructions
scheme
Air conditioning system detected 1）Repaired harness line short-circuited to 1) Repair the harness
Duration ＞3s power positive pole
2）Relay damaged 2) Replace the relay
3）ECM fault 3) Replace the ECM
-217-
Fault code: P1530-2 Air conditioning compressor relay line open-circuited or short-circuited to
ground
control scheme: ● Air conditioning not operating (open-circuited)
● Air conditioning operating constantly (short-circuited to ground)
Connection terminal: MT20U Compressor relay Normal measuring signal
instructions
scheme
Air conditioning system 1） Connectors not connected securely 1) Re-connect
detected 2） Line to battery open-circuited 2) Repair harness
Duration＞3s 3） Repaired harness short-circuited to power 3) Repair harness
negative pole
4） Repaired harness line open-circuited 4) Repair harness
5）Relay damaged 5) Replace the relay
-218-
Fault code: P2000-1 Air conditioning evaporator temperature too high

Connection terminal: MT20U Front evaporator Normal measuring signal
temperature sensor
Temperature signal: 26 Refer to electrical system 0.5～4.5V
instructions
Sensor signal ground: 05 Refer to electrical system 0V
instructions
scheme
Temperature indication＞144℃ 1） Temperature signal line short-circuited to 1) Repair harness
Duration ＞3s power negative pole
2）Sensor damaged 2) Replace the sensor
Fault code: P2000-2 Air conditioning evaporator temperature too low
Connection terminal: MT20U Front evaporator Normal measuring signal
temperature sensor
Temperature signal: 26 Refer to electrical system 0.5～4.5V
instructions
Sensor signal ground: 05 Refer to electrical system 0V
instructions
scheme
Temperature indication＞-36℃ 1） Connectors not connected securely 1) Re-connect
Duration ＞3s 2） Temperature signal line short-circuited to 2) Repair harness
power positive pole
3） Temperature signal line open-circuited 3) Repair harness
-219-
V. Common faults repairing procedure of the engine
1. During starting, engine does not rotate or rotate slowly
Problem with starter (jamming or internal short circuit), excessive engine drag, defect in circuit system
(voltage, earth).
No. Operation steps Checking result Subsequent step

Use universal meter to check whether there is Yes Next step
1 voltage of approx. 10 ~ 12.5V between two Repair or replace battery
No
wiring terminals of the battery.
Set the ignition switch to “ON”. Use universal Yes Next step
meter to check whether there is battery voltage Repair wiring terminal or
2 of approx. 10~12.5V on the wiring terminal replace wire
No
connecting the battery positive pole on the
ignition switch.
Maintain the ignition switch at start gear, use Yes Next step
universal meter to check whether there is over Repair or replace the
3 8V voltage on the wiring terminal connecting the ignition switch
No
starter motor operating coil on the ignition
switch.
Use universal meter to check whether the engine Repair or replace the
Yes
4 is open-circuited or short-circuited. starter motor
No Next step
Check whether the engine is jammed due to poor Yes Eliminate the trouble
5
lubrication. No Next step
If in winter, check whether the resistance of Change with proper lube
Yes
starter motor is too high due to improper oil
6 selection of engine lube oil and gear case oil Check the others
(engine’s resistance becomes high as the oil No
viscosity is high).
-220-
2. When starting, engine can run by trailing, but cannot start successfully
Checking
No. Operation steps Subsequent step
result
Set the ignition switch to “ON”. Use faultfinder to check Clear the displayed
Yes
1 whether there is fault information record. fault
No Next step
Pull out the cylinder-split wire and connect the spark plug, Yes 8
make the spark plug electrode 5 ~ 10mm away from the engine
2
body, use the starter motor to trail the engine to run, check No Next step
whether there is blue white high tension spark.
Check whether the high tension wire resistance value is normal Yes Next step
3 (not lower than 4K ohms)
Repair or replace high
No
tension wire
Check whether the cylinder-split high-tension wire, spark plug Yes Replace
4 is damaged.
No Next step
Check whether crankshaft position sensor is damaged. Yes Replace
5
No Next step
Check whether the ignition coil is normal. Yes Next step
6
No Replace
Check whether the intake pressure sensor connectors are Yes Next step
7 securely connected (MT20U has intake pressure
Connect securely the
cylinder-judgment technique). No
plug
Set the ignition switch to “ON”. Check whether the fuel pump Yes Next step
8 relay and fuel pump are able to operate.
Repair the fuel pump
No.
circuit
Connect the fuel pressure gauge valve. Short-circuit #30 and Yes Next step
9 #87 pins of the fuel relay and let the pump run; check whether
the fuel pressure is at 300kPa. No 13
Pull out the fuel distribution pipe together with the injector and Yes 12
pull out one-by-one the injector connector on the harness and
10
supply 12V voltage directly from the battery to injector, and
No Next step
check whether the injector can inject fuel.
Check again whether the injector can inject fuel after it is Yes Next step
11 cleaned.
No Replace injector
Check whether the fuel is deteriorated or moisture contained. Yes Replace the fuel
12
No 18
Check whether the fuel pressure is lower than 300kPa. Yes Next step
13
No 17
Close the fuel valve, switch on the ignition switch again and Yes Next step
14 make the fuel pump run again, and check whether the fuel
pressure can be established. No 16
-221-
Checking
result
Open the fuel gauge valve and clamp tightly the fuel return Replace the fuel
Yes
pipe with fuel return interceptor and make it no return fuel. pressure regulator
15 Check whether it can establish fuel pressure (the fuel pump
aging and operation capability decreasing must also be Repair or replace the
No
considered). injector or fuel pipe
Check whether the fuel inlet pipe is leaking or blocked. Repair or replace the
Yes
16 inlet pipe
No Replace the fuel pump
Check whether the fuel return pipe is blocked or bent. Repair or replace the
Yes
fuel return pipe
17
Replace the fuel
No
pressure regulator
Connect an adaptor between ECU and harness, check whether Yes Next step
there is voltage on pins 1, 17 and 18 of ECU, whether the
18 positive power wire connecting the above-mentioned ECU pins
and the grounding wire connecting the pin 73 of the ECU are Repair or replace the
No
normal. harness
Check whether there is leakage in the components of the intake Yes Repair
19 system.
No Next step
Check whether the intake manifold absolute pressure and Yes Repair or replace
20 temperature sensor is blocked.
No Next step
Check whether the coolant temperature sensor is normal. Yes Next step
21
No Repair or replace
Check whether the unsuccessful startup is due to mechanical Remove the mechanical
Yes
problem such as, too big clearance between the piston and trouble
22
cylinder, cylinder leaking.
No Replace ECU
For this test, make sure to disconnect fuel injector control coil to prevent excessive fuel into 3-element
catalyzer (the converter will otherwise be burnt after engine start).
3. Difficult hot start
No. Operation steps Checking Subsequent step

result
Set the ignition switch to “ON”. Use faultfinder to check Yes Clear the displayed fault
1 whether there is fault information record.
No Next step
Connect the fuel pressure gauge valve. Short-circuit the pins Yes Next step
2 #30 and #87 of the fuel pump relay and make the fuel pump
run, and check whether the fuel pressure is at 350kPa. No 9
Disconnect 300kPa, turn off the ignition switch, observe Yes Next step
whether the pressure of the fuel system can still be
3 No Repair fuel system
maintained at 250 ~ 300kPa in one hour (whether there is
system internal leakage). leakage
-222-
No. Operation steps Checking Subsequent step

result
Connect the connection fuel pipe and intercept the return fuel Yes Replace fuel pressure
pipe with return fuel interceptor, and close the fuel pressure regulator
4 valve at the same time. Turn off the ignition switch and
observe whether the pressure of the fuel system can still be No
Next step
maintained at 250 ~ 300kPa in one hour.
Check whether there exists fuel leakage in injector and pipe. Replace the injector and
Yes
5 fuel pipe
No Next step
Pull out water temperature sensor connector and start the Yes Check coolant
6 engine. Observe whether it can start successfully. temperature and line
No Next step
Connect an adaptor between ECU and harness, check Yes
Next step
whether there is voltage on pins 1, 17 and 18 of ECU,
7 whether the positive power wire connecting the No
above-mentioned ECU pins and the grounding wire Repair or replace harness
connecting the pin 73 of the ECU are normal.
Replace the fuel, carry out hot startup again, and observe Yes End
8 whether it can be started successfully.
No Replace ECU
Check whether the fuel pipe is blocked or bent, whether the Yes Next step
9 fuel pump pressure regulation valve is operating normally.
Use universal meter to check whether there is battery voltage Yes Next step
10 on both ends of the fuel pump connector.
No Repair or replace fuel
pump relay and wire
Use universal meter to check whether the fuel pump Yes Next step
11 resistance value is correct.
Check whether the fuel pump is jammed. Yes Replace the fuel pump
12
No Replace ECU
4. Speed is normal, but always difficult to start

Checking
result
Set the ignition switch to “ON”. Use faultfinder to check whether Yes Clear the displayed fault
1
there is fault information record. No Next step
Check whether the air filter is free. Yes Next step
2
No Replace
After successful startup, check whether the intake manifold Yes Next step
3 pressure at idle is between 35 ~ 55kPa. No Clear intake system
leakage
Step on the throttle gently and observe whether the startup is Replace and check the
4 Yes
easy. throttle and idle channel
Connect the fuel pressure gauge valve. Short-circuit the pins 30 Yes Next step
5 and 87 of the fuel pump relay and make the fuel pump run, and No
check whether the fuel pressure is at 300kPa. 9
6 Use special connector to supply 12V voltage directly from battery Yes 8
-223-
to injector to check whether the injector operates normally. No Next step
Check again whether the injector can operate normally after it is Yes Next step
7 cleaned. No Replace the injector
8
No 14
9 No 13
Close the fuel gauge valve, switch on again the ignition switch Yes Next step
10 and let the pump run again, check whether the fuel pressure can No
be established. 12
Open the fuel gauge valve, use fuel return interceptor to clamp Yes Replace the fuel
tightly the fuel return pipe and make it no return fuel, and check pressure regulator
11
whether the fuel pressure can be established quickly. No Repair or replace
injector or fuel pipe
Check whether the fuel inlet pipe is leaking or blocked. Yes Repair or replace the
12 fuel inlet pipe
Check whether the fuel return pipe is blocked or bent. Yes Repair or replace the
fuel return pipe
13
No Replace the fuel
pressure regulator
Pull out the idle actuator connector on the harness before the Yes Next step
14 engine coolant temperature reaching 35℃, and observe whether
the engine speed is dropped (engine enters fault mode). No Repair or replace idle
actuator
Set the ignition switch to “ON”. Check whether the voltage of the Yes Next step
15 following pins of the ECU is normal: approx. 12V battery voltage
for pins 1, 17 and 18, and 0 for pin 73. No Check the harness and
connectors
Make the engine run at idle speed, and check whether the ignition Yes Next step
16 advance angle is normal after the coolant temperature reaches No Check the harness and
normal value. connectors
Check whether the cylinder pressure of the engine is normal. Yes Next step
17
No Clear the trouble
18
temperature sensor is blocked. No Next step
Check whether the coolant temperature sensor is normal. Yes Replace ECU
19
-224-
5 . Difficult startup of cold vehicle
Checking
result
Set the ignition switch to “ON”. Use faultfinder to check Yes Clear the displayed
1 whether there is fault information record. fault
No Next step
Use universal meter to check whether the coolant Yes Next step
temperature sensor is normal. Or connect in series a 15k
ohm between the pins 43 and 05 of ECU to start the No
2
engine instead of the coolant temperature sensor. If the
Replace the sensor
engine can be started, it indicates the coolant temperature
sensor is abnormal.
Switch on the ignition switch. Connect an adaptor Yes Next step

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

4
No Replace
After successful startup, check whether the intake Yes Next step
5 manifold pressure at idle speed is between 35 ~ 55kPa.
No Eliminate intake
system leakage
Step on the throttle gently and observe whether the Yes Check the throttle and
6 startup is easy. idle channel
No Next step
Pull out the idle actuator connector on the harness before Yes Next step
the engine coolant temperature reaching 35 ℃ , and
7 No Repair or replace idle
observe whether the engine speed is dropping (engine
enters fault mode). actuator
Connect the fuel pressure gauge valve (the connecting Yes Next step
point depends on vehicle model). Make the pins 86 of the
fuel pump relay grounded directly. Switch on the ignition No
8
switch and make the fuel pump relay and the fuel pump
12
operate, and check whether the fuel pressure is at approx.
300kPa.
Use special connector to supply 12V voltage directly Yes 11

9 from the battery to injector, and check whether the
No Next step
injector is operating normally.
-225-
Checking
result
Check again whether the injector can operate normally Yes Next step
10 after it is cleaned.
No Replace injector
Check whether the fuel is deteriorated or moisture Yes Replace the fuel
11 contained.
No 17
12
No 16
Close the fuel gauge valve, switch on again the ignition Yes Next step
13 switch and let the pump run again, check whether the
No 15
fuel pressure can be established.
Open the fuel gauge valve, use fuel return interceptor to Yes Replace the fuel
clamp tightly the fuel return pipe and make it no return pressure regulator
14
fuel, and check whether the fuel pressure can be No Repair or replace
established quickly. injector or fuel pipe
Yes Repair or replace the

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

fuel return pipe
16 Check whether the fuel return pipe is blocked or bent.
No Replace the fuel
pressure regulator
Check whether the cylinder pressure of the engine is Yes Next step
17
normal. No Clear the trouble
Check whether the intake system of the engine is leaking Yes Repair
18
or blocked. No Next step
19
temperature sensor is blocked. No Replace ECU
-226-
6. Idle unstable at any time

Checking
result
Yes Clear the displayed
Set the ignition switch to “ON”. Use faultfinder to check whether
1 fault
there is fault information record.
No Next step
2 Check whether the idle actuator of stepping motor is jammed. idle actuator
No Next step
Switch on the ignition switch. Check whether the connection Yes Check the harness
3 wire between the water temperature sensor, idle stepping motor and connectors
and ECU is normal. No Next step
Make the engine run at idle speed, cut fuel of the cylinders Yes 8
4 one-by-one, and observe whether the engine speed is dropping or No
Next step
fluctuating.
Yes Next step
Check whether the operation of the injector of each cylinder is
5 No Check the injector
normal.
and harness
Check whether the resistance value of high-tension wire of each Yes Next step
6
cylinder is normal. No Replace
Yes Replace
7 Check whether the ignition coil is damaged.
No Next step
Yes Next step
8 Check whether the spark plug is normal. No Replace the spark
plug
9 and 87 of the fuel pump relay and make the fuel pump run, and
No 13
check whether the fuel pressure is at 300kPa.
Use special connector to supply 12V voltage directly from the Yes 12
10 battery to injector, and check whether the operation of injector is No
Next step
normal.
11
cleaned. No Replace injector
Yes Replace fuel
12 Check whether the fuel is deteriorated or moisture contained.
No 18
Yes Next step
13 Check whether the fuel pressure is lower than 300 kPa.
No 17
14 and let the pump run again, check whether the fuel pressure can No 16
be established.
Yes Replace the fuel
Open the fuel gauge valve, use fuel return interceptor to clamp
pressure regulator
15 tightly the fuel return pipe and make it no return fuel, and check
No Repair or replace the
whether the fuel pressure can be established quickly.
injector or fuel pipe
-227-
Checking
result
16 Check whether the fuel inlet pipe is leaking or blocked. fuel inlet pipe
No Replace fuel pump
fuel return pipe
17 Check whether the fuel return pipe is blocked or bent.
No Replace the fuel
pressure regulator
Check whether the detection hole of the intake manifold pressure Yes Clear it
18 and intake temperature sensor is blocked. No Next step
Make the engine run at idle speed, and observe whether the Yes Next step
operation of oxygen sensor is normal after the coolant No
19 Check the oxygen
temperature reaches the temperature activated by closed-loop
sensor and harness
control. (Fluctuated between 0-1V)
Check whether the engine intake system is leaking. Yes Eliminate the leakage
20
No Next step
21
Make the engine run at idle speed. Check whether the ignition Yes Replace ECU
22 advance angle is normal after the coolant temperature reaches the No
normal value. Check others
7. Idle unstable during warming up

Checking
result
Yes Clear the displayed
Set the ignition switch to “ON”. Use faultfinder to check whether
1 fault
there is fault information record.
No Next step
Yes Next step
2 Check whether the air filter is free.
No Replace
Yes Next step
Make the engine run at idle speed, and check whether the intake
3 No Eliminate the intake
manifold pressure during warming up is between 35 ~ 55kPa.
system leakage
Turn off the engine, and switch on the ignition switch. Connect Yes
Next step
an adaptor between ECU and harness and check whether the
4
voltage of intake temperature, water temperature sensors and pins No
4, 20 of ECU (used as 4.5~5V sensor power) is normal. Repair
Pull out the idle actuator connector before end of warming up, Yes Next step
5 and observe whether the engine speed is changed (engine enters No Replace the idle
fault mode). actuator
Yes Next step
6 Check whether the coolant temperature sensor is normal.
No Replace
Make the engine run at idle speed. Check whether the ignition Yes Replace ECU
7 advance angle is normal after the coolant temperature reaches the No
-228-
8. Idle unstable at end of warming up

Checking
result
Set the ignition switch to “ON”. Use faultfinder to check whether Yes Clear the displayed
1 there is fault information record. fault
No Next step
Set the ignition switch to “ON”, connect an adaptor between Yes
ECU and harness and check whether the voltage of ECU intake Next step
manifold absolute pressure sensor output, intake temperature
2 No
sensor output, coolant temperature sensor output, oxygen sensor Repair or replace the
output pins and the voltage outputted to the idle actuator pins by harness and related
ECU are normal. parts
Turn off the engine and chemical whether the air filter is free. Yes Next step
3
No Replace
Check whether the intake manifold pressure at idle speed is Yes Next step
4 between 35 ~ 55kPa. No Eliminate intake
system leakage
Connect fuel pressure gauge valve (connecting point depends on Yes Next step
vehicle model). Short-circuit the pins 30 and 87 of the fuel pump No
5
relay and make the fuel pump run, and check whether the fuel 9
pressure is approx. 300kPa.
6 battery to injector, and check whether the injector is operating
No Next step
normally.
7 cleaned. No Replace injector
8
No 14
9
No 13
12
be established.
Open the fuel gauge valve, use fuel return interceptor to clamp Yes Replace the fuel
tightly the fuel return pipe and make it no return fuel, and check pressure regulator
11
whether the fuel pressure can be established quickly. No Repair or replace the
injector or pipe
12 fuel inlet pipe
fuel return pipe
13
No Replace the fuel
pressure regulator
Make the engine run at idle speed. Check whether the ignition Yes Next step
14 advance angle is normal after the coolant temperature reaches the No Adjust ignition
normal value. advance angle
-229-
Checking
result
Pull out coolant temperature sensor and observe whether the Yes Replace the coolant
15 engine is normal. temperature sensor
No Next step
16
Check whether the resistance value of high-tension wire of each Yes Next step
17 cylinder is normal.
No Replace
Check whether the ignition coil and high-tension wire is damaged Yes Replace
18
or cracked. No Next step
Check whether the spark plug is normal. Yes Replace ECU
19 No Replace the spark
plug
9. Idle unstable or fire cut-off when using load (air conditioning)

Checking
result
No Next step
Switch on the air conditioning switch. Connect an adaptor Yes Next step
2 between ECU and harness and measure whether there is signal No Repair air
input for ECU air conditioning switch and pressure signal. conditioning circuit
Check whether the air-conditioning system pressure, Yes Next step
3 electromagnetic clutch of the compressor and the air conditioning No
Repair or replace
pump are normal.
Set the ignition switch to “ON”. Check whether the voltage of Yes Next step
4 pins 33, 34, 53 and 54 (output to idle actuator) of ECU is normal. No Check the control
circuit
Take off the stepping motor and check whether the stepping Yes Repair or replace the
5 motor is jammed or failure to run. stepping motor
No Next step
Start the engine and switch on the air conditioning, use Yes Replace ECU
faultfinder to check whether the operation of the idle actuator at No
6 Replace the idle
this time is normal by checking the number of steps of the
actuator
stepping motor.
-230-
10. Periodically unstable (Self-learning must be carried out after ECU power off)
Checking
result
No Next step
2
No Replace
Make the engine run at idle speed and check whether the intake Yes Next step
3 pressure is at 35 ~ 55kPa.
No Repair intake and
leakage
Make the engine run at idle speed, cut fuel of the cylinders Yes 7
4 one-by-one, and observe whether the engine speed is dropping or
No Next step
fluctuating.
Set the ignition switch to “ON”. Connect an adaptor between Yes
ECU and harness and check whether the voltage of ECU’ s intake Next step
manifold absolute pressure sensor output, intake temperature
5
sensor output, coolant temperature sensor output, oxygen sensor
output, electronic ground, ignition switch pin and ECU’
s pins 33, No Repair or replace the
34, 53 and 54 (output to idle actuator) is normal. harness
Make the engine run at idle speed. Check whether the ignition Yes Next step
6 advance angle is normal after the coolant temperature reaches the
No Check others
normal value.
Check whether the detection hole of the intake manifold pressure Yes Clear
7 and intake temperature sensor is blocked.
No Next step
8
No Next step
Use special connector to supply 12V voltage directly from the Yes
Next step
battery to injector, and check whether the operation of injector is
9 normal.
No Repair the injector
and corresponding
harness
Check whether the resistance value of the high-tension wire of Yes Next step
10 each cylinder is normal.
No Replace
Check whether the ignition coil and high-tension wire is damaged Yes Replace
11 or cracked, etc.
No Next step
Check whether the spark plug is normal. Yes Replace ECU
12 No Replace the spark
plug
-231-
11. Too high idle speed (self-learning must be carried out after ECU power off)
Checking
result
1 Set the ignition switch to “ON”. Use faultfinder to check whether Yes Clear the displayed
there is fault information record. fault
No Next step
2 Check whether the cable connected with accelerator pedal is Yes Adjust or replace
jammed or too tight.
No Next step
3 Check whether the canister solenoid valve, fuel pressure Yes Repair or replace
regulator, crankcase forced-draft vacuum tube, brake system
vacuum booster hose are installed reliably or damaged.
No Next step
4 Make the engine run at idle speed, shift into neutral, step on the Yes Next step
brake pedestal, and observe whether the idle speed is too high.
No 6
5 Clamp the vacuum booster hose and observe whether the idle Yes Repair or replace the
becomes normal. vacuum booster
No Next step
6 Clamp the crankcase forced-draft vacuum tube and observe Yes Replace PCV valve
whether the idle becomes normal.
No Next step
7 Clamp the canister control valve hose and observe whether the Yes Replace the canister
idle becomes normal. control valve
No Next step
8 Check whether the idle actuator is not free or jammed. Yes Repair or replace
No Next step
9 Check whether there is leakage in other part of the intake pipe Yes Repair or replace
No Next step
10 Check whether the sealing ring of the injector is perfect. Yes Next step
No Replace the sealing

ring
11 Check whether the intake manifold absolute pressure and intake Yes Replace ECU
temperature sensor is perfect.
No Replace the sensor
-232-
12. Speed cannot be increased or fire is cut-off when accelerating

Checking
result
1 Set the ignition switch to “ON”. Use faultfinder to check Yes Clear the displayed fault
whether there is fault information record. No Next step
2 Check whether the air filter is free. Yes Next step
No Replace
3 Make the engine run at idle speed, and check whether the Yes Next step
speed is normal at idle.
No Maintenance according to
idle fault items
4 Make the engine run at idle speed, and check whether the Yes Next step
intake pressure is 35 ~ 55kPa.
No Repair
5 Make the engine run at idle speed, and check whether the Yes
Next step
ignition advance angle is normal after the coolant
temperature reaches normal value. No Adjust the ignition advance
angle
6 Connect the fuel pressure gauge valve. Short-circuit the Yes Next step
pins 0 and 87 of the fuel pump relay and make the fuel
No 10
pump run, and check whether the fuel pressure is at
300kPa.
7 Use special connector to supply 12V voltage directly from Yes 9
the battery to injector, and check whether the injection is No
normal. Next step
8 Check again whether the injector can operate normally Yes Next step
after it is cleaned. No Replace injector
9 Check whether the fuel is deteriorated or moisture Yes Replace the fuel
contained. No 15
10 Check whether the fuel pressure is lower than 300kPa. Yes Next step
No 14
11 Close the fuel gauge valve, switch on again the ignition Yes Next step
switch and let the pump run again, check whether the fuel No 13
pressure can be established.
12 Open the fuel gauge valve, use fuel return interceptor to Yes Replace the fuel pressure
clamp tightly the fuel return pipe and make it no return regulator
fuel, and check whether the fuel pressure can be No Repair or replace the
established quickly. injector or pipe
13 Check whether the fuel inlet pipe is leaking or blocked. Yes Repair or replace the fuel
inlet pipe
14 Check whether the fuel return pipe is blocked or bent. Yes Repair or replace fuel return
pipe
No Replace fuel pressure
regulator
15 Set the ignition switch to “ON”. Connect an adaptor Yes Next step
between ECU and harness, and check whether the voltage No Repair or replace harness
of the output signal terminal of ECU throttle position
sensor and pins 4, 20 (used as 4.5 ~ 5V sensor power) is
normal.
16 Check whether the ignition coil, high-tension wire and Yes Replace ECU
spark plug are normal. No Repair the related parts and
components
-233-
13. Reacting slowly when accelerating
Whether the fuel is up to the standard, whether the intake pressure sensor, throttle position sensor is
fault.
Checking
result
1 Set the ignition switch to “ON”. Use faultfinder to check whether Yes Clear the displayed
there is fault information record. fault
No Next step
2 Turn off the engine, and check whether the air filter is free. Yes Next step
No Replace
3 Make the engine run at idle, and check whether it is normal at Yes Next step
idle speed.
No Repair according to
idle fault items
4 Make the engine run at idle speed, and check whether the intake Yes Next step
pressure is 35 ~ 55kPa.
No Repair
5 Switch on the ignition switch. Connect an adaptor between ECU Yes
Next step
and harness, and check whether the voltage of the output signal
terminal of ECU throttle position sensor, grounding terminal and No Repair or replace the
pins 4, 20 (used as 4.5 ~ 5V sensor power) is normal. harness
6 Make the engine run at idle speed, and check whether the ignition Yes Next step
advance angle is normal after the coolant temperature reaches No Check others
normal value.
7 Connect the fuel pressure gauge valve. Short-circuit the pins 30 Yes
Next step
and 87 of the fuel pump relay and make the fuel pump run, and
check whether the fuel pressure is between 300kPa. No 11
8 Use special connector to supply 12V voltage directly from the Yes 10
battery to injector, and check whether the operation of the
injector is normal. No Next step
9 Check again whether the injector can operate normally after it is Yes Next step
cleaned.
No Replace injector
10 Check whether the fuel is deteriorated or moisture contained. Yes Replace the fuel
No 16
11 Check whether the fuel pressure is lower than 300 kPa. Yes Next step
No 16
12 Close the fuel gauge valve, switch on again the ignition switch Yes
Next step
and make the pump run again, check whether the fuel pressure
can be established. No 14
13 Open the fuel gauge valve, use fuel return interceptor to clamp Yes Replace the pressure
tightly the fuel return pipe and make it no return fuel, and check regulator
whether the fuel pressure can be established quickly. No Repair or replace
injector or pipe
14 Check whether the fuel inlet pipe is leaking or blocked. Yes Repair or replace the
fuel inlet pipe
No Replace the fuel
pump
15 Check whether the fuel return pipe is blocked or bent. Yes Repair or replace the
fuel return pipe
No Replace the pressure
regulator
16 Check whether the exhaust system and 3-way catalytic reactor is Yes Replace or clean
blocked.
No Replace ECU
-234-
14. Performance is poor, asthenic when accelerating

Confirm whether the fuel is up to the standard, whether hand brake, brake is dragging.
Checking
result
Check whether there exist such troubles as clutch slip, tyre Yes Repair
1 pressure low, brake dragging, tyre dimension not right, and No
Next step
four-wheel positioning incorrect.
Check whether the throttle can be fully opened. Yes Next step
2 No Repair or replace
throttle
No Next step
Make the engine run at idle speed, and check whether the ignition Yes Next step
4 advance angle is normal after the coolant temperature reaches No
Set the ignition switch to “ON”. Connect an adaptor between Yes Next step
ECU and harness, and check whether the voltage of ECU’ s intake No
manifold absolute pressure sensor, throttle position sensor, intake
5 Repair or replace the
temperature sensor, coolant temperature sensor pin, ECU’ s
harness
oxygen grounding terminal and signal output terminal pins, and
ECU pins 4, 20 (used as 4.5 ~ 5V sensor power) is normal.
Make the engine run at idle speed, and check whether the intake Yes Next step
6
pressure is 35 ~ 55kPa. No Repair
7 and 87 of the fuel pump relay and make the fuel pump run, and No
11
check whether the fuel pressure is at approx. 300kPa.
8 battery to injector, and check whether the operation of injector is No
Next step
normal.
9
cleaned. No Replace injector
10
No 16
Check whether the fuel pressure is lower than 300 kPa. Yes Next step
11
No 15
14
be established.
Open the fuel gauge valve, use fuel return interceptor to clamp Yes Replace pressure
tightly the fuel return pipe and make it no return fuel, and check regulator
13
whether the fuel pressure can be established quickly. No Repair or replace the
injector or pipe
14 fuel inlet pipe
fuel return pipe
15
No Replace pressure
regulator
Check whether the data of the intake manifold absolute pressure Yes Next step
16
and intake temperature sensor is normal. No Replace the sensor
-235-
Checking
result
17 Check whether the ignition coil, high-tension wire and spark plug Yes Next step
are normal. No replace or adjust
18 check if it's caused by conditioning system Yes check conditioning
system
No Replace ECU
15. Air conditioning system trouble

Checking
result
1 Check whether the system has sufficient coolant, whether the air Yes Next step
conditioning belt is normal, and whether the air conditioning No Clear the trouble
clutch, pressure switch are normal.
2 Make the engine run at idle speed and switch on the air Yes Clear the displayed
conditioning switch. Use faultfinder to check whether the air fault
conditioning thermistor is fault. No Next step
3 Switch on the air conditioning switch. Connect an adaptor Yes Next step
between ECU and harness to measure whether there is signal No Check the harness
input for ECU’ s air conditioning switch, air conditioning
pressure.
4 If this vehicle adopts low level control, check whether the air Yes Repair the harness
conditioning is still working when it is switched off. No Next step
5 Check whether there is low level output at the grounding terminal Yes Repair the air
of the operating coil of ECU’ s air conditioning relay. conditioning relay
and harness
No Replace ECU
-236-
VI. Wiring diagrams
Ignition Main relay

Main relay
switch (MPR)
Battery Power
steering
The frame is a part of the electric

diagram for ignition-injecting wiring
harness
Fuel pump
Reserved,
Crankshaft undeveloped
signal wheel
Crankshaft
position sensor
Camshaft position
sensor
Vehicle speed sensor
Knock sensor
Intake pressure
Oxygen sensor temperature sensor
A/C request Pressure A/C switch

Throttle position Temperature
signal (high switch
sensor efficiency)
switch
Coolant Temperature
Sensor Connect to the
instrument
-237-
Ignition Coil
Ignition Coil
Spark plug
Idle
speed Fuel injector
motor
Carbon canister solenoid valve The frame is a part of the electric

diagram for ignition-injecting
wiring harness
Diagnosis request Diagnosis access
Engine Ignition
tachometer switch
Connect to the tachometer Engine malfunction

indicating light
A/C clutch A/C clutch

A/C clutch relay
A/C fan
A/C fan relay
A/C condenser fan
-238-
Refine MPV Workshop Manual Electrical System
Section V Engine electrical system
I. Size and parameters
1. Starting motor
Model Speed reduction driving
Voltage 12V
Power 1.2kw
No-load characteristics
Terminal voltage 11V
Current intensity 90A or lower
Rotation speed 2,800rpm
Number of teeth of a gear 8
Gear clearance 0.5-2.0mm
2. Generator
2.4 14
Model Battery voltage induction
Rated power 13.5V/95A
Voltage regulator model Built-in electronic type
Regulator set voltage 14.4 0.3V
Temperature compensation -10 3Mv/℃
3. Batteries
All generators
Model MF 68 AH,MF 90 AH
Ampere hours
5HR 55AH or higher
Cold start (at-17.8℃) 540AH or higher
Reverse supply capability 122min
Specific weight (at25℃) 1.280±0.01
Caution:
Cold start current intensity refers to the battery current that can maintain 7.2 or higher terminal voltage for
30s under specified temperature. Rated reverse supply capability refers to the time during which batteries
can supply 25A and maintain minimum terminal voltage of 10.5 at 26.7℃.
4. Tightening torque
Item Ｎm
Generator terminal (Ｂ+) 5-7
Starting motor terminal (B+) 10-12
Battery terminal 4-6
Spark plug 20-30
- 237 -
II. Common troubleshooting

1. Charging system
Fault phenomena Fault causes Repair
With ignition switch “On” Melt fuse Check and replace fuse
and engine not rotating, Burnt light Replace light
charging alarm indicator Loose HV line connector Tighten loose connector
does not light up Fault of electronic voltage regulator Replace voltage regulator
During engine operation, Belt loose or worn Adjust tension or replace driving belt
batteries frequently request Loose, corroded or worn battery wire Repair or replace wire
recharging and charging Melt fuse Replace fuse
alarm indicator does not go Melt fuse wire Replace fuse
out Fault of electronic voltage regulator or Detect generator
generator
Line fault Repair line
Engine acceleration slow or Loose or worn driving belt Adjust tension or replace driving belt
failed; excessive charging Loose line connector or open circuit Tighten loose connector or repair line
Melt fuse Replace fuse
Poor grounding Repair
Fault of electronic voltage regulator or Detect generator; repair or replace in
generator case of fault
Old batteries Replace batteries
Fault of electronic voltage regulator Replace voltage regulator
Fault of voltage induction line Repair line
2. Starting system
Fault phenomena Fault causes Repair
Engine cannot Low batteries Charge or replace batteries
rotate Loose, corroded or worn battery wire Repair, replace wire
Fault of driving axle shifting switch (only Adjust or replace switch
for vehicles with auto transmission)
Melt fuse Replace fuse
Fault of starting motor Repair starting motor
Fault of ignition switch Replace ignition switch
Fault of ignition lock switch Replace ignition lock switch
Engine rotates Low batteries Replace ignition lock switch
slowly Loose, corroded or worn battery wire Repair or replace wire
Fault of starting motor Repair starting motor
Starter operating all Fault of starting motor Repair starting motor
the time Fault of ignition switch Replace ignition switch
Starter operates but HV line short circuit Replace high voltage line
engine not starting Broken driving gear or damaged starting Repair starting motor
motor
Broken gear ring tooth Replace flywheel ring gear or torque converter
- 238 -
III. Charging system
Adjusting bolt
调节螺栓
Generator
发电机
Bracket
支架螺栓 bolt
Torque:
扭矩
The charging system includes batteries, generator with built-in regulator, charging indicator and lines. There are 6
built-in diodes (3 positive and 3 negative). Each diode rectifies AC power to DC power. Therefore, AC power is on
generator “B”end.
Besides, charging voltage of this generator is regulated by battery voltage detection system. The generator is also
regulated by this system. Main parts of generator include rotor, stator, rectifier, brush, bearing and V belt. The
brush seat includes a built-in electronic voltage regulator.
Stator
Rotor 定 Generator
发电机
转
Front
前轴承
Rear后轴承
bearing bearing
Ammeter
安培表
Inspection:
Measurement of generator output line voltage drop
This test checks for normal line between generator terminal 电压表
Voltmeter Battery
蓄电池
“B”and battery (+) by measuring voltage drop.
- 239 -
Preparations
1. Turn ignition switch to “Off”.
Note:
To locate connector abnormity, do not use the method to check 2 terminals and 1 connector at the same time
during testing.
2. Connect digital ammeter between generator “B”and battery (+). Connect voltmeter wire (+) to terminal “B”,
and wire (-) to battery terminal (-).
Testing conditions
1. Start engine;
2. Turn on headlight, fans and motors etc., and read voltmeter reading under such conditions.
Results:
1. Voltmeter can display standard value.
Standard value: max. 0.2V
2. If voltmeter value is higher than expected value (max. 0.2V or higher), the fault may be on the line. In such
case, check the line connecting generator terminal “B”to battery (+). Check for loose connector and change of
color of harness due to heat. Before testing again, repair these.
3. After testing, set engine rotation speed, close headlights, and turn off fans, motors and ignition switch.
Testing of output current
This test aims to determine normal output current of generator.
Preparations
1. Before testing, check the following items and perform corrections if required;
1） Check for normal operation of batteries installed on the vehicle. For method refer to section “Batteries”;
Batteries used for testing of output current shall be partly discharged. If fully charged batteries are used for this
test, correct results cannot be achieved due to insufficient load.
2） Check tension of generator driving belt. For inspection of belt tension, refer to relevant chapters in “EM”.
2. Turn off ignition switch.
3. Disconnect batteries grounding wire.
4. Disconnect generator output wire from terminal “B”.
5. Connect DC ammeter (0 to 100A) between terminal “B and disconnected output wire and ensure that
negative pole (-) of ammeter is connected to disconnected output wire of batteries.
Caution:
Tighten each connector; as high current will Voltmeter
电压表安 Ammeter
培
flow past, do not rely on clamps.
6. Connect a voltmeter (0 to 20V) between Generator
terminal “B” and ground wire. Connect positive inspection
检查发电
pole (+) wire to generator “B”and negative pole (-)
wire to ground.
7. Connect engine tachometer and battery
ground wire.
8. Open engine cover.
Testing
1. Check if voltmeter reading is the same as battery voltage. If voltmeter reading is 0V, possible cause includes
open circuit between generator terminal “B”and battery pole (-), melt fuse and poor grounding.
- 240 -
2. Start engine and turn on head lights.

3. Set high beam of head lights; turn heater and fans to HIGH. Fast accelerate engine to 2500rpm and use
ammeter to measure max. output current.
Caution
After start of engine, charging current will fall fast. Therefore, you must quickly perform above
operations to read correct max. current.
Results
1. Ammeter reading must be higher than limit value. If not, but engine output wire is normal, remove generator
from vehicle and test it.
Limit (for 95A engine): 63A
Caution:
Rated output voltage is marked on generator nameplate.
Output current varies with electric load and generator temperature. Therefore, you may not obtain rated
output current. In such case, keep head lights on to discharge batteries, or add lights of other vehicles to
increase electric load.
If generator temperature or air temperature is too high, rated output current may not be reached. In such
case, lower temperature before testing again.
2. After testing of output current, lower engine rotation speed to idling speed and turn off ignition switch.
3. Disconnect battery grounding wire.
4. Remove ammeter, voltmeter and engine tachometer.
5. Connect generator output wire to generator terminal “B”.
6. Connect battery grounding wire.
Testing of regulated voltage
Purpose of this test is to check if the electronic voltage regulator can correctly adjust voltage.
Preparations:
1. Before testing, check the following items; correct if required:
☆ Check if batteries on vehicle are fully charged. Refer to Chapter “Batteries”for method of inspection.
☆ Check generator driving belt tension. Refer to Chapter “Engine machinery”for this inspection.
2. Turn ignition switch to “OFF”.
4. Connect a digital voltmeter between generator terminal “S(L)”and ground wire. Connect voltmeter (+) to
generator “S(L)”and (-) to ground wire or battery (-).
5. Disconnect generator output line from generator
terminal “B”. Ammeter
安培表
6. Connect a DC ammeter (0 to 100A) in series
between terminal “B”and disconnected output line.
Connect ammeter (-) wire to disconnected output
line.
7. Fit engine tachometer and connect battery Voltmeter
ground wire. 电压
Testing
1. Turn on ignition switch and check if value displayed on voltmeter is the following:
Voltage: Battery voltage
- 241 -
If the reading is 0V, possible cause includes open circuit and melt fuse in line between generator terminal “S(L)”
and battery/battery pole (+);
2. Start engine and turn off all lights and accessories.
3. Operate engine at about 2500rpm; when generator output current falls to 10A or below, read voltage
reading.
Results
1. If voltage reading is consistent with values listed in the table below (Table of regulated voltage), functioning
of voltage regulator is normal. If the reading is not in range of standard values, this indicates fault in voltage
regulation or generator.
Table of regulated voltage
Voltage regulator environmental temperature ℃ Regulated voltage (V)
-20 14.2-15.4
20 13.9-14.9
60 13.4-14.6
80 13.1-14.5
2. After completion of test, reduce engine speed to idling speed and turn off ignition switch.
4. Remove voltmeter, ammeter and engine tachometer.
5. Connect generator output line to generator terminal “B”.
6. Connect battery grounding wire.
Testing of generator output line voltage drop
This test determines if the line (including fuse) from generator terminal “B”to battery (+) is normal.
1. Before testing, check the following items:
☆ Generator installation and line connectors;
☆ Generator driving belt tension;
☆ Fuse;
☆ When the generator is operating, abnormal noise in generator.
2. Turn ignition switch to OFF.
3. Disconnect battery negative pole lead wire.
4. Disconnect generator output line from generator terminal “B”. Connect a DC ammeter (0-100A) in series
between terminal “B”and disconnected output line (connect ammeter (+) to terminal “B”, and ammeter (-) to
disconnected output line).
Note:
Induction type ammeter is recommended. This ammeter can perform measurement without disconnecting
generator output line. Using this ammeter, possible voltage drop due to loose connector at terminal “B”
can be reduced.
5. Connect a digital voltmeter between generator terminal “B” terminal and battery pole (+) (connect
voltmeter (+) to terminal “B”and voltmeter (-) to battery (+)).
6. Again connect battery (-) pole wire.
7. Connect a tachometer or speed measuring tool.
8. Start engine.
9. With engine operating at about 2500rpm, turn head lights and other lights on or off to adjust generator load
so that ammeter reading is slightly higher than 30A.
- 242 -
Limit value: max. 0.3V

Note
When generator output current is high, and value displayed on ammeter cannot fall to 30A, set the setting
to 40A. Read value on voltmeter. In such case, limit value changes to max. 0.4V.
10. If value on voltmeter is still higher than limit value, fault may exist at generator output wire. Check the line
(including fuse) between generator terminal “B”and battery (+) pole. If terminal connector is not tightened or
harness changes color due to overheat, repair or retesting shall be carried out.
11. After the test, idle the engine.
12. Turn off all lights and turn ignition switch to OFF.
13. Disconnect tachometer or testing tool.
14. Disconnect battery (-) pole wire.
15. Disconnect ammeter and voltmeter.
16. Connect generator output line to generator terminal “B”.
17. Connect battery (-) pole wire.
Ammeter
安培表
Generator
发电机
Voltmeter
电压表（数字式） (digital)
Battery
蓄电池
- 243 -
IV. Dismantling and installation
Rear bearing
Front 后轴承
前罩 cover Rotor assembly
转子总成
保持架
Holder
Screw (4EA)
螺钉(4EA)
Pulley 前轴承
Front bearing
皮带轮
Hexagon
六角螺母 nut
盖Cover
－B 端
Rectifier
整流器 -terminal
子 B
Isolation
隔离圈 ring Bolt
螺栓(4EA)
（4EA）
Flange
法
Cover
盖
Controller assembly
调节器总成
Rear后罩
cover
Stator assembly
定子总成
Dismantling
1. Remove 4 penetrating bolts.
2. Insert a flat screw driver between front
support and stator core, and pry downward.
Caution:
a． Do not insert the screw driver too deep;
otherwise stator core maybe damaged.
b． Since there is a lock ring at rear bearing, it
may be very difficult to remove the rear cover.
To facilitate removal of rear cover, use a 200W
electric iron to heat bearing cover surface. Do
not use a blow gun, as this will damage the
diode assembly.
- 244 -
3. Face belt pulley edge up and use a soft jaw

vice to fix the rotor.
Note: Do not damage rotor with the jaw vice.
4. Remove belt pulley nut, spring washer, belt
pulley and spacer ring.
5. Remove front support and 2 seals.
6. Remove stator assembly from jaw of the vice.
7. Remove brush seat screw, rectifier screw and
nut from terminal “B”.
8. Remove stator assembly from rear support.
9. Remove oil deflector from brush seat.
10. If the stator has been removed, weld the 3
stator wires off rectifier main diode.
Note:
a． When welding on or off, confirm that heat
of electric iron will not be transferred to diode
for a long time.
b． Do not use excessive force on diode lead
wire.
11. When separating rectifier from brush seat, weld
off the two plates on rectifier.
Inspections
Rotor
1. Check rotor for connectivity and confirm
conduction among slip rings. If resistance is too
small, there is short circuit. If there is no
conduction, an open circuit exists; replace rotor
assembly.
Resistance: about 3.1Ω
2. Check grounding of rotor coil and conduction
between slip ring and stator core. If there is
conduction, replace rotor assembly.
- 245 -
Stator
1. Perform conduction test of stator coil. Check
for conduction among coil lead wires. If there is no
conduction, replace stator assembly.
2. Check grounding of coil. Check for

conduction between coil and stator core. If there is
conduction, replace stator assembly.
Rectifier
Testing of positive pole rectifier
Use ohmmeter to check conduction between
connecting terminals of positive rectifier and stator
core lead wire. Ohmmeter shall only be conducting
in one direction. If conduction in 2 directions is
found, the diode has been broken-down. Replace
rectifier assembly.
Testing of negative pole rectifier

Use ohmmeter to check conduction between
connecting terminals of negative rectifier and
stator core lead wire. Ohmmeter shall only be
conducting in one direction. If conduction in 2
directions is found, the diode has been
broken-down. Replace rectifier assembly.
Testing of 3 groups of diodes

Connect ohmmeter to the two pins of each diode to
check conduction. Each diode shall be conducting
at only one direction.
If a diode is conducting in two directions, this
diode is defective and radiator board assembly
must be replaced.
- 246 -
Replacement of brush
1. Measure extended length of brush as shown. If
measured value is below the following limit value,
replace brush.
Limit value: 2mm or less
2. After welding off brush lead wire, you can
remove the brush.
3. To install a new brush, insert the new brush
into brush seat and then weld on lead wire.
Re-installation
Sequence of re-installation is the reverse of
dismantling. Note the following:
Before fitting rotor in rear support, insert a steel
wire into the small hole on rear support to hold the
brush. After installation of rotor, remove this steel
wire.
V. Visual inspection of batteries

1. Check current
Check if there is any loss or damage obviously

caused by the electrolyte on the cover or hood, for
example crack of break. Identify the cause for such No Good
damage and repair as the specific situation. Clean Replace the battery
the corrosive parts with soda water solution.
Good The height

difference of the
electrolyte is above
Check the height of the electrolyte. 10mm
检查电解液的高度 Replace
更换蓄电池 the battery
The electrolyte
is not enough
Good Replace the battery
更换蓄电池
Below 11.0V
Battery test Replace
Good Above 12.5V

(11.0-12v) Replace the battery
更换蓄电池
Below 11.0V
Loading test (use the battery tester) Replace
Battery is normal
- 247 -
2. Inspection table
Item Fault Cause Repair Responsibility
User MFTR
Visual *Battery terminal damaged *Carelessness
inspection *Battery wire over Replace ○
tightened
Cracked cover *Carelessness Replace ○
*Leaking electrolyte
Cracked cover *Carelessness Replace ○
Leading cover *Poor cover sealing Replace ○
Inspection *Single cell electrolyte height *Cell short circuit Replace
○
of between poles larger than 10mm *evaporation due to too Replace
○
electrolyte high temperature Replace
○
height *Insufficient electrolyte *Loss of electrolyte
due to over discharge
Inspection 1. Battery voltage >13.2V 1. Over charging Replace ○
of voltage 2. 12.5V<Battery voltage<12.9V 2. Normal Check electrical
system
3. 12.0V<Battery voltage<12.4V 1. Insufficient charging Battery load test ○
(pure discharging) 2. Internal fault (reference load
4. 11.0V<Battery voltage<12.0V test below) ○
(over discharge)
5. Battery voltage: 11.0V or lower 1. Charging condition Replace
fault
○
2. Battery extended
○
discharging
○
3. Internal circuit open
circuit
3. Load test
1) Under half the current of cold start power (CCP), discharge batteries for 15s; battery voltage shall be as
indicated in the following table.
Table of regulated voltage
Ambient temperature Regulated voltage
Above 20℃ 9.6V
～18℃ 9.5V
～10℃ 9.4V
～4℃ 9.3V
～-1℃ 9.1V
～-7℃ 8.9V
～-12℃ 8.7V
2) If the voltage is not in specified range, repeat load test and charge batteries.
- 248 -
3) If after recharging and placing of battery for 2 hours, its output exceeds 12.5V, and voltage after load test
exceeds standard value, this battery can be used.
Visual inspection of batteries
1. Ensure that ignition switch and all accessories
are at OFF.
2. Disconnect battery wires (first disconnect
negative pole wire).
3. Remove batteries from vehicle.
Caution:
With cracked or leaking battery cover, avoid
electrolyte hurting your skin. To remove
batteries, wear thick rubber gloves.
4. Check for damage of battery holder due to leakage of electrolyte. If acid corrosion is found, use clean hot
water and dry soda water to clean surrounding areas. Use steel wire brush and wet cloth (dipped in soda water) for
cleaning.
5. Use the same solvent as in step (4) to clean top of batteries.
6. Check battery cover and box for cracking. Replace battery if there is cracking.
7. Use suitable tool to clean battery pole columns.
8. Use suitable battery cleaning tools to clean inner surfaces of terminal clamps. Replace damaged or worn
wires and damaged terminal clamps.
9. Install batteries on vehicle.
10. Connect wire terminals to battery pole columns and ensure terminal ends flush with top of pole column.
11. Tighten terminal nuts.
12. After tightening, apply mineral oil on all connectors.
Caution:
During battery charging, inflammable gas may be generated under battery cover of each cell. Keep
surrounding areas of batteries free of open flame. Prohibit smoking near batteries being charged or
charged recently. Do not break pole circuit of batteries being charged, as disconnection of this circuit will
generate sparks.
VI. Starting system

- 249 -
起动马达
Torque:
扭矩：Nm（kg.cm.lb.ft）
The starting system consists of batteries, starting

motor, EM switch, ignition switch, protection
switch (only available for vehicles with auto
transmission), connecting lines and battery wires.
When ignition key is turned to starting position,
electric current passes and excites starter EM coil.
The electromagnetic plunger and clutch shift lever
are driven (excited) and clutch pinion engages the
tube-ferrule to start the motor.
To prevent damage caused by excessive rotation of
starting motor pivot during engine stating, clutch
pinion will undergo overspeed.
Inspection of starting motor relay

Remove starting motor relay to check conduction relay
继电器
- 250 -
among terminals. If this conduction is not in

specified range, replace the relay.
Terminal No.
85 86 87 30
Condition
Not excited ○ ○
Excited ○ ○ ○ ○
Inspection of ignition lock switch
Remove ignition lock switch and check conduction

among terminals. If this conduction is not in
specified range replace the switch.
Terminal No.
1 2
Condition
Pushed on ○ ○
Released
VII. Dismantling and installation of starting system
1. Disconnect battery ground wire.

2. Remove odometer and shaft wires.
3. Disconnect starting motor connectors and terminals.
4. Remove starting motor assembly.
5. Installation procedure is the reverse of dismantling.
- 251 -
电磁线圈
Solenoid
开口环
Split ring
螺丝
Screw
Washer A
球填垫圈 A
Ball
Sun gear
太阳齿轮行星齿轮
Planetary gear
行星齿轮座螺钉
Planetary gear seat screw
圈齿环
Gear ring
Overdrive clutch
超速离合器
Check
止位环 ring
Front support
前支架
后支架
Back support
Brush bracket
电刷座
Armature
电枢
Centering holder assembly

定心架总成
- 252 -
VIII. Inspection of operation

Pinion gap adjusting procedure during Switch
开关
maintenance service
1. Disconnect excitation coil lead wire from EM
coil terminal M.
2. Connect 12V battery between terminals S and
M. Stopper
起动 Field coil圈lead
励磁线引
3. Remove pinion. motor
马
Caution:
To prevent coil overheat, this test must be
completed quickly (within 10min).
4. Use feeler gauge to check pinion stopper gap
(pinion gap).
Pinion gap: 0.5-2.0mm
Stopper
止动器
小齿轮间隙
Pinion clearance
Pinion
小齿轮 clearance
5. If pinion gap exceeds specified value, adjust
the gap by adding or deleting shims between EM
coil and front support.
Testing of EM switch
switch terminal M;
2. Connect 12V battery between terminals M
and S.
Caution: 蓄电池
Battery
To prevent coil overheat, this test must be Stopper
起动
completed quickly (within 10s or less). 马motor
3. If the pinion can be removed, suction coil is
fine. If not, replace EM switch.
- 253 -
Test of EM switch retentivity

switch terminal M.
2. Connect 12V battery between terminal S and
switch body.
Caution: Field
励磁 coil
线lead
圈引
起Stopper
动马
To prevent coil overheat, this test must be 线
达motor
completed quickly (within 10s or less).
3. If the pinion is removed, all is fine. If the
pinion moves forward and backward repeatedly,
the circuit remains open, and the line is open,
replace EM switch.
Test of no-load operation Stackup carbon bar

层叠碳板变阻器
rheostat
Place starting motor in a jaw vice with soft clamp.
Ammeter
安培表
Connect fully charged 12V battery to starting
motor as follows:
1. Connect testing ammeter (100A scale) to Stopper
起动
蓄电池
Battery
carbon pile rheostat as shown. motor
马达 Voltmeter
电压表
2. Connect a voltmeter (12V scale) to starting
motor in parallel.
3. Rotate carbon pile to OFF.
4.Connect battery wire from battery wiring pole (-)
to starting motor body.
5. Adjust carbon pile till battery voltage reading is
11V.
6. Confirm max. current in specified range and free
and balanced operation of starting motor.
Current: max. 90A
Speed: min. 3000rpm
Testing of return of EM switch

switch terminal M.
2. Connect 12V battery between terminal M and
motor body.
Caution:
Stopper
起动励磁线圈引线
Field coil lead
To prevent coil overheat, this test must be
completed quickly (within 10s or less). motor
马达
3. Pull out and release pinion. If the pinion
returns to original position fast, all is normal. If not,
replace EM switch.
- 254 -
Inspections
Inspection of steering gear
1. Place armature on a V-shaped pad and use a
scale meter to check radial runout.
Armature radial runout

Standard value: 0.05 mm
Limit value: 0.1 mm
2. Inspection of steering gear OD

Limit value: 28.4mm
3. Inspection of root cutting depth between sectors

Sector gear
扇形齿 Undercut
根切
Limit value: 0.2mm
Isinglass
云母
Brush seat
Check conduction between brush seat plate and
brush seat; normally, there shall be no such
conduction.
- 255 -
Overdrive clutch
1. Jack up clutch hood and rotate pinion.

Driving pinion shall rotate smoothly in one
direction but not the other direction. If clutch does
松开
Released
not function normally, replace overdrive clutch
assembly.
2. Check pinion for wear or rolled edge. If yes,
锁紧 up
Lock
replace overdrive clutch assembly. If pinion is
damaged, also check if the ring gear is worn or has
rolled edge.
Front and rear support lining
Check lining for wear or rolled edge. If yes,

replace front or rear support assembly.
Re-installation of stop ring and split ring

Use suitable pull-out tool to pull out stop ring and
split ring of overdrive clutch.
Cleaning of starting motor pars

1. Do not immerse parts in cleaning agent.
Immersed cleaning of centering support, excitation
coil or armature will damage insulation. Only use
cloth to clean these parts.
2. Do not immerse driving parts in cleaning
agent. Overdrive clutch had been lubricated in
factory; use of solvent will remove lubricant.
3. Driving elements can be cleaned by brush
dipped with cleaning agent, and then by cloth (to
wipe dry). Carbon brush
碳刷引出线
Replacement of carbon brush and spring lead
1. Replace carbon brush if worn or dipped in oil
2. To replace excitation coil carbon brush, use
pliers to clamp and crush worn carbon brush; do
not damage carbon brush leading out wire.
- 256 -
3. Use sandpaper to polish carbon brush leading

New carbon
out wire end to ensure good brazing property. 新碳刷
brush
Carbon
4. Insert leading out wire into hole on new brush lead Welding points
碳刷引线焊点 sure
(make （确that
信
carbon brush and weld it on. Ensure that surplus there is刷
no表面
在碳
remaining
solder of leading out wire will not be left on
welding
上没有tin剩on
余
surface of carbon brush. the carbon
的焊锡）
brush)
5. To replace grounded carbon brush, pry up
positioning spring to slide out the carbon brush
from brush holder.
Disassembling
Removal of split ring and stop ring
1. Use socket wrench to press stop ring to split
ring side. Sleeve
套筒
Check
止位环 ring
小齿轮
Pinion
超速离合器
Overdrive clutch
Armature
电枢
2. After removal of spilt ring (using split ring

Split ring
pliers), remove stop ring and overdrive clutch. Split
开口环 ring
clamp
开口环钳
Pinion
小齿轮
Overdrive
超速离合器
clutch
电枢
Armature
- 257 -
IX. Circuit diagrams

starting system (1)
Junction box
5.0W Ignition switch

Fusible piece
With theft-deterrent alarm Without theft-deterrent warning
Fuse
Battery block
y
Starting relay Theft-deterrent
warning relay
20R
Manual Auto
Body ground
With start Without start Without With start

Fan relay relay start relay relay
Magnet
Adjustment Diesel engine
rod Gasoline engine
Starting
motor
Start
solenoid
valve
Diesel engine
Engine Gasoline engine
Motor
Pinion
Manual Auto
Overdrive clutch
- 258 -
starting system (2)
Gasoline engine
With current at the ON or
Keep power on START shift
Engine compartment Fuse block
relay box
Fusible piece Fusible piece
Refer to the fuse

block in the
passenger
compartment
Connector Pre-excitation Instrument

Battery Refer to the
power supply
resistor Charge cluster
distribution
Body ground
Generat
Battery Signal Lamp
Start
coil
Rotor coil
- 259 -

4 2.4L Gasoline

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Refine MPV Workshop Manual Gasoline Engine

Chapter I Gasoline engine (2.4 L4)

Engine ID code is printed on cylinder below the exhaust manifold.

ID code of domestic engine consists of 12 digits.

3. Engine development serial number

Type of engine Code Type of engine Code

7. Engine ex-factory No.

ID code of imported engine consists of 11 digits.

II. Size and parameters

Item Size/parameter Limit value

Item Size/Parameters Limit value

Cylinder gasket surface planeness Less than 0.05 mm 0.1 mm

Item Size/parameters Limit value

Driven gear 0.18-0.21 mm 0.25 mm

Item Size/parameters Limit value

III. Tightening torque

Not using new parts +20+90º+90º Safety plug 40-50

IV. Common troubleshooting

Thinning of engine oil Replace engine oil and find cause

Phenomena Possible causes Repair

Piping or silencer damaged Repair or replace

Balance shaft bearing puller Removal of balance shaft rear

Balance shaft bearing mounting device Mounting of balance shaft

Guide plate Removal & mounting of

Screw plug wrench Removal and mounting of

Crankshaft front oil seal mounting device Mounting of crankshaft front

Tool (No. and description) Figure Purpose

Camshaft oil seal mounting device Mounting of camshaft oil seal

Camshaft oil seal guide rod Used as guide rod when

Cylinder head bolt sleeve Removal and mounting of

Valve guide pipe mounting device Removal and mounting of

Tool (No. and description) Figure Purpose

Valve guide pipe mounting accessory Mounting of valve guide pipe

Crankshaft rear oil seal mounting device 1． Mounting of engine rear

Piston pin removal set Removal and mounting of

Tool (No. and description) Figure Purpose

Cross beam stud bolt sleeve Removal and mounting of

09353-38000 For measurement of fuel oil

Section II Engine mechanism

I. Replacement of timing belt

Timing belt upper cover

Timing belt left rear

Balancer axis sprocket

Tension pulley arm

2. Remove fixing bolts on crankshaft belt disk and

3. Loosen fixing bolts on engine timing belt lower hood

4. Turn engine crankshaft clockwise so that cylinder 1 piston

5. Loosen the two fixing bolts on automatic tensioner and

6. Remove loose timing belt.

8. Loosen the 2 fixing bolts on crankshaft position sensor and

9. To remove engine oil pump gear, first remove a sight screw

13. Remove crankshaft driving gear and signal disc.

Warning: Shim iron

2. Install right balance shaft gear and align timing marking

3. Install timing belt and eccentric tensioner; press tensioner

4. Check belt tensioning: When the belt is pressed with finger,

5. Tighten right balance shaft gear fixing bolts.

8. Install crankshaft position sensor and tighten 2

9. Install camshaft belt gear, align timing mark on cylinder

12. According to belt operation direction, wind belt on timing

II. Oil tray and centralized filter

2. Remove 19 fixing bolts on oil tray in the sequence shown.