Sistema Dinamico Motor Byd PDF

BYD F0 Maintenance & Repair Manual
CONTENT
Chapter 1 Engine ....................................................................................................................................................... 1
Section 1 General.............................................................................................................................................. 2
Section 2 Drive Belt ......................................................................................................................................... 6
Section 3 Valve Clearance Inspection and Adjustment ................................................................................... 7
Section 4 Timing Chain .................................................................................................................................. 12
Section 5 Spark Plug and Compression Pressure Inspection ......................................................................... 14
Section 6 Engine ............................................................................................................................................. 15
Chapter 2 Lubrication System ................................................................................................................................. 36
Section 1 Engine Lubrication Circuit Schematic Drawing ............................................................................ 37
Section 2 Oil Pressure Inspection................................................................................................................... 37
Section 3 Engine Oil ....................................................................................................................................... 37
Section 4 Oil Filter ......................................................................................................................................... 38
Section 5 Oil Pan ............................................................................................................................................ 38
Section 6 Oil Pump ......................................................................................................................................... 39
Chapter 3 Cooling System ....................................................................................................................................... 43
Section 1 Engine Cooling System Schematic Drawing ................................................................................. 44
Section 2 Coolant Replacement and Filling ................................................................................................... 45
Section 3 Thermostat ...................................................................................................................................... 46
Section 4 Water Pump .................................................................................................................................... 46
Chapter 4 Engine Management System .................................................................................................................. 48
Section 1 Electronic Injection System Service Tip ........................................................................................ 49
Section 2 M7 System Description .................................................................................................................. 51
Section 3 M7 System Component Configuration, Principle and Trouble Analysis ...................................... 58
Section 4 M7 System Performs Inspection and Diagnosis Procedure According to Trouble Code ............. 87
Section 5 Repair and Service Procedure by M7 Diagnosis System According to Malfunction Symptoms109
Section 6 M7 System Tester Instruction for Use ......................................................................................... 118
Section 7 Accessories ................................................................................................................................... 125
Chapter 5 Fuel System ........................................................................................................................................... 130
Section 1 Fuel System .................................................................................................................................. 131
Section 2 Fuel Injector.................................................................................................................................. 136
Section 3 Fuel Pump Assembly.................................................................................................................... 140
Section 4 Fuel Tank Assembly..................................................................................................................... 145
Chapter 6 Cooling System ..................................................................................................................................... 150
Section 1 Cooling System ............................................................................................................................ 151
Section 2 Electronic Fan System .................................................................................................................. 151
Section 3 Coolant.......................................................................................................................................... 154
Section 4 Radiator ........................................................................................................................................ 155
Chapter 7 Exhaust System ..................................................................................................................................... 165
Section 1 Layout ........................................................................................................................................... 166
Section 2 Removal ........................................................................................................................................ 167
Section 3 Installation .................................................................................................................................... 167
Chapter 8 Transmission Case ................................................................................................................................ 169
Part 1 Disassembly and Inspection ........................................................................................................................ 170
Section 1 Disassembly (Fig.1-1-1) and Detail (Table 1-1-1) For the Front Case Peripheral Components.......... 170
Section 2 Disassembly Diagram of the Rear Case Peripheral Components ......................................................... 173
Section 3 Transmission Case Assembly Disassembly Diagram ........................................................................... 174
Section 4 Case Set Disassembly Diagram ............................................................................................................. 175
Section 5 Main Shaft Set Inspection and Disassembly ......................................................................................... 177
Section 6 SUB Shaft Set Inspection and Disassembly .......................................................................................... 180
Section 7 Differential Inspection and Disassembly .............................................................................................. 183
Section 8 Manual Shift Assembly Disassembly and Inspection ........................................................................... 185
Section 9 Shift Lever Fork Disassemly ................................................................................................................. 187
Part 2. Assemble and Inspection .......................................................................................... 189
Section 1 Manual Shift Assembly Assemble ........................................................................................................ 189
Section 2 Fork Installation ..................................................................................................................................... 191
Section 3 Differential Installation.......................................................................................................................... 193
Section 4 SUB Shaft Installation ........................................................................................................................... 195
Section 5 Main Shaft Installation .......................................................................................................................... 199
- I -
Section 6. Rear Case Installation ........................................................................................................................... 203

Section 7 Front Case Installation ........................................................................................................................... 204
Section 8 Closing ................................................................................................................................................... 205
- II -
Chapter 1 Engine
Section 1 General ....................................................................................................................................................... 2
1.1 Main Parameters ............................................................................................................................................ 2
1.2 Service Technical Data .................................................................................................................................. 2
1.3 BYD371QA/QB Engine Tightening Torque Table....................................................................................... 4
Section 2 Drive Belt................................................................................................................................................... 6
2.1 Drive Belt Removal and Installation ............................................................................................................. 6
2.2 Belt Inspection ............................................................................................................................................... 6
2.3 Drive belt adjustment ..................................................................................................................................... 6
Section 3 Valve Clearance Inspection and Adjustment ............................................................................................ 7
3.1 Valve Clearance Inspection ........................................................................................................................... 7
3.2 Valve Clearance Adjustment ......................................................................................................................... 8
Section 4 Timing Chain ........................................................................................................................................... 12
4.1 Timing Chain Removal ................................................................................................................................ 12
4.2 Timing Chain Installation ............................................................................................................................ 13
Section 5 Spark Plug and Compression Pressure Inspection .................................................................................. 14
5.1 Spark Plug Removal and Installation .......................................................................................................... 14
5.2 Spark Plug Inspection .................................................................................................................................. 14
5.3 Compression Pressure Inspection ................................................................................................................ 15
Section 6 Engine ...................................................................................................................................................... 15
6.1 Engine Disassembly ..................................................................................................................................... 15
6.2 Engine Inspection ......................................................................................................................................... 21
6.3 Engine Installation ....................................................................................................................................... 27
- 1 -
Section 1 General
BYD371QA achieves high power, lower fuel consumption, low noise, less emissions and compact construction.
BYD371QA engine can operate optimally under any condition. This ensures reliability, comfortable drivability, best
fuel economy and environment-friendly performance of the Auto.
1.1 Main Parameters
The main parameters of the BYD371QA Engine are as follows:
Data Model
BYD371QA
Item
3-Cylinder, in line, water-cooled, double overhead camshaft, 12-valve,
Type 4-stroke
Closed loop electronic fuel injection engine
Rated power 50 kw (6, 000 r/min)
Max. torque/speed 90 N·m (4, 000 r/min-4, 500 r/min)
Min. fuel consumption ≤250+10 g/kW·h
Bore×stroke 71 mm×84 mm
Displacement 0.998 L
Compression ratio 10.5:1
Valve mechanism Synchronized chain drive, double overhead camshaft, 12-valve DOHC
Combustion chamber Ball type
Fuel type 93# Unleaded gasoline （GB17930-1999）
Idle speed (840±50) r/min
Cylinder compression pressure 1.2～1.6 MPa (400 r/min)
Fuel supply Electronic sequential multiport fuel injection
Injection pressure (differential
pressure before and after the 390-400 kPa
injection)
Ignition order 1—2—3
Ignition timing BTDC 8°～12°
Lubricating method Forced and splash lubrication
SAE 10W-30/40 (SG or higher )(for four seasons in the South and except
Engine oil the winter in the North)
SAE 5W-30 (SG or higher) (for the winter in the North)
Exhaust emission system Three-way catalytic converter
Oil pressure 300～490 kPa (3, 000 r/min～4, 500 r/min)
Engine mass 76 KG
Dimension
525×575×720
(length×width×height)
Emission regulation EURO IV
1.2 Service Technical Data
Item Standard
Cylinder diameter 7100.02
mm
Cylindricity 0.008 mm
Cylinder Block Top flatness 100:0.03
Verticality Φ0.04
Cylinder compression pressure 1.2～1.6 MPa/(400 r/min)
Piston Piston skirt diameter 7100.03
.01
mm
- 2 -
Piston pin hole diameter 18 00..011

005 mm
Fit clearance of the piston and

0.02～0.04 mm
cylinder
Piston pin diameter 18 00.005 mm
Piston pin
Fit clearance of the piston pin and
0.005～0.016 mm
piston
1st compression ring 0.20～0.35 mm
Piston ring
2nd compression ring 0.35～0.5 mm
Opening clearance
Oil ring component 0.20～0.70 mm
1st compression ring 0.03～0.07 mm
Piston ring side clearance 2nd compression ring 0.02～0.06 mm
Oil ring 0.02～0.17 mm
Allowable twist limit 0.05 mm (per 100 mm)
Allowable bending limit 0.05 mm (per 100 mm)
Connecting rod Connecting rod small end hole 18 00..016
029 mm
diameter
Piston pin and connecting rod
0.011～0.029 mm
Interference fit
Main journal diameter 44 00.018 mm
Connecting rod journal diameter 40 00.018
mm
Crankshaft Journal Cylindricity 0.007 mm
Crankshaft radial runout 0.03 mm
Connecting rod big end axial
0.1～0.27 mm
clearance
Crankshaft thrust clearance 0.02～0.16 mm
Flywheel axial runout 0.1 mm
Cylinder head bottom surface
0.05 mm
flatness
Cylinder head Manifold joint flatness 0.05 mm
0.021
Cylinder head camshaft bore  23 0 mm
Cylinder head bolt length 122 mm
Camshaft journals diameter 2300..040
053 mm
Cam journal Cylindricity 0.004 mm
Camshaft Gap between the cam journal and
0.040～0.074 mm
shaft hole
Intake camshaft axial clearance 0.1～0.175 mm
Exhaust camshaft axial clearance 0.1～0.171 mm
Intake valve diameter 27.5±0.125 mm
Exhaust valve diameter 23.6±0.125 mm
0.020
Valve stem diameter Intake valve: 50.0035 mm

Exhaust valve: 50.045 mm
.030
Valve guide inner diameter 5 00..03

01
Valve system mm
Gap between the valve stem and Intake valve: 0.03～0.065 mm,
valve guide Exhaust valve: 0.040～0.075 mm
Valve spring free length 51.6 mm
Intake and exhaust valve clearance Intake valve: 0.19 mm
(cold) Exhaust valve: 0.32 mm
Thermostat initializing and full open temperature 82±2℃, Full open 95℃
Spark plug type and gap K6RTM2, 1.0 mm～1.2 mm
Generator belt tension deformation 98 N•m, Press into 7～8 mm
- 3 -
1.3 BYD371QA/QB Engine Tightening Torque Table
Amount
Tightening area or
No. Bolt specification (one Tightening torque (N·m)
parts
engine)
Main bearing cap
1 M10×1.5 Hexagon head bolt 8 60
bolt
Crankshaft rear end
2 M6×16 Hexagon flange bolt 5 10
cover
3 Flywheel bolt M10×1.25 Hexagon head bolt 6 75
4 Labyrinth cover plate M8×16 Hexagon flange bolt 8 25
5 Knock sensor M8×30 Hexagon flange bolt 1 20
6 Oil pressure siren 1 15
First: 15
7 Connecting rod bolt M8×0.75 Torx bolt 6
Second: +85°～95°
First: 32
8 Cylinder head bolt M9×1.5 Inner hexagon bolt 8
Second: +175°～185°
9 Plug Inner hexagon 1 25
10 Cam bearing cap Ⅰ M8×45 Hexagon flange bolt 3 15
11 Cam bearing cap Ⅱ M6×35 Hexagon flange bolt 12 12
Camshaft sprocket bolt
12 Camshaft sprocket 2 45
subassembly
13 Chain guide plate M6×12 Hexagon flange bolt 2 10
14 Chain tensioner plate Chain tensioner plate bolt 1 20
15 Chain tensioner M6×25 Hexagon flange bolt 2 10
16 Oil pump assembly M8×45 Hexagon flange bolt 2 25
M8×80 Hexagon flange bolt 1 25
M10×1.25×40 Hexagon flange
2 40
bolt
6 40
bolt
Crankshaft position
sensor
18 Water pump M8×20 Hexagon flange bolt 2 25
19 Oil receiver M6×25 Hexagon flange bolt 3 8
Oil pan M8×16 Hexagon Flange bolt 9 25
20 Oil filter seat M8×80 Hexagon flange Bolt 3 25
21 Oil dipstick guide M6×12 Hexagon flange bolt 1 10
Wire harness clamp
22 supportⅠ M6×12 Hexagon flange bolt 1 10
(oil pump)
Water pump inlet
pipe
M8 Nut 2 30
24 Intake manifold M8×35 Hexagon flange bolt 2 25
M8 Nut 2 25
Intake manifold
support
26 Oil rail M8×20 Hexagon flange bolt 2 25
Intake temperature
27 ST5.5×19A Self-tapping screw 1 5
and pressure sensor
28 Throttle M6×16 Hexagon flange bolt 3 10
Accelerator cable
bracket
30 Exhaust manifold M8×16 Hexagon flange bolt 2 30
- 4 -
M8 Nut 2 30
Exhaust manifold
heat insulator I
Exhaust manifold
support
M8 Nut 1 25
33 Front oxygen sensor 1 45
34 Thermostat cover M6×30 Hexagon flange bolt 2 8
Camshaft phase
sensor
Water temperature
36 1 20
sensor
37 Cylinder head cover M6×60 Hexagon flange bolt 2 8
38 Wire nailⅠ M6×12 Hexagon flange bolt 1 8
39 Wire nail Ⅱ M6×12 Hexagon flange bolt 1 8
40 Wire nail Ⅲ M6×12 Hexagon flange bolt 1 8
41 Spark plug M141.25 3 25
42 Ignition coil M6×25 Hexagon flange bolt 3 10
Wire nail support
(intake manifold)
Canister control
valve bracket
45 Crankshaft pulley Crankshaft pulley bolt 1 150
46 Water pump pulley M6×12 Hexagon flange bolt 4 15
Generator support
weldment
Generator adjusting
carrier weldment
49 Generator 1 50
bolt
Wire harness clamp
50 support Ⅱ M6×12 Hexagon flange bolt 1 10
(generator)
Clutch cover
assembly
52 Transmission 5 65
bolt
Transmission cover M10×1.25×12 Hexagon flange
53 3 40
plate bolt
54 Starter 2 40
bolt
Wire nail bracket
(starter)
Screw plug
56 1 35
M12×1.25
Inner hexagon
57 tapered screw plug 1 15
NPT3/8
58 (oil pump cover) M6×25 Hexagon flange bolt 6 10
M6×14 Cross recessed
2 8
countersunk head screw
Cylinder head (intake
59 Stud bolt AM8-M8×30-8.8 2 10
manifold)
Cylinder head
60 Stud bolt M8 2 10
(exhaust manifold)
Cylinder head (water
61 Stud bolt M8 2 10
pump inlet pipe)
- 5 -
Section 2 Drive Belt

2.1 Drive Belt Removal and Installation
2.1.1 Loosen the bolt A firstly.

2.1.1 And then loosen the bolt B.
2.1.1 Finally loosen the bolt C and generator, and remove the timing belt.
Generator
Water Pump
Loosen
Crankshaft Pulley
During installing, install the belt and tighten the bolt B

slightly at first, and then turn the bolt C, adjust the belt
tension, tighten the bolt B (torque: 35 N•m). Finally
tighten the bolt A (torque: 50 N•m).
After the installing, check for the staggered tooth of the
belt (as shown in below illustration). And then start the
engine for 5 min., check the tension of the belt.
2.3 Drive belt adjustment

Loosen the bolt A and B, and turn the bolt C to adjust
Correct Wrong the belt tension. Then tighten the bolt B and A.
NOTICE:
If a new belt or the drive belt that operates for less than
2.2 Belt Inspection 5 minutes should be replaced, adjust it to the extent as a
new one.
2.2.1 Drive belt appearance inspection
Inspect the appearance. If the belt is worn seriously, Drive belt
New (mm/98N) Old (mm/98 N)
replace it. deformation
Generator +
7～8 9～11
water pump
2.2.2 Drive belt deformation inspection
NOTICE: When 30 minutes have elapsed after engine
If the drive belt that operates for more than 5 minutes
stalls or stops running, inspect the deformation.
should be replaced, adjust it to the extent as an old one.
Apply 98N pressure to both belts (area indicated by the
Inspect the belt tension and deformation. If the result is
arrow).If the deformation exceeds the limit, adjust it to
not in compliance with the requirements, adjust
7～8 mm. repeatedly.
2.2.3 Drive belt tension inspection
NOTICE: For the tension inspection, it can be
substituted by the deformation check. The inspection
should be conducted after cooling.
- 6 -
Section 3 Valve Clearance

Inspection and Adjustment
3.1 Valve Clearance Inspection
3.1.1 Confirm that engine has cooled down.

3.1.2 Remove the air cleaner cap.
3.1.3 Remove the ignition coil.
3.1.4 Remove the cylinder head cover.
3.1.5 Turn the crankshaft pulley clockwise with the Valve clearance indicates as the follow chart:
camshaft timing mark facing right above. Intake Valve: 0.19±0.04 mm
Exhaust valve: 0.32±0.04 mm
Timing Mark
If the measured value is within the specification, go to
next step. If not, proceed to the 3.2 Valve Clearance
Adjustment.
3.1.8 Install the cylinder head cover.
Apply seal packing to the contact surface of the cylinder
head and timing cover as shown in the figure below:
3.1.6 Measure the valve clearance.

Check the 8 valves clearance indicated below with
a feeler gauge and make a record for further use.
Seal Packing
Install the cylinder head cover in the order shown in the

figure below (torque: 8 N*m).
3.1.7 Turn the crankshaft 360°. Check the other 4

valves clearance indicated below with a feeler
gauge and make a record for further use.
3.1.9 Install the ignition coil;

Tightening torque: 10 N*m
HINT: When measuring, insert the feeler gauge to

the valve clearance from the center (spark plug
3.1.10 Install the air cleaner cap.
side).
- 7 -
3.2 Valve Clearance Adjustment 3.2.4 Remove the inner hexagon tapered screw plug
on the timing cover.
This procedure is for all the valves that need to
adjust the clearance.
3.2.1 Check if the valve clearance needs to be
adjusted. Turn the crankshaft pulley and align the
mark.
Timing Mark
Timing Pointer 3.2.5 While holding the hexagon square on the intake
camshaft with a wrench, loosen the bolt on the intake
camshaft sprocket.
3.2.2 Check if the mark on the 2 camshaft

sprockets faces toward the colored link of the chain
right upwards. If not, turn the crankshaft one
revolution to align the mark.
Blue Mark Blue Mark
3.2.6 Remove the inner hexagon tapered screw plug.

Insert a screwdriver into plug hole and move the
tensioner keeper to the unlocked position without
loosening.
3.2.3 Turn the crankshaft clockwise approximately

90° to prevent the piston hitting the valve when
removing the camshaft.
Keeper
HINT: If the keeper can not move, turn the hexagon

square on the camshaft with a wrench slightly to loosen
it.
- 8 -
3.2.7 While turning the hexagon square on the

camshaft with a wrench, turn the camshaft
clockwise to press into the tensioner plunger by the
chain.
NOTICE: When removing the cam bearing cap, move

the intake camshaft toward the engine front for a short
distance for easy removal.
3.2.8 Take out of the screwdriver. Insert the special

tool through the small hole of the tensioner keeper
and hold it.
NOTICE: When removing the screwdriver and

inserting the special tool, do not release the wrench
on the camshaft to prevent tensioner plunger
popping out.
Special tool
3.2.11 Remove the camshaft.
These above steps are for pressing back the plunger

and making preparations for removing the chains.
If they are performed unsuccessfully, please repeat
from the step 6. NOTICE: Hold the chain with a rope or other tools to
3.2.9 Remove the bolt on the exhaust camshaft prevent it falling into the timing cover.
sprocket, and remove the sprocket.
3.2.10 Remove the bolt and cam bearing cap in the

order shown in the figure below.
- 9 -
3.2.12 Remove the lifter to be changed. A New Lifter Thickness

3.2.13 Measure the thickness of the lifter with a Lifter (to be changed) Lifter (to be changed)
micrometer. thickness thickness
C Measured valve clearance
For example:
Measured valve clearance=0.39 mm 0.39 mm-0.19
mm=0.20 mm
(Measured clearance - standard clearance = deviation)
Lifter (to be changed) thickness = 5.25 mm

0.20 mm + 5.25 mm = 5.45 mm (deviation + lifter (to be
changed respectively) thickness = installed lifter
thickness) Use the lifter closest to the 5.45mm. Choose a
larger size lifter (46) as it is an odd.
3.2.14 Calculate the thickness of a new lifter.
Ensure the valve clearance is in the specified range. NOTICE: Try to choose the lifter nearest to the
The calculation method is as follow: calculated data. The lifter thickness is divided into 31
Intake Valve Clearance A=B+ (C-0.19 mm) groups from 5.00 mm to 5.60 mm with a 0.02 mm
Exhaust Valve Clearance A=B+ (C-0.32 mm) difference between each two adjacent groups.
Group No. Thickness Group No. Thickness Group No. Thickness

00 5.00 20 5.20 40 5.40
02 5.02 22 5.22 42 5.42
04 5.04 24 5.24 44 5.44
06 5.06 26 5.26 46 5.46
08 5.08 28 5.28 48 5.48
10 5.00 30 5.30 50 5.50
12 5.12 32 5.32 52 5.52
14 5.14 34 5.34 54 5.54
16 5.16 36 5.36 56 5.56
18 5.18 38 5.38 58 5.58
60 5.60
- 10 -
3.2.15 Install the lifter.

3.2.16 Install the camshaft. 3.2.16.6 Install the camshaft sprocket.
3.2.16.1 Turn the crankshaft pulley 90° clockwise at Tighten the exhaust camshaft sprocket bolt using a
the timing position as in the removal. If the crankshaft tool (torque: 45 N•m).
has never rotated after the removal, this step can be
omitted.
3.2.16.2 Apply oil to the camshaft, cylinder head
camshaft journal and the top of the lifter.
3.2.16.3 In the reverse order of the removal, install the
intake camshaft first, with the mark on the sprocket
aligned with the left colored mark on the chain.
Blue Mark
3.2.16.7 Turn the intake camshaft clockwise with a

wrench and tension the chain LH. Install the chain on
the exhaust sprocket, and align the mark on the
sprocket with the colored mark on the chains.
Blue Mark
3.2.16.4 Install the camshaft according to the position
shown in the figure below.
Intake Camshaft Exhaust Camshaft
Cylinder 3 Cylinder 1
Cylinder 2
NOTICE: If the marks are not aligned, turn the

exhaust camshaft clockwise with a wrench.
3.2.16.5 Tighten the bolts in the order shown in the 3.2.16.8 Remove the special tool on the tensioner, and
figure below, and install the camshaft bearing cap. tighten the hexagon head tapered plug.
Be sure to make the arrow on the bearing cap face Tightening torque: 15 N•m.
forward. 3.2.16.9 Turn the crankshaft pulley counterclockwise
Tightening torque: Camshaft bearing capⅠ: 15 N•m to its original position (the mark on the pulley is
aligned with the timing pointer). Check if the mark on
Camshaft bearing capⅡ: 12 N•m
the camshaft sprocket faces right upwards and has
aligned with the blue mark on the chain.
For the above steps, make sure that the crankshaft
sprocket and chain always engage. For the removal
and installation of the camshaft, the method in the
section 4 can be used to remove the front cover.
3.2.17 Reconfirm the valve clearance.
- 11 -
Section 4 Timing Chain 4.1.4 Remove the crankshaft position sensor.

4.1 Timing Chain Removal
4.1.1 Remove the bolt A and B shown in the figure
below, and remove the generator and V-ribbed belt.
4.1.5 Remove the crankshaft pulley.
4.1.2 Remove the water pump inlet hose in the order

4.1.6 Remove the oil pan.

4.1.7 Remove the oil receiver.
4.1.8 Remove the bolt shown in the figure below, and
remove the timing cover body and the seal ring of the
main oil path.
Seal Ring
- 12 -
4.1.9 While moving the keeper clockwise, press the 4.1.12 Remove the crankshaft sprocket. Be sure to
plunger and release the tensioner plate. remove the woodruff key on the crankshaft.
4.1.10 While pressing the plunger, insert the special tool 4.2 Timing Chain Installation
into the small hole of the keeper and lock the plunger to Perform the installation in the reverse order of the
prevent it popping out. removal. Following precautions should be taken:
4.2.1 In the same manner of the removal, before
installing the chain, insert the special tool into the small
hole of the keeper and lock the plunger to prevent it
popping out.
4.2.2 Install the timing chain as shown in the illustration,
with the colored surface facing outside. Never install
the chain reversely. Face the timing mark on the
camshaft sprocket right upwards. Align the blue link
with the timing mark on the exhaust camshaft sprocket,
and the black link with the timing mark on the
crankshaft sprocket.
Blue Mark Blue Mark
4.1.11 Remove the tensioner plate bolt, and remove the

tensioner plate and the timing chain.
Timing Mark
Black Mark
4.2.3 Turn the intake camshaft slightly to tension the

chain RH. Confirm the both sides of the chain are in the
installation position of the guide plate and the tensioner
plate, and remove the special tool. Check if the
tensioner will pop out automatically, and press the
tensioner plate firmly.
- 13 -
If the resistance is less than 10 MÙ, go to the step 7.

NOTICE: If the ohmmeter is not available, conduct the
following inspection. Choose one of them.
5.2.2 Increase the engine speed to 4, 000 rpm rapidly,
and run the engine for 5 minutes:
5.2.3 Remove the spark plug.
5.2.4 Examine the spark plug electrode.
If the electrode is dry, the spark plug is normal. If the
electrode is wet, continue to next step.
5.2.5 Inspect if the spark plug thread and insulator are
damaged. Replace the spark plug if they are damaged.
Recommended spark plug model: K6RTM2
4.2.4 Tightening torque relative data is as follows: 5.2.6 Check the spark plug electrode gap.
Guide plate bolt: 10 N•m The allowable value of the spark plug electrode gap is
Tensioner plate bolt: 20 N•m 1.3 mm. If it is above 1.3 mm, replace the spark plug.
Tensioner bolt: 10 N•m New spark plug electrode gap should be 1.0～1.2 mm.
NOTICE: If the new spark plug electrode gap needs to
Section 5 Spark Plug and Compression adjust, always adjust the root of the side electrode rather
Pressure Inspection than the top. Never adjust the old spark plug.
WARING: Oil temperature is very high when the
engine is hot. Be careful not to be burnt when installing
and removing the components.
5.1 Spark Plug Removal and Installation

5.1.1 Remove the ignition coil bolt, and remove the
ignition coil.
5.2.7 Clean the spark plug.

If the spark plug is fouled, clean it with a plug cleaner.
5.1.2 Remove the spark plug with a special wrench.

5.1.3 Perform the installation in the reverse order of the
removal. Spark plug installation torque: 25 N•m,
ignition coil installation torque: 10 N•m.
5.2 Spark Plug Inspection

5.2.1 Using an ohmmeter, measure the resistance as
shown in the illustration. Check if the resistance is more
than 10 MΩ.
NOTICE: If the surface of the spark plug is attached
Ohmmeter with oil, remove the oil with gasoline. And then wash
the plug with a cleaner.
Ground
- 14 -
5.3 Compression Pressure Inspection Section 6 Engine

5.3.1 Confirm that the battery has fully charged. 6.1 Engine Disassembly
5.3.2 Warm up the engine to the normal operating 6.1.1 Remove the cylinder head cover
temperature. Remove the 13 bolts and 2 nuts in the order given in the
5.3.3 Stop and cool the engine for 10 minutes. illustration, and remove the cylinder head cover
5.3.4 Remove the fuel pump relay according to ―OIL together with the seal ring. Then remove the seal ring
PATH SAFETY INSPECTION PROCEDURE‖. from the head cover.
5.3.5 Disconnect the ignition coil connector.
5.3.6 Remove the spark plug.
5.3.7 Connect a compression gauge into the No.1
cylinder spark plug hole.
5.3.8 Depress the accelerator pedal to the end and start
the engine.
5.3.9 Start the engine and record the max. readings of
the compression gauge.
5.3.10 Inspect each cylinder pressure in the way
described above. If the pressure of one or more
cylinders is too low, or the differential pressure between
the cylinders exceeds the specified value largely, drop
some engine oil inside and recheck the pressure. 6.1.2 Remove the oil filter
5.3.11 If the compression pressure increases, the piston, Remove the 3 bolts on the oil filter seat, and remove the
piston ring and cylinder wall may be worn. It is oil filter and seal ring.
necessary to overhaul.
5.3.12 If the pressure of the adjacent cylinder is low,
maybe the cylinder gasket was damaged or the cylinder
head was deformed. It is necessary to overhaul.
5.3.13 If the compression pressure is still low, the
valves may be stuck or the seal surface has a poor
contact. It is necessary to overhaul.
Compression pressure MPa

Item
(≥400 r/min)
Standard 1.2～1.6
Min. limit 1.0
Differential pressure
max. limit between 0.15 6.1.3 Remove the V-ribbed belt
each cylinder 6.1.3.1 Loosen the bolt A firstly.
6.1.3.2 And then loosen the bolt B.
5.3.14 Remove the compression gauge. 6.1.3.3 Finally loosen the bolt C and generator, and
remove the timing belt.
5.3.15 Install the spark plug and tighten.
Loosen
- 15 -
Generator
Water Pump
6.1.8 Remove the oil receiver

Remove the 3 bolts on the oil receiver together with the
receiver seal ring.
Crankshaft Pulley
6.1.4 Remove the generator

Unscrew the bolt A and B shown in the above
illustration, and remove the generator.
6.1.5 Remove the water pump
Unscrew the 5 bolts on the water pump, and remove the
water pump.
6.1.9 Remove the crankshaft pulley

While holding the crankshaft pulley using a special tool,
remove the bolt on the pulley.
6.1.6 Align the timing mark Special tool

Turn the crankshaft pulley clockwise with the timing
mark aligned with timing pointer. Check if the camshaft
timing mark is facing right upwards. If not, turn the
crankshaft pulley one revolution.
6.1.10 Remove the timing cover body

Timing Mark Remove the bolt shown in the figure below, and pry off
the timing cover, then remove the seal ring of the main
oil path.
Be careful not to scratch the timing cover contact
surface.
6.1.7 Remove the oil pan

Remove the 15 bolts on the oil pan, and disengage the
contact surface of the oil pan and cylinder block using a
tool.
Be careful not to scratch the oil pan edge.
- 16 -
6.1.11.3 Remove the tensioner plate bolt, and remove

the tensioner plate and the timing chain.
6.1.12 Remove the crankshaft sprocket. Be sure to

remove the woodruff key on the crankshaft.
Seal Ring
6.1.11
Remove the tensioner plate and chain
6.1.11.1 While moving the keeper clockwise, press
the plunger and release the tensioner plate.
6.1.13 Install the pulley bolt temporarily, and turn the

crankshaft about 90° clockwise.
This prevents the interference between the piston and

valve due to the camshaft rotation in the following
steps.
6.1.11.2 While pressing the plunger, insert the

special tool into the small hole of the keeper and lock
the plunger to prevent it popping out.
90 degrees
- 17 -
6.1.14 Remove the camshaft sprocket 6.1.17 Remove the cylinder head
While holding the camshaft with a wrench, remove the 6.1.17.1 Loosen the bolt in several steps in the order
camshaft sprocket bolt and sprocket. shown in the figure below.
6.1.15 Remove the camshaft 6.1.17.2 Remove the cylinder head and cylinder gasket.
Remove the camshaft bearing cap bolt in the order
shown in the figure below, and remove the camshaft.
6.1.18 Remove the valve

6.1.18.1 Remove the valve spring, valve spring upper
seat and valve clip with special tool.
Special tool
6.1.16 Remove the lifter

NOTICE: Before removing the lifter, record the mark
on each lifer. 6.1.18.2 Remove the valves in order.
- 18 -
6.1.18.3 Extract the valve oil seal with needle-nose

pliers.
6.1.18.4 Remove the valve spring under seat.
6.1.19 Clean foreign matters on the cylinder head

surface
Scrap off the foreign matters such as seal packing on the
cylinder head surface with a blade.
6.1.21 Remove the 8 bolts on the labyrinth cover plate,

and remove the labyrinth cover plate.
NOTICE:
1) Always wear the eye protector during working.
2) Be careful not to scratch the cylinder head surface.
3) Do not fall any foreign matters into the cylinder head
water jacket.
6.1.20 Check the flatness of the below 3 surfaces with a 6.1.22 Remove the crankshaft rear end cover.
straightedge and feeler gauge. 6.1.22.1 Remove the 5 bolts on the crankshaft rear end
The Max. allowable gap is 0.05 mm. If the gap is more cover, and remove the crankshaft rear end cover.
than 0.05 mm, replace the cylinder head as necessary. 6.1.22.2 Remove the oil seal on the crankshaft rear end
cover with a screwdriver.
- 19 -
6.1.24.3 Remove the piston connecting rod on 2 other

cylinders in order.
6.1.25 Inspect the crankshaft axial clearance
Pry the crankshaft in one way with a screwdriver, and
measure the crankshaft axial clearance by inserting the
feeler gauge into the clearance.
Standard clearance: 0.02～0.16 mm
Max. allowable clearance: 0.30 mm
If the clearance is more than the above value, replace
the thrust plate. If above operation does not work,
replace the crankshaft.
6.1.23 Connecting rod big end journal axial clearance 6.1.26 Remove the piston ring
Check the axial clearance of the connecting rod big end Remove two compression rings and one oil ring with a
journal with a feeler gauge. piston ring expander.
Standard clearance: 0.1～0.27 mm, 6.1.27 Remove the piston pin

Max. allowable clearance: 0.35 mm. Remove the piston pin with special tool, and place the
6.1.24 Remove the connecting rod. piston, piston ring, piston pin, connecting rod and
6.1.24.1 Remove the 2 bolts on the connecting rod cap, connecting rod bearing in order.
and remove the cap and bearing.
Special tool
Special tool
6.1.24.2 Push the piston, connecting rod and connecting

rod upper bearing to pass through the cylinder block.
Remove the rod from the block.
- 20 -
6.2 Engine Inspection
6.2.1 Scrap off the packing on the oil pan seal surface
with a blade.
6.2.7 Inspect the camshaft

6.2.7.1 Measure the runout of camshaft 3rd journal.
Measure the camshaft 3rd journal using 2 V-blocks and
a dial indicator.
The max. allowable runout is 0.03 mm. If it is above
0.03 mm, replace the camshaft.
6.2.2 Inspect the timing chain.

Visually check for serious wear or flaw on the timing
chain. If it is found, replace the chain and check the
responding sprocket.
6.2.3 Inspect the camshaft sprocket.

Check for the wear or damage on the camshaft sprocket.
If it is found, replace the camshaft sprocket.
6.2.4 Inspect the crankshaft sprocket.

Check for the wear or damage on the crankshaft
sprocket. If it is found, replace the crankshaft sprocket.
6.2.5 Inspect the chain guide plate and tensioner plate. NOTICE: The actual runout is a half of the dial
Check the wear level of the chain guide plate and readings.
tensioner plate. If the wear is greater than 0.5 mm,
replacement must be conducted. 6.2.7.2 Measure the size of the camshaft nose.
Measure the nose height with a micrometer. If the nose
height does not reach the allowable value, replace the
camshaft.
Intake camshaft Exhaust camshaft

(mm) (mm)
Standard
41.385-41.615 40.895-41.125
height
Allowabl
41.44 40.87
e height
6.2.6 Inspect the tensioner.

Press the plunger of the tensioner. If it cannot be
pressed down, tensioner operates normally.
Rotate the tensioner keeper clockwise, and press and
hold the keeper with one hand, then press the plunger of
the tensioner with another hand. If the plunger can be
pressed down and pops up automatically, tensioner
operates normally.
If the tensioner operates abnormally, replace it.
- 21 -
6.2.7.3 Measure the camshaft axial clearance.

Install the camshaft and move it back and forth.
Measure its axial clearance with a dial indicator.
Intake camshaft standard axial clearance: 0.1～0.171
mm. Exhaust camshaft standard axial clearance: 0.1～
0.175 mm.
Max. allowable clearance: 0.24 mm.
Measure the free height of the valve spring with a

vernier caliper. Standard height is 51.6 mm.
If the measured clearance exceeds the maximum value,

inspect the camshaft and camshaft bearing cap. If the
bearing cap is worn, replace the cylinder head. If
camshaft thrust surface is worn, replace the camshaft.
6.2.8 Clean the valve.

Clean the carbon deposits on the valve using a brush.
6.2.10 Inspect the valve.

6.2.10.1 Measure the overall height of the valve with a
vernier caliper. If the measured height is less than the
value in the below table, replace the valve.
Height
Intake valve 88.39 mm
Exhaust valve 89.11 mm
NOTICE: Always wear the eye protector during

working.
6.2.9 Inspect the valve spring. Overall Height

Check the verticality of the valve spring by measuring
the clearance as given in the illustration with a
straightedge. The max. clearance is 1.5mm. If the
measured value is higher than 1.5mm, replace the valve
spring.
- 22 -
6.2.10.1 Measure the diameter of the valve tip with a 6.2.11 Inspect the valve and valve race.
micrometer. If the measured diameter is less than 3.9～ 6.2.11.1 Apply some paints (Prussian blue or others) to
4.5 mm, replace the valve. the valve seal surface.
Seal Surface
6.2.10.3 Measure the thickness of the valve rim with a 6.2.11.2 Press the valve on the valve race with the
vernier caliper. If the measured thickness is less than the cylinder head installed. Be careful not to rotate.
specified value below, replace the valve. 6.2.11.3 Check if the paint appears 360° around the
valve seal surface evenly. If not, replace the valve.
Standard Min. allowable 6.2.11.4 Apply some paints to the new valve, and
thickness thickness perform the above operation. Check if the paint appears
Intake valve 1.05～1.45 mm 360° around the valve race evenly. If not, repair the
0.7 mm
Exhaust valve 1.10～1.50 mm race.
6.2.12 Repair the valve race.
6.2.12.1 Refinish the valve race with a 45° scraper,
ensuring the width of the race seal surface within
specification.
Intake valve 1.20～1.70 mm

Exhaust valve 1.11～1.61 mm
NOTICE: Before finishing, please confirm the center

position of the valve race.
Decrease the apply force gradually to avoid the
deterioration on the quality of the valve race seal
surface.
6.2.10.4 Measure the diameter of the valve head with a

vernier caliper. If the measured diameter is not specified
with the value in the below table, replace the valve.
Diameter
Intake valve 27.35～27.65 mm
Exhaust valve 23.45～23.75 mm
6.2.12.2 Check for the location of the valve race seal

surface. Make sure that the valve seal surface is in the
center of the race seal surface.
6.2.12.3 Finish the 45° seal surface width and position
with a 70° and 20° scraper, ensuring the valve sealed
with the surface completely. Make sure the seal surface
width is proper.
- 23 -
6.2.15 Inspect the flatness of the cylinder block surface.

Inspect the flatness of cylinder block upper surface with
a straightedge and feeler gauge as shown in the figure
below. The size of the feeler gauge that can be inserted
is 0.05 mm. If it is more than 0.05 mm, replace the
cylinder block.
6.2.12.4 Add the abrasive compound, and grind the

valve and valve seat by hand.
6.2.16 Inspect the valve inner diameter.

6.2.16.1 Measure the cylinder diameter at depth A and B
in the axial and radial direction for 4 positions with an
air gauge.
Standard size: 71.000～71.013 mm, Max. allowable
size: 71.013 mm.
Calculate the average diameter of the 4 measurements.
If the average is greater than the above value, replace
6.2.13 Check the cylinder head bolt. the cylinder block.
Measure the length of the cylinder head bolt with a
vernier caliper.
Max. length is 123.5 mm. If the measured length is
more than 123.5 mm, replace the cylinder head bolt.
6.2.14 Clean the cylinder block.

Clean the contact surface of the cylinder and timing
cover, cylinder head, oil pan and labyrinth cover plate
using an oil stone or similar tool.
6.2.16.2 Measure the cylinder diameter at the positions

shown in the figure below. Calculate the cylinder
NOTICE: Always wear the eye protector during ellipticity and conicity.
working. The Max. allowable ellipticity and conicity are 0.02
Do not scratch the cylinder block surface. mm.
Do not fall any foreign matters into the cylinder block Calculation method: ellipticity = A - B or a – b
water jacket. conicity = A – a or B – b
- 24 -
6.2.19.2 If the calculated clearance is greater than the

above value, replace the piston.
Piston option: Examine the numbers (including 3
figures) indicating the cylinder tube diameter on the
cylinder block under surface.
1: indicates corresponding cylinder tube diameter is
710.01
0.02
mm,
Choose the piston with a red mark on its top, and the
skirt size is
710.01
0.02 mm.
2: indicates corresponding cylinder tube diameter is

7100.01 mm,
6.2.17 Clean the piston. Choose the piston with a blue mark on its top, and the
Clean the carbon deposits on the piston using an old
skirt size is
710.02
0.03 mm.
piston ring or similar tool.
For example: If the identification beneath the cylinder
block is ―123‖, choose the red, blue and red piston for
cylinder 1, 2 and 3 respectively.
6.2.19.3 If the calculated clearance is still greater than
the above value after replacing the piston, it is necessary
to replace the cylinder block.
NOTICE: A minor step is formed on the upper cylinder

due to the reciprocation motion of the piston ring.
Therefore the cylinder diameter measurement must be
performed in where the wear is most serious (beneath
the minor step).
6.2.20 Inspect the piston ring groove clearance.

NOTICE: Always wear the eye protector during Insert a new piston ring into the ring groove, and
working. inspect the clearance of the piston ring groove with a
Do not scratch the piston surface. feeler gauge.
6.2.18 Inspect the piston.
Measure the piston outer diameter at the position
perpendicular to the piston pin, 10mm from the piston
bottom as shown in the illustration.
Standard size: 70.99～70.97 mm, Min. allowable size:
70.96 mm. If the result is less than the above value,
replace the piston.
Standard clearance
1st Compression ring 0.03～0.07 mm
2nd Compression ring 0.02～0.06 mm
Oil ring 0.020～0.175 mm
6.2.19 Inspect the clearance between the piston and
cylinder. If the measured clearance is greater than the above
6.2.19.1 Cylinder lateral diameter subtracts the piston value, replace the piston.
diameter.
Standard clearance: 0.080～0.103 mm 6.2.21 Measure the piston ring cutout clearance.
Max. clearance: 0.103 mm 6.2.21.1 Push a piston ring into the cylinder by 45 mm
using a piston, and then remove the piston.
- 25 -
NOTICE: The actual runout is a half of the dial

readings.
6.2.22.2 Measure the diameter of each main journal
with a micrometer at the position shown in the figure
below.
6.2.22.2.1 Standard size is 43.982～44.000 mm. If the
measured size is less than the above value, replace the
crankshaft.
6.2.22.2.2 Inspect the main journal ellipticity and
conicity. Max. allowable ellipticity and conicity are 0.03
mm.
Ellipticity and conicity calculation:
6.2.21.2 Measure the piston ring cutout clearance with a Ellipticity: A - B or a – b
feeler gauge. Conicity: A - a or B – b
If the calculated value is greater than the maximum,
replace the crankshaft.
6.2.22.3 Measure the diameter of each connecting rod
journal with a micrometer at the position shown in the
figure below.
6.2.22.3.1 Standard size is 39.982～40.000 mm. If the
measured size is less than the above value, replace the
crankshaft.
6.2.22.3.2 Inspect the connecting rod ellipticity and
conicity.
The Max. allowable ellipticity and conicity are 0.03
mm.
Ellipticity and conicity calculation:
Max. Ellipticity = A-B or a–b
Standard cutout
allowable Conicity: A - a or B – b
clearance
clearance If the calculated value is greater than the maximum,
1st replace the crankshaft.
Compression 0.20～0.35 mm 0.79 mm
ring 6.2.23 Check the crankshaft thrust plate.
2nd Compression Measure the thrust plate thickness with a micrometer.
0.35～0.50 mm 0.75 mm
ring
Oil ring 0.20～0.70 mm 0.69 mm
If the measured clearance is greater than the maximum,

replace the piston ring.
If the measured clearance is still greater than the
maximum after replacing a new piston ring, replace the
cylinder block.
6.2.22 Inspect the crankshaft.
6.2.22.1 Measure the main journal runout.
Measure the crankshaft main journal using 2 V-blocks
and the dial indicator.
The max. allowable runout is 0.03 mm. If it is above
0.03 mm, replace the crankshaft.
Standard thickness: 1.87～1.90 mm
If the measured result is not specified with the above
value, replace the thrust plate.
- 26 -
6.2.24 Inspect the connecting rod. If the measured result is less than 6.4 mm, replace the
6.2.24.1 Measure the inner diameter of the connecting connecting rod bolt.
rod big end with an air gauge as shown in the
illustration. 6.3 Engine Installation
6.3.1 Install the connecting rod piston.
6.3.1.1 Heat the connecting rod to 80～90°C slowly.
6.3.1.2 Apply oil to the connecting rod small end, piston
pin hole and piston pin.
6.3.1.3 Assemble the connecting rod, connecting rod
cap and piston, with the matchmark in one direction.
Standard Inner Diameter: 43.000～43.024 mm. If the

measured result exceeds it, replace the connecting rod.
6.2.24.2 Measure the connecting rod bearing thickness
with a micrometer. The standard thickness is 1.486～
1.502 mm. If the measured result is not specified with
the above value, replace the connecting rod bearing. Match mark
6.3.1.4 Press the piston pin into the connecting rod with
special tool.
Calculation formula for the connecting rod bearing: X

＝7－A－B
X Connecting rod bearing group no.
A Connecting rod journal group no.

Special tool
B Connecting rod big end hole group no.
X is made up of 5 groups (1－5). A (three digits) locates

on the balance weight of the crankshaft and B locates on
the side raphe of the connecting rod body. Piston Pin
6.2.25 Inspect the connecting rod bolt.
Measure the diameter of the connecting rod bolt bar
with a vernier caliper. Connecting Rod
Special tool
Piston
6.3.1.5 Check if the connecting rod can swing freely.
Min. Diameter: 6.4 mm

- 27 -
6.3.2 Install the piston ring.

6.3.2.1 Install the oil ring firstly.
6.3.2.2 Install the 2nd and 1st compression ring secondly.
1st Compression Ring
2nd Compression Ring
Mark NOITCE: Do not fall the foreign matters such as oil

into the backside of the bush.
Compression Ring Section
6.3.4 Install the crankshaft.
6.3.4.1 Install 2 thrust plates into the 3rd main bearing
NOTICE: Distinguish the 1st and 2nd compression seat, with the oil groove on the thrust plates facing
ring section. Make sure that the mark on the outside.
compression ring faces upward.
6.3.2.3 Adjust the position of the piston ring cutout as
Liner Ring Opening
Under Scrapper Opening 2nd Compression Ring Opening
Oil Groove
Match mark
6.3.4.2 Apply lubrication oil to the inner surface of the
main bearing upper bush, and then install the
1st Compression Ring Opening Upper Scrapper Opening
crankshaft.
Apply lubrication oil to the main bearing under bush,
Each Ring Opening Direction Schematic with the arrow on the bearing cap facing engine front,
Drawing when Installing the Piston
and install the bearing cap according to the figures in
the illustration.
6.3.3 Install the crankshaft main bearing bush. Apply a little of lubrication oil to the bolt, and tighten
6.3.3.1 Install the main bearing under bush onto the the main bearing cap bolt in 2 to 3 times in the order
main bearing cap. Align the set lip on the bush with the given in the below illustration. Torque: 59 N•m
locking notch on the bearing cap. Check if the crankshaft can rotate freely.
Optional main bearing bush: 6.3.5 Install the connecting rod bearing.
Calculation formula for the main bearing bush: X＝7－ Install the connecting rod bearing onto the connecting
A－B rod and rod cap respectively, and align with the set
notch of the bearing.
X Main bearing bush group no.
A Main journal group no.
B Main bearing hole group no.
X is made up of 5 groups (1－5). A (four digits) locates

on the balance weight of the crankshaft and B (four
digits) locates bottom of the cylinder block.
6.3.3.2 Install the main bearing upper bush onto the
main bearing seat. Align the oil hole on the bush with
that on the main bearing seat.
- 28 -
NOITCE: Do not fall any foreign matters such as 6.3.6.4 Apply a little of lubrication oil to the connecting
lubrication oil into the backside of the bearing. rod bolt and connecting rod cap bolt hole, and then
6.3.6 Install the connecting rod. tighten the connecting rod bolt in 2 to 3 steps
6.3.6.1 Apply lubrication oil to the friction surfaces alternatively. Torque: 15N•m.
given in the illustration.
6.3.6.2 Press the piston into the cylinder block with a 6.3.6.5 Mark the connecting rod bolt with a making pen
piston ring compressor, with the mark on the piston in the direction of the engine front.
facing the engine front. 6.3.6.6 Retighten the connecting rod bolt, and turn the
bolt 90° clockwise.
Matchmark
Piston Ring
Compressor
Engine Front
Mark
6.3.6.3 Apply lubrication oil to the connecting rod cap 6.3.6.7 Check if the crankshaft can rotate freely.
bearing. Install the connecting rod with the matchmark 6.3.7 Install the crankshaft rear oil seal.
facing forward. 6.3.7.1 Take out a new oil seal, and apply lubrication oil
to it.
6.3.7.2 Press the oil seal into the rear end cover with
special tool. The distance between the oil seal and rear
Matchmark end cover should not be above 0.5 mm. The oil seal
upper surface thickness away from the rear end cover
should not be above 1 mm.
Special tool
NOTICE: Do not change the connecting rod and

connecting rod cap. Do not install the matchmark in
wrong direction to avoid the incorrect installation of the
connecting rod cap pin.
- 29 -
6.3.7.3 Apply seal packing with a diameter of 3～4 mm 6.3.9 Install the valve.
to the position shown in the figure below. 6.3.9.1 Place 12 valve spring under seats.
NOTICE: Install the rear end cover within 3 minutes 6.3.9.2 Replace the valve oil seal with a new one, and
after the application. apply lubrication oil to it.
Install the 5 bolts on the rear end cover (torque: 10 6.3.9.3 Press the valve oil seal onto the valve guide with
N•m). special tool.
6.3.8 Install the labyrinth cover plate.

6.3.8.1 Clean the seal surface of the labyrinth cover
Special tool
plate and cylinder block separately.
6.3.8.2 Apply seal packing with a width of 3～4 mm to
the position shown in the bellow illustration.
6.3.9.4 Check if the oil seal is installed in its position,

and measure the height shown in the figure below.
6.3.8.3 Tighten the 8 bolts in the order given in the

below illustration and install the labyrinth cover plate
(torque: 25 N•m).
Intake Exhaust
6.3.9.5 Apply lubrication oil to the valve stem 30 mm

away from the valve tip.
- 30 -
6.3.9.6 Install the valve, valve spring and valve spring 6.3.10 Install the cylinder head.
upper seat. 6.3.10.1 Place a new head gasket onto the cylinder
block upper surface and place the cylinder head onto the
cylinder block slowly. Please place them as softly as
possible. Do not damage the cylinder gasket.
6.3.9.7 Compress the valve spring with special tool, and

install the valve clip onto the valve tip.
6.3.10.2 Apply lubrication oil to the cylinder head bolt.
6.3.10.3 Tighten the cylinder head bolt in the order
shown in the figure below (torque: 32 N•m).
6.3.9.8 Tap the valve end lightly with a pin punch for a
better fitting.
6.3.10.4 Mark the cylinder head bolt with a making pen

in the direction of the engine front.
6.3.10.5 Retighten the cylinder head bolt, and turn the
bolt 180° clockwise.
Engine Front
Mark
6.3.9.9 Apply lubrication oil to the position shown in

the illustration.
6.3.11 Install the lifter.

Lubrication Oil 6.3.11.1 Apply lubrication oil to the lifter
circumference.
6.3.11.2 Place the lifter into the cylinder head.
6.3.11.3 Check if the lifter can rotate freely in the
cylinder head.
- 31 -
6.3.12 Install the camshaft.
6.3.12.1 Turn the 1st cylinder to the TDC and rotate the
crankshaft 90° clockwise to avoid the interference of
the piston and valve due to the following operation.
NOTICE: Be sure to make the arrow on the bearing

cap face forward.
The installation of the bearing cover must follow the
position in the illustration.
6.3.12.5 Install the camshaft sprocket.
6.3.12.2 Apply lubrication oil to the position shown in

the illustration.
Lubrication Oil 6.3.12.6 Hold the camshaft with a wrench, and then
tighten the camshaft sprocket bolt with a torque wrench
(torque: 45 N•m).
6.3.12.3 Install the camshaft as shown in the illustration,

keeping the cam nose not push the valve open.
Intake Camshaft Exhaust Camshaft
Cylinder 3
Cylinder 1
Cylinder 2
6.3.12.7 Inspect the valve clearance. Refer to the
SECTION Ⅲ of the CHAPTER Ⅰ.
6.3.13 Install the chain.
6.3.13.1 Place the woodruff key into the key groove on
the crankshaft.
6.3.12.4 Tighten the bolts in the order shown in the

figure below, and Install the camshaft bearing cap.
Tightening torque:
Camshaft bearing capⅠ: 15 N•m
Camshaft bearing cap Ⅱ: 12 N•m
- 32 -
6.3.13.2 Align the groove on the crankshaft sprocket

with the woodruff key, and install the crankshaft.
NOTICE: Keep the tensioner removed (special tool

still inserted in the keeper). If the tool has been removed,
6.3.13.3 Install the chain guide plate. insert it before installing.
Guide plate bolt tightening torque: 10 N•m
6.3.13.4 Install the timing chain as shown in the
illustration, with the colored surface facing outside.
Never install the chain reversely. Align the blue link
with the timing mark on the exhaust camshaft sprocket,
and the black link with the timing mark on the
crankshaft sprocket.
Blue Mark Blue Mark
6.3.13.8 Remove the tool on the tensioner, and turn the

crankshaft 2 revolutions. Check if the tensioner works
well.
NOTICE: Keep the mark on the camshaft sprocket
faces over right after turning 2 revolutions.
Timing Mark
6.3.14 Install the timing cover.

6.3.14.1 Apply lubrication oil to the crankshaft front oil
seal.
6.3.14.2 Tap the oil seal lightly. Make sure its upper
Black Mark surface is not 0.5 mm higher than the timing cover, and
1 mm lower than the cover.
Timing Mark
6.3.13.5 Install the chain tensioner plate.

Tightening torque: 20 N•m
6.3.13.6 Turn the intake camshaft counterclockwise
slowly to loose one side of the tensioner plate. (7) And
then install the tensioner. Tightening torque: 10 N•m
- 33 -
6.3.14.3 Apply seal packing to the contact surface of the cylinder block head on the engine front, with a width of
4.5-5.5 mm.
6.3.14.4 Apply sealant to the seal surface of the timing 6.3.15 Install the water pump.
cover, with the width and position as shown in the 6.3.15.1 Tighten the bolt shown in the illustration, pay
illustration. attention to the installation direction of the gaskets. No
not install reversely.
6.3.15.2 Install the water inlet hose, and then install the
resilient ring clamp.
Then tighten the lower bolt.
6.3.15.3 Tighten the bolt in the order shown in the
figure below when installing the water pump.
6.3.15.4 Hold the disc in place, and then tighten the bolt
when installing the connecting disc.
6.3.15.5 Check for the water leak after installing.
6.3.16 Install the crankshaft pulley.

Hold the pulley with a tool, and tighten the pulley bolt
(torque: 150 N•m).
6.3.14.5 Install the timing cover bolts in the order

Install the bolts in the order shown in the figure, and
tighten them with the following torque:
Tightening torque: 25 N•m for bolt 9, 10 and 11; 40 6.3.17 Install the oil receiver.
N•m for other bolts: 6.3.17.1 Install a new oil receiver washer.
6.3.14.6 Clean the remaining sealants. 6.3.17.2 Install the oil receiver and tighten the bolt
(torque: 10 N•m).
- 34 -
6.3.18 Install the oil pan. 6.3.19 Install the oil filter.
6.3.18.1 Apply continuous seal packing to the inside of 6.3.19.1 Install the oil filter seat washer onto the timing
the oil pan bolt hole circumference, with the tip cover, and then install the oil filter union.
overlapped. Apply seal packing according to the width 6.3.19.2 Tighten the 3 bolts on the oil filter seat (torque:
shown in the figure below. Dashed line: 5 mm, Solid 25 N•m).
line: 3-4 mm.
6.3.20 Install the V-ribbed belt.

6.3.18.2 Install the bolt in the order shown in the figure 6.3.20.1 Install the V-ribbed belt firstly.
below. 6.3.18.3 Tighten other bolts at random. 6.3.20.2 And then install the generator.
Tighten the oil pan screw to the below torque. Install the belt and tighten the bolt B slightly at first,
Torque: 25 N•m for bolt A 10 N•m for bolt B and then turn the bolt C, adjust the belt tension, tighten
the bolt B (torque: 35 N•m). Finally tighten the bolt A
(torque: 50 N•m).
Generator
Water Pump
Tighten Slightly
Crankshaft Pulley
6.3.21 Install the cylinder head cover. 6.3.21.3 Install the cylinder head cover in the order
6.3.21.1 Install the cylinder head cover gasket into its shown in the figure below (torque: 8 N*m).
groove.
6.3.21.2 Apply seal packing to the contact surface of
the cylinder head and timing cover as shown in the
figure below.
Seal Packing
- 35 -
Chapter 2 Lubrication System

Section 1 Engine Lubrication Circuit Schematic Drawing ..................................................................................... 37
Section 2 Oil Pressure Inspection ............................................................................................................................ 38
2.1 Remove the Oil Pressure Siren. ................................................................................................................... 38
2.2 Install the special tool to the Oil Pressure Siren Installation Hole. ............................................................. 38
2.3 Warm up the Engine to the Normal Operating Temperature. ..................................................................... 38
2.4 Increase the Engine Speed to the Specified Value, and Pay Attention to the Readings on the Oil Pressure
Gauge. ...................................................................................................................................................................... 38
2.5 Stop and Cool the Engine. ........................................................................................................................... 38
2.6 Remove the special tool. .............................................................................................................................. 38
2.7 Apply Seal Packing to the Oil Pressure Siren Thread. ................................................................................ 38
2.8 Install the Oil Pressure Siren. ...................................................................................................................... 38
2.9 Start the Engine and Check for the Oil Leak. .............................................................................................. 38
Section 3 Engine Oil ................................................................................................................................................ 38
3.1 Oil Inspection ............................................................................................................................................... 38
3.2 Oil change .................................................................................................................................................... 38
Section 4 Oil Filter................................................................................................................................................... 39
4.1 Oil Filter Replacement ................................................................................................................................. 39
Section 5 Oil Pan ..................................................................................................................................................... 39
5.1 Oil Pan Installation and Removal ................................................................................................................ 39
5.2 Oil Pan Removal Description ...................................................................................................................... 39
5.3 Oil Pan Installation Description ................................................................................................................... 39
Section 6 Oil Pump .................................................................................................................................................. 40
6.1 Oil Pump Removal ....................................................................................................................................... 40
6.2 Oil Pump Installation Description ............................................................................................................... 41
6.3 Oil Pump Inspection..................................................................................................................................... 42
- 36 -
Section 1 Engine Lubrication Circuit Schematic Drawing
Cylinder Block Main Oil Path
Main Bearing
Cylinder Head Main
Oil Path
Connecting Rod
Oil Filter
Bearing
Camshaft hole
Piston Pin
Oil Pump Camshaft Bearing
Piston Pin Seat

Pressure Relief Valve
Oil Receiver
Oil Pan
- 37 -
Section 2 Oil Pressure Inspection 2.5 Stop and Cool the Engine.
2.6 Remove the special tool.
CAUTION: 2.7 Apply Seal Packing to the Oil Pressure
The hot oil temperature is very high. It is easy to be Siren Thread.
scalded. Start the work after stopping and cooling
the engine.
2.1 Remove the Oil Pressure Siren.
2.8 Install the Oil Pressure Siren.

Tightening torque: 15～20 N•m
Do not start the engine within 1 hour after installing the
2.2 Install the special tool to the Oil oil pressure siren.
Pressure Siren Installation Hole.
2.9 Start the Engine and Check for the Oil
Leak.
Section 3 Engine Oil

3.1 Oil Inspection
3.1.1 Park the vehicle on a level surface.
3.1.2 Warm up the engine to the normal operating
temperature, and then stop.
3.1.3 Wait for 5 minutes.
3.1.4 Pull out the oil dipstick and examine the oil level
and oil condition. Check if the oil level is between A and
B.
2.3 Warm up the Engine to the Normal

Operating Temperature.
2.4 Increase the Engine Speed to the

Specified Value, and Pay Attention to the
Readings on the Oil Pressure Gauge.
﹡If the pressure is not as specified, find out the

cause and repair or replace as required.
NOTICE:
﹡Oil pressure varies according to the viscosity and 3.1.5 Fill or change the engine oil as required.
temperature. 3.1.6 Insert the oil dipstick again.
Oil Pressure: 300～500 kPa [3, 000 r/min]
3.2 Oil change
Engine speed Oil pressure CAUTION:
750 rpm 30 kPa or more The oil temperature of the hot engine is very high. Be
3, 000 rpm 200 kPa or more careful not to be scalded.
¡¤ Wash your skin with a soap and clear water as the old
oil will cause cancer.
3.2.1 Park the vehicle on a level surface.
3.2.2 Remove the oil filler cap and oil pan drain plug.
- 38 -
3.2.3 Drain the oil into a proper container. 4.1.5 Start the engine and check for the oil leak.
3.2.4 Install the oil drain plug with a new washer. 4.1.6 Add the lubrication oil and check the level.
Tightening Torque: 30 N•m
3.2.5 Add the engine oil with specified type and Section 5 Oil Pan
volume into the engine again.
Reinstall the oil filler cap.
5.1 Oil Pan Installation and Removal
3.2.6 Start the engine and check for the oil leak.
5.1.1 Disconnect the battery negative terminal.
3.2.7 Check the engine oil level and add oil as
5.1.2 Drain the oil.
required.
5.1.3 Remove the bolt of the oil pan.
NOTICE:
5.1.4 Install the oil pan in the reverse order of the
﹡In some cases, the oil mass filled according to removal.
the oil level differs from the specified actual mass. 5.1.5 Start the engine and check for the oil leak.
Item Capacity (L) 5.2 Oil Pan Removal Description
Oil change 3.0 5.2.1 Remove the oil pan bolt.
Oil and oil filter change 3.5 5.2.2 Remove the seal packing on the thread and seal
surface.
Engine oil grade SG or higher 5.2.3 Tap the oil pan lightly to loose with a rubber
hammer. Remove the oil pan with a remover as necessary
Oil viscosity choice (see the below fig.).
Oil grade
standard
Above -25℃ SG 10W-30
-30¡æ～37¡æ SG 5W-30 Remover
Section 4 Oil Filter

4.1 Oil Filter Replacement
4.1.1 Remove the oil drain plug and drain the oil.
4.1.2 Remove the oil filter with special tool.
5.3 Oil Pan Installation Description

5.3.1 Apply continuous seal packing to the inside of the
oil pan bolt hole circumference, with the tip overlapped.
Apply seal packing according to the width shown in the
figure below. Dashed line: 5 mm, Solid line: 3-4 mm.
4.1.3 Wipe off the oil filter surface with a piece of

clean cloth.
4.1.4 Install the oil filter firmly according to the
instruction procedure on the filter or packing case.
3/4 turns
- 39 -
5.3.2 Tighten the oil pan screw to the below torque.

Torque:
24 N•m for bolt A
10 N•m for bolt B
Section 6 Oil Pump

6.1 Oil Pump Removal
6.1.1 Remove the bolt A and B shown in the figure
below, and remove the generator and V-ribbed belt.
6.1.4 Remove the crankshaft position sensor.
6.1.2 Remove the water pump inlet hose in the

order shown in the figure below.
6.1.5 Remove the crankshaft pulley.
- 40 -
6.1.6 Remove the oil filter. 6.1.10 Perform the removal in the order indicated in the
below illustration.
Outer Rotor
Inner Rotor
Seal Ring
6.1.7 Remove the oil pan. Timing Cover body

6.1.8 Remove the oil receiver. Oil Pump Cover
6.1.9 Remove the bolt shown in the figure below,
and remove the timing cover body and the seal ring Pressure Limiting Valve
of the main oil path. Pressure Limiting Valve Spring
Spring Seat
Retainer Ring 13
6.1.11 Take out of the oil seal, and pry up the oil seal
with a screwdriver with a wood under it.
Wood
Seal Ring
6.2 Oil Pump Installation Description

6.2.1 Install the oil pump in the reverse order of the removal.
6.2.2 When installing the oil pump inner and outer rotors, pay attention to face the triangle mark side outward.
6.2.3 Apply seal packing to the contact surface of the cylinder block head on the engine front, with a width of 4.5～
5.5 mm.
- 41 -
6.2.4 Apply sealant to the seal surface of the timing 6.3 Oil Pump Inspection
cover, with the width and position as shown in the 6.3.1 Measure the below clearance. Replace the rotor as
illustration. necessary.
Standard mating clearance: 0.06 mm-0.18 mm
Maximum mating clearance: 0.21 mm
6.3.2 Standard body clearance: 0.24～0.336 mm

Maximum body clearance: 0.36 mm
6.2.5 Install the timing cover according to the

below illustration.
6.3.3 Pressure limiting valve spring inspection

Apply pressure to the spring and inspect its height.
Replace the limiting valve spring if necessary.
Pressure: 63.6 N±6.36 N
Standard height: 38 mm
Install the bolts in the order shown in the figure

below, and tighten them with the following torque:
Bolt 9, 10 and 11 Torque: 24 N•m
Other bolts: 40 N•m.
6.2.6 Oil Filter Seat Bolt Torque: 24 N•m,

Crankshaft pulley bolt torque: 170 N•m,
Crankshaft position sensor tightening torque: 7.5
N•m.
- 42 -
Chapter 3 Cooling System

Section 1 Engine Cooling System Schematic Drawing .......................................................................................... 44
Section 2 Coolant Replacement and Filling ............................................................................................................ 45
2.1 Drain the Coolant ..................................................................................................................................... 45
2.2 Fill the Coolant ......................................................................................................................................... 46
2.3 Coolant Filling Description ...................................................................................................................... 46
Section 3 Thermostat ............................................................................................................................................... 46
3.1 Thermostat Removal and Installation ...................................................................................................... 46
3.2 Thermostat inspection .............................................................................................................................. 46
Section 4 Water Pump ............................................................................................................................................. 46
4.1 Water Pump Removal and Installation .................................................................................................... 46
4.2 Water Pump Installation Description ....................................................................................................... 47
- 43 -
Section 1 Engine Cooling System Schematic Drawing

The schematic drawing of the engine cooling system in the entire vehicle pipe line system is as follow :
The coolant pumped by the water pump flows into the cylinder block from the front side and then flows into the
cylinder head. And it flow out from the cylinder head rear end. Thermostat (opening temperature is 82℃) is mounted
on the water outlet of the cylinder head rear end. The coolant from the middle of the cylinder block front side flows in
left and right line along the water cavity of the cylinder block lengthwise, and flows up to the cylinder head while
flowing. And then it flows into thermostat mounted on the cylinder head rear end. Under the performance of
thermostat, coolant flows into the water pump and then returns to the cylinder block when the water temperature is
lower than 82℃. It flows into the radiator and then returns to the cylinder block through thermostat water pump when
the water temperature is higher than 95℃. Coolant perform the big and small circulation synchronously in response
with the water temperature (82-95℃). Some high coolant flows into the heating device, and returns to the water
pump and up to the cylinder body.
A/C system in engine: The compressor which is the core component in A/C system is connected to the engine by the
pulley to work. It compressed the gaseous refrigerant into the liquid status and sends the liquid refrigerant to the A/C
radiator. The refrigerant begins to expand after cooling, absorbs the temperature in the vehicle as well as sublimates
to be gaseous. The refrigerant is compressed by the compressor again and sent to the A/C radiator for the circulation
continuously.
From the Engine Bottom
Water Filler Hole

Heating
Device
Heater Water Outlet
Sub Tank
Heating Device
Cylinder Head Sub Tank
Heater
Water Inlet Water Pipe
A/C Device
Engine Body
Water
Pump Thermostat
Compressor
Vapor Pressure
Relief Hose
Water Tank
A/C Radiator
- 44 -
Section 2 Coolant Replacement and Filling

Cooling system must contain sufficient coolant to ensure the engine can operate normally when the engine is running.
Otherwise the ―boiling‖ will occur. When the engine is overheated in operation, it will affect the servicing life and
even the cylinder score will occur.
2.1 Drain the Coolant
2.1.1 Unscrew the plug on the lower end of the water pump and drain the coolant.
2.1.2 Loosen the plug screw below the radiator and its upper cap, and then drain the coolant.
Radiator Cap
Plug Screw
- 45 -
2.2 Fill the Coolant

Fill the coolant in the following order:
2.2.1 Unscrew the radiator cap after the engine has
cooled down.
2.2.2 Add the coolant to make the level to reach the
laryngeal of the radiator filler hole.
2.2.3 Close the radiator cap and tighten it.
2.2.4 Start the engine and idle for 3～5 minutes.
Unscrew the radiator cap, drain some air in the water
line. The coolant level lows and refill the coolant to
make the level reach to the upper of the ―LOW‖ line
(close to the ―FULL‖ line). Be careful not to exceed
the ‖FULL‖ line.
2.3 Coolant Filling Description Open temperature (℃) 82

2.3.1 The vehicle must be parked in a level surface Full open temperature (℃) 95
when filling, adding and replacing the coolant. Full open stroke (mm) 8.5～9.5
2.3.2 If the coolant reduces sharply in a short time, the
cooling system may leak. Check it carefully.
Section 4 Water Pump
WARNING: 4.1 Water Pump Removal and Installation
Never open the radiator cap when the engine is hot to 4.1.1 Loosen the generator, and remove the timing belt.
avoid a scald. 4.1.2 Loosen the bolt A firstly.
4.1.3 And then loosen the bolt B to make it move.
4.1.4 Finally loosen the bolt C and generator, and
Section 3 Thermostat remove the timing belt.
3.1 Thermostat Removal and Installation

3.1.1 Disconnect the battery negative terminal cable.
3.1.2 Remove the water pump plug and drain the
coolant.
3.1.3 Remove the bolt, and remove thermostat and
gasket seal.
Loosen
Thermostat installation precaution:

When installing, the torque of the water inlet pipe union
bolt is 8.0 N•m.
Check for the water leak after the installation.
3.2 Thermostat inspection

Inspect thermostat as follow. If it is not as specified,
replace thermostat.
- 46 -
Generator
Water Pump
4.2.2 Install the water inlet hose. Install the resilient ring
clamp as shown in the illustration and then tighten the
bolt below.
Torque: 25 N•m.
Crankshaft Pulley
4.1.5 Remove the plug on the lower end of the water

pump and drain the engine coolant.
4.1.6 Remove the water pump connecting disc, and
unscrew the 5 bolts on the water pump.
4.2.3 Install the bolts in the order shown in the right

illustration when installing the water pump.
Torque: 25 N•m.
4.2.4 Hold the disc in place, and then tighten the bolt
when installing the connecting disc.
Torque: 15 N•m.
4.1.7 Install the water pump in the reverse order of the

removal.
4.2 Water Pump Installation Description

4.2.1 Tighten the bolt shown in the illustration, pay
attention to the installation direction of the gaskets. No
not install reversely.
Torque: 25 N•m. 4.2.5 Check for the water leak after installing.
- 47 -
Chapter 4 Engine Management System

Section 1 Electronic Injection System Service Tip ................................................................................................. 49
1.1 General Service Tip .................................................................................................................................. 49
1.2 Precaution during Servicing ..................................................................................................................... 49
1.3 Recommended Service Tool List ............................................................................................................. 49
1.4 Abbreviations Explanation in This Manual ............................................................................................. 51
Section 2 M7 System Description ........................................................................................................................... 51
2.1 Basic Principle .......................................................................................................................................... 51
2.2 Control Signal: M7 System Input/Output Signal ..................................................................................... 54
2.3 System Function Description ................................................................................................................... 54
2.4 System Trouble Diagnosis Function Description .................................................................................... 55
2.5 Description Concerning the Item ............................................................................................................. 57
Section 3 M7 System Component Configuration, Principle and Trouble Analysis ............................................... 58
3.1 Intake Pressure and Temperature Sensor ................................................................................................. 58
3.2 Throttle Position Sensor ........................................................................................................................... 59
3.3 Coolant Temperature Sensor .................................................................................................................... 61
3.4 Oxygen Sensor.......................................................................................................................................... 63
3.5 Inductive Speed Sensor ............................................................................................................................ 66
3.6 Phase Sensor ............................................................................................................................................. 70
3.7 Electronic Control Unit (ECU) ................................................................................................................ 71
3.8 Electrical Fuel Pump (Type EKP13.5)..................................................................................................... 74
3.9 Magnetic Injector...................................................................................................................................... 76
3.10 Idle Actuator Step Motor ........................................................................................................................ 78
3.11 Single Spark Ignition Coil ...................................................................................................................... 80
3.12 Canister Control Valve ........................................................................................................................... 81
3.13 Fuel Pressure Regulator.......................................................................................................................... 84
3.14 Steel Fuel Distribution Assembly .......................................................................................................... 86
Section 4 M7 System Performs Inspection and Diagnosis Procedure According to Trouble Code ...................... 86
Section 5 Repair and Service Procedure by M7 Diagnosis System According to Malfunction Symptoms ........ 108
Section 6 M7 System Tester Instruction for Use .................................................................................................. 117
Section 7 Accessories ............................................................................................................................................ 124
7.1 Components Installing/Torque Specification Table .............................................................................. 124
7.2 Electronic Injection System Maintenance Schedule .............................................................................. 124
7.3 Trouble Code (PCODE) List .................................................................................................................. 126
7.4 Wire Harness Diagram ........................................................................................................................... 128
- 48 -
Section 1 Electronic Injection System resulting in the three-way catalytic converter damage.
1.2.8 Manual idle adjustment is unnecessary, because it
Service Tip can be operated almost by the electronic injection
1.1 General Service Tip system. The accelerator stop screw of the throttle body
has been well adjusted at factory. The user is not
1.1.1 Perform the electronic injection system inspection allowed to change its initial position at random.
only using a digital multimeter. 1.2.9 Connect the battery positive and negative
1.1.2 Use the genuine components during servicing, or correctly to avoid damaging the electronic elements.
it is impossible to ensure the normal operation of the Minus earth is used in this system.
electronic injecting system. 1.2.10 Never remove the battery cable when the engine
1.1.3 Only unleaded gas can be used during servicing. is running.
1.1.4 Please observe the regulatory service diagnosis 1.2.11 Before welding, make sure to remove the battery
procedure to conduct the repair. positive and negative cable and ECU.
1.1.5 Never disassembly and remove the electronic 1.2.12 Do not detect the component input and output
injection system during servicing. electronic signal by piercing the wire coat.
1.1.6 Be very careful when holding the electronic
elements (ECU, sensor etc.). Do not drop them on the 1.3 Recommended Service Tool List1.3.1
ground.
1.1.7 Environmental sense should be established. Treat
waste gas produced during servicing effectively.
1.2 Precaution during Servicing
1.2.1 Do not remove any components of the electronic

injection system or its socket connectors at random
from its installation position to avoid accidental damage
or foreign matter (moisture, oil etc.) entry into the
connectors. Therefore the normal operation of the
electronic injection system can be affected.
1.2.2 Be sure to turn off the ignition switch when
disconnecting and connecting the socket connectors, or
the electronic elements will be damaged.
1.2.3 When conducting the hot condition simulation for
the trouble and performing other repair work that may Tool name:
increase temperature, ECU temperature is never above BYD ED300 tester
80℃. Function:
1.2.4 A high-pressure resistant fuel pipe is adopted for Read/clear the trouble code of the electronic injection
all the fuel lines, because the supply pressure of the system, examine the data stream and test the
electronic injection system is high (about 300kPa). The components operation etc.
1.3.2
fuel pressure in the oil path keeps high even if the
engine is not running. Be careful not to remove the fuel
pipes during servicing at random. In case the fuel pipes
are needed to repair, discharge the fuel system pressure
before removing the fuel pipes. The method is as below:
Remove the fuel pump relay, and start the engine and
keep it idle until the engine stops automatically. The
removal of the fuel pipes and the replacement of the
fuel filter should be performed in a well-ventilated area
by a professional service technician.
1.2.5 Do not energize the electrical fuel pump when
removing it from the fuel tank to avoid a spark which
will cause a fire.
1.2.6 Never perform the running test for the fuel pump
in dry condition or in water, or its service life will
shorten. Make sure connect the poles correctly.
1.2.7 During checking the ignition system, spark jump
test will be conducted only when it is unavoidable. And
the test time should be as short as necessary. Do not
open the throttle during testing, or a large amount of
uncombusted gas will enter into the exhaust pipe
- 49 -
Tool name: Tool name:

Electronic injection system adapter Vacuum gauge
Function: Function:
Inspect the electronic signal of each ECU pin and the Check the pressure of the intake manifold.
circuit etc.
1.3.3 1.3.6
Tool name:
Cylinder pressure gauge
Function:
Check the pressure of each cylinder.
1.3.7
Tool name:
Ignition timing light
Function:
Check the engine ignition timing etc.
1.3.4
Tool name:
Fuel pressure gauge
Function:
Check the pressure of the fuel system, and judge the
operation of the fuel pump and fuel pressure regulator
in this system.
Tool name: 1.3.8
Digital multimeter
Function:
Check the characteristic parameter of the electronic
injection system, such as voltage, current, resistance etc.
1.3.5
- 50 -
Tool name: Section 2 M7 System Description

Exhaust analyzer
2.1 Basic Principle
Function:
Check the emission condition helping to the trouble
2.1.1 General description: M7-Motronic engine
judgment to the electronic injection system.
management system
1.3.9 Engine Management system mainly consists of the
sensor, electronic control unit (ECU) and actuator. It
controls the air inflow, injection volume and spark
advance angle when the engine is in operation. The
basic configuration is shown as fig. 2.1.
Diagnosis Diagnosis
Sensor ECU Actuator
Engine
Fig.2.1 Engine Electronic Control System Constitutes

Tool name:
Injector cleaning analyzer The sensor as an input part in the engine electronic
Function: control system is used to measure all kinds of physical
Perform the cleaning analysis to the injector. signals (temperature, pressure etc.) and converts those
signals to the corresponding electronic signals. The
1.4 Abbreviations Explanation in This Manual ECU receives the input signals from the sensor to
calculate according to the setting program to generate
DG Speed sensor the corresponding control signals and output to the
DKG Throttle position sensor power drive circuit. This circuit drives each actuator to
DLA Idle adjuster/step motor perform different action to make engine run according
DR Fuel pressure regulator to the set control method. At the same time, the trouble
DS-S-TF Intake pressure and temperature sensor diagnosis system in ECU monitors all the components
ECU Electronic control unit (ordinarily called or the control function. The trouble code will be stored
computer) when the malfunction is tested and confirmed. Then the
EKP Fuel pump ―Limp Home‖ function is recalled. The normal value is
EMS Engine management system activated when the trouble is erased.
EWD Idle adjuster/rotating pilot valve M7 engine electronic management system features to
EV Injector perform the control based on the torque. The main
LSH Heated oxygen sensor purpose of considering the toque as the master control
KSZ Fuel distribution pipe assembly strategy is to connect a large amount of the different
KVS Fuel distribution pipe control objectives. This is the only way to integrate all
PG Phase sensor the functions into the different variants for ECU
ROV Ignition system with distributor according to the engine and vehicle type flexibly. M7
RUV Ignition system without distributor engine electronic control system configuration is shown
TEE Oil pump bracket assembly as fig. 2.2.
TEV Canister control valve
TF-W Coolant temperature sensor
ZSK Ignition coil
- 51 -
Canister Control Valve

Intake Fuel Fuel
Canister Distribution Phase
Pressure/ Pressure Pipe Sensor Ignition Coil
Temperature Regulator Assembly
Sensor
Throttle Body Assembly Oxygen Sensor
Injector Three-way Catalytic

Converter
Throttle Position Water Temperature
Sensor
Sensor
Step
Motor
Fuel
Filter
Speed
Sensor
Diagnosis Port Produced by UAES

Fuel Tank
Power Fuel Pump and Bracket Assembly
Fig. 2.2 M7 Engine Electronic Control System Configuration
The basic components for the engine electronic control system:
Electronic control unit (ECU) Idle adjuster

Mass air flow meter Injector
Intake pressure/temperature sensor Electronic fuel pump
Water temperature sensor Fuel pressure regulator
Throttle position sensor Oil pump bracket
Camshaft position sensor Fuel distribution pipe
Speed sensor Canister control valve
Oxygen sensor Ignition coil
M7-Motronic engine management system is an electronic-control gasoline engine control system which supplies
many control features of the operator, vehicle or equipment. Open loop and closed loop (feedback) control are
combined to supply various control signals for engine operation.
- 52 -
Main function for the system: 2.1.1.3 On-line diagnosis for the OBD II
2.1.1.1 Basic management function for the engine Achieve a series of OBD II functions
adopted the physical model Serve as a management system for the diagnosis
(ⅰ) System configuration based on the torque function
(ⅱ) Cylinder load is determined by the intake pressure
sensor and air flow sensor 2.1.2 Torque configuration: M7 system based on the
(ⅲ) Improve the mixture control function under the torque control
static and dynamic situation As shown in fig. 2.3, in the M7 engine management
system centering on the torque, both inside and outside
(ⅳ)  Closed control.
demand for the engine is defined by the engine torque
(ⅳ) Fuel sequential injection by each cylinder or efficiency requirement. Various engine requirements
(ⅴ) Ignition timing, including the cylinder by cylinder are converted into the torque or efficiency control
knock control variables, and these variables are processed in the center
(ⅵ) Emission control function torque requirements coordinator firstly. M7 system can
(ⅶ) Catalyst heated arrange these incompatible requirements in priority and
(ⅷ) Canister control perform the most important one. Obtain the required
(ⅸ) Idle control engine control parameters (injection time, ignition
(x) Limp home timing etc.) by the torque conversion module. The
2.1.1.2 Additional function actuation of the control variable does not affect other
Theft deterrent function variables. This is the advantage for using the torque as
Connection between the torque and external system (i.e.: the master control system.
drive mechanism or vehicle dynamic control) Similarly, only the engine data is demanded when
Supply the control for several engine components to the calibrating the engine performance curve and map data
calibration, EOL-development tool and service tool as the variable of the system based on the torque control
interface. is independent
Efficiency Requirement
● Engine starts
●Catalyst heats
● Idle control
Efficiency
External Torque Requirements Torque Requirement Torque

Coordinator Conversion Injection Time
● Cruise control
● Vehicle speed limitation Coordinate the torque Ideal torque is
● Vehicle dynamic control and efficiency achieved
requirement Wheel Cylinder
● Driving performance Torque Fuel Cut Off
Internal Torque Requirements Torque

● Engine starts
● Idle control Ignition Timing
● Engine speed limitation
● Engine protection
Fig.2.3 System configuration based on the torque
Main features of the M7 system comparing with the previous M series engine electronic injection management
system:
(1) New engine configuration with the torque as a variable, easy compatible with other system, strong expansibility.
(2) New modularized software and hardware configuration, strong transportability.
(3) Engine basic characteristic diagram based on the module, independently with each other, simplify the calibration
process.
(4) With a phase sensor, sequential fuel injection helps to improve the emission.
(5) This system is integrated with theft deterrent function.
(6) Coordinate various torque requirements intensively to enhance the drivability.
(7) 16-digit center processor, 40 MHZ clock frequency, 768 k cache.
(8) System can be extended according to the future requirements such as: the future emission regulation, OBDII,
electronic throttles etc.
- 53 -
2.2 Control Signal: M7 System Input/Output catalytic converter by the exhaust emission.
Signal 2.3.3 Acceleration/deceleration control and the fuel cut
Main sensors input signal of the ECU in the M7 system: control for towing astern
The fuel injected to the intake manifold partially will
（1） Intake pressure signal
not reach the cylinder to combust on time. It will form a
（2） Intake temperature signal
fuel film in the intake manifold wall instead. The fuel
（3） Throttle angle signal
volume stored in the fuel film will increase sharply
（4） Coolant temperature signal according to the increased load and extended injection
（5） Engine speed signal duration.
（6） Phase signal Some injected fuel is drawn into the fuel film when the
（7） Oxygen sensor signal throttle opening increases. Therefore, corresponding
（8） Vehicle speed signal supplement fuel must be injected to compensate to
（9） A/C pressure signal prevent the mixture air becoming lean when
The above information outputs into the ECU and then it accelerating. When the load coefficient becomes small,
is processed to generate the required actuator control the additional fuel in the fuel film in the intake manifold
signal which is enlarged in the output drive circuit and will release again, and then during the decelerating,
is transmitted to each corresponding actuator. These corresponding injection duration must be reduced.
control signals includes following items: Towing astern or towing operation is the condition that
(1) Idle adjuster opening the power supplied by the engine in the flywheel is
(2) Injection timing and injection duration negative value. Under this situation, the engine friction
(3) Fuel pump relay and pumping gas loss will make the vehicle decelerate.
(4) Canister control valve opening Fuel injection is cut off to reduce the fuel consumption
(5) Ignition coil closed angle and spark advanced angle and the emission when the engine is in the towing astern
(6) A/C compressor relay or towing condition and to protect the three-way
catalytic converter more importantly.
(7) Cooling fan relay
The injection system resumes supplying fuel when the
speed reduces to a specified speed at which the fuel
2.3 System Function Description supply will resume. In fact, there is a speed range in the
2.3.1 Start control ECU program, in which the fuel supply will resume.
During the start control, a special calculation method The range varies with the parameters for the engine
should be used to control the charging, injection and temperature, engine speed dynamic change and prevents
ignition timing. At the very beginning of the process, air the speed decreasing to the specified lowest threshold
in the intake manifold is static and the inner pressure in value by calculating.
the intake manifold is displayed as ambient pressure. The system starts to use initial injection pulse to supply
The throttle closes and the idle adjuster is designated as fuel and rebuild the fuel film on the intake manifold
a fixed parameter in accordance with the start wall once the injection system resume supplying fuel.
temperature. The control system Increase in engine torque is slow
In the similar process, a specified ―injection timing‖ is and steady in the control system majored in torque
designated as the initial injection pulse. when injecting again.
The fuel injection volume varies with the engine 2.3.4 Idle control
temperature to actuate the oil film generation in the When idling, engine does not supply the torque to the
intake manifold and the cylinder wall. Therefore, enrich flywheel. Closed loop idle control system must maintain
the mixture air before the engine speed reaches a certain the balance between the generated torque and engine
value. ―power consumption‖ to ensure that the engine operates
Once the engine starts to operate, the system begins to steadily at a low idle speed as possible. When idling, it
slow down the start enrichment immediately. When the is necessary to generate certain power to meet the
start is finished (600…700 min-1), the start enrichment various load demand, including that from the engine
is cancelled completely. crank, valve mechanism and accessory, such as the
The spark angle is adjusted constantly under the start inner friction of the water pump.
condition by the engine temperature, intake temperature M7 system considers the torque as the main control
and engine speed. strategy to determine the engine output torque required
2.3.2 Warm-up engine and three-way catalytic converter by the idle speed maintained under any condition
heating control according to the closed loop idle control. The output
When the engine is started in a low temperature, the torque increases as the engine speed drops and
cylinder charging, fuel injection and electronic spark are decreases as the engine speed rises. The system
adjusted to compensate a higher torque required by the responds to the new ―interference factor‖ by requiring a
engine. The process will continue until the temperature larger torque such as turning on/off A/C compressor or
increases to a proper threshold value. shifting the transmission. It is necessary to increase the
In this process, it is most important to heat the torque to compensate the heavy inner friction loss
three-way catalytic converter as fast as possible because and/or maintain a higher idle speed when the engine
a quick transit to the operation of the catalytic converter temperature is low. The total of the output torque
will reduce the exhaust emission greatly. Under this requirements is transferred to the torque adjuster that
operation condition, a method of delaying the spark calculates the corresponding charging density, mixture
advanced angle can be used to heat the three-way
- 54 -
air composition and ignition timing. 2.4 System Trouble Diagnosis Function
2.3.5  Closed loop control Description
Post emission disposal of the three-way catalytic On-Board Diagnosis System (briefly called OBD
converter is an effective way to reduce the exhaust System) is a diagnosis system that is integrated into the
harmful material density. The three-way catalytic engine control system to monitor the malfunction
converter can reduce the hydrocarbon (HC), carbon components that affects the exhaust emission and main
monoxide (CO) and nitrogen oxide (NOx) by about engine function status. It has a function of the
98% or more and transform them into water (H2O), recognition, storage and displaying the trouble
carbon dioxide (CO2) and nitrogen (N2). It can be information through the self-diagnosis malfunction
achieved only when the engine excessive air coefficient indicator light (MIL).
=1 near the quite small range. The objective of the  To secure the durability of the emission control
closed loop control is to ensure that the mixture air performance during vehicle is in service, ―Limits and
density is within this range. Measurement Methods for Emissions from Light-duty
 closed control system can operate only when the Vehicles (China III, IV)‖ clearly demands that all the
oxygen sensor is equipped. The oxygen sensor on the vehicles should be equipped with OBD system which
side of the three-way catalytic converter monitors the can make the vehicle recognize the components
oxygen content in the exhaust gas, and the lean mixture deterioration or malfunction in the whole life cycle.¡±
(1) will generate about 100 mV sensor voltage while When repairing the vehicle with an OBD system, the
the rich mixture will generate about 800 mV sensor technician can recognize the malfunction components
voltage. At =1, there is a jump for the sensor quickly and exactly by the tester, thus improving the
voltage.Closed loop control responds to the input service efficiency and quality.
signal (1=mixture too lean, 1=mixture too rich) to OBD technology involves many brand-new concepts.
trim the control variable, and generate a trim gene as The following is the basic introduction related to OBD
multiplier to trim the fuel injection duration. technology to have a better understanding of the further
2.3.6 Evaporation emission control content.
As the external radiant heat and return heat is 2.4.1 Trouble information record
transferred, the fuel in the tank is heated and generates Electronic control unit constantly monitors the sensor,
the fuel vapor. The vapor with a large quantity of HC is actuator, related circuit, malfunction indicator light and
limited to discharge into the atmosphere directly due to battery voltage etc. and even ECU itself. It also checks
the restriction of the emission regulation. The fuel vapor the authenticity of the sensor output signal, actuator
in the system is gathered in the active canister through drive signal and inner signal (i.e.  closed loop control,
the pipe and enters the engine to combust by rinsing at coolant temperature, idle speed control and battery
the appropriate time. The rinsing air flow is obtained by voltage control, etc.). Electronic control unit will set the
ECU controlling the canister control valve, which trouble information record in the RAM trouble memory
operates only when the  closed loop control system rapidly once a malfunction is found in a certain
operates under the closed loop condition. procedure or certain signal is suspected. Trouble
information record is stored as a trouble code mode and
is displayed in the order of occurrence of the trouble.
The trouble can be divided into ―steady trouble‖ and
―casual trouble‖ (such as caused by the harness transient
open or poor contact of the socket connector.) according
to the problem occurrence frequency.
Function Diagnosis Function Diagnosis

ECU
Data Collection Control Command
Sensor Actuator
Engine
Fig.2.4 Electronic injection system trouble diagnosis schematic diagram
- 55 -
2.4.2 Malfunction indicator light description and control 2.4.3 Four trouble types
method B_mxdfp Max trouble, the signal exceeds the normal
Malfunction indicator (MI): An indication is demanded range upper limit.
by the regulation when the component or system related B_mndfp Min. trouble, the signal exceeds the normal
to the emission is in trouble. Generally speaking, MI is range lower limit.
an indicator light that could be displayed on the B_sidfp Signal malfunction, no signal
instrument panel with the shape conformed to the B_npdf Unreasonable malfunction, signal exists but not
regulation. reasonable.
The activation of the MIL follows below rules:
1 Supply to the ignition switch (not start), MIL keeps 2.4.4 Malfunction repair procedure
on. For the vehicle with OBD function, malfunction repair
2 3 seconds have elapsed after the engine is started. is done in the following step:
MIL will turn off if there is no MIL ON trouble request
in the trouble memory. 1. Connect the diagnosis tester
3 MIL will turn on if there is a MIL ON trouble request to the diagnosis port, and turn
in the trouble memory or in the external of the ECU. on the diagnosis tester.
4 When there is a MIL flashing request in the external
of the ECU or in the trouble memory, or due to the
misfire, MIL flashes in 1HZ.
SVS (or EPC) Light: SVS Light is a malfunction 2. Turn on the ―ignition
indicator light for service set by the vehicle switch‖.
manufacturer. There is no clear regulation for the shape
and the activation principle in EOBD.
SVS Light control method is defined based on the
assembly factory. Turn ignition key to the ON mode.
The time for the K-line ground is longer than 2.5 3. Read the information related
seconds, and SVS light is in the output flash code mode. to malfunction (DTC, freeze
In different mode, SVS light operates as follow: frame). See the repair manual
(1) Normal mode, and trouble memory is blank to determine the trouble
Turn the ignition switch to ON status, and ECU component and type. Make the
performs initialization immediately. SVS is on for 4 service scheme according to
seconds and then turns off as the initialization. If the the related malfunction
engine starts within 4 seconds, the SVS turns off information and experience.
immediately when the engine speed is obtained.
(2) Normal mode, and problem exists in the trouble 4. Perform the troubleshooting.
memory
Turn the ignition switch to ON status, SVS light keeps
on. After the engine is started, if the problem in the
trouble memory asks SVS to turn on under the trouble
mode, SVS will be on in the following driving circle. If
not, SVS will be off when engine speed is obtained. 5. Erase the trouble memory.
(3) Flash code mode, and trouble memory is blank Operate the vehicle properly,
If ECU detects that SVS light is in flash code mode, the operation method must
SVS will flash to display the corresponding trouble conform to the corresponding
code in the trouble memory. After turning ignition trouble diagnosis condition.
switch to ON status, SVS keeps on for 4 seconds. Then Read the malfunction
1 second elapses, SVS flashes in 2HZ to indicate no information and confirm the
malfunction until the engine is started and speed is trouble has been shooted.
obtained.
(4) Flash code mode, and problem existed in the trouble 2.4.5 Tester connection
memory ―K‖-line communication protocol and ISO 9141-2
If ECU detects that SVS light is in flash code mode, standard diagnosis connector are applied in this system.
SVS will flash to display the corresponding trouble See fig. 2.5. This connector is connected to the engine
code in the trouble memory. After turning ignition harness securely. No.4, 7 and 16 pins on this connector
switch to ON status, SVS keeps on for 4 seconds. Then are used for the engine management system (EMS).
1 second elapses, SVS flashes code to indicate the No.4 pin is connected to the earth wire on the vehicle,
malfunction code (DTC) in the trouble memory. If all No.7 is connected to No.15 pin of the ECU (engine data
the problems in the trouble memory have been ―K‖ line), and No.16 pin is connected to the battery
expressed by the SVS flash code, SVS will be off until positive.
the flash code mode exits.
- 56 -
(6) Malfunction display

Intake pressure sensor, intake temperature sensor,
engine coolant temperature sensor, throttle position
sensor, oxygen sensor, oxygen sensor heating line,
air-fuel ratio trim, each cylinder injector, fuel pump,
speed sensor, phase sensor, canister control valve,
Fig. 2.5 ISO 9141-2 Standard Diagnosis Connector cooling fan relay, speed signal, idle speed, idle adjuster,
system voltage, ECU, A/C compressor relay, evaporator
ECU communicates with the external tester by temperature sensor, malfunction indicator light.
K-line. The following operations can be done: 2.4.6 Read the malfunction information according to the
(For the details of the functions and tester operation, see flash code
―BYD ED300 diagnosis tester introduction‖) Turn on ignition switch, and make the engine data
(1) Engine parameter display K-line (standard diagnosis connector 7#) ground more
1、speed, coolant temperature, throttle opening, spark than 2.5 seconds. If there is a trouble code in the ECU
advanced angle, injection pulse width, intake pressure, trouble memory, engine SVS malfunction indicator light
intake temperature, vehicle speed, system voltage, outputs a flash code that is P-code value. For example:
injection trim, canister rinsing rate, idle air control, P0203 flash mode: flash 10 times
oxygen sensor waveform. continuously-interval-flash twice
2. Target RPM, engine relative load, ambient continuously-interval-flash 10 times
temperature, spark closed time, evaporator temperature, continuously-interval-flash 3 times continuously.
intake air flow, fuel consumption. NOTE: Flash code can not operate for vehicle without
3. Throttle position sensor signal voltage, coolant SVS light.
temperature sensor signal voltage, intake temperature
sensor signal voltage, intake pressure sensor signal 2.5 Description Concerning the Item
voltage.
(2) Electronic injection system status display System features:
Theft deterrent system status, security status, program Multi-port sequential injection system.
status, cooling system status, steady operation status, New engine configuration with the torque as a variable,
dynamic operation status, emission control status, easy compatible with other system, strong expansibility.
oxygen sensor status, idle status, malfunction indictor New modularized software and hardware configuration,
status, emergency operation status, A/C system status, easy compatibility and strong transportability.
automatic transmission/torque require status. Cylinder judgment signal is used (phase sensor PG3.5).
(3) Actuator test function Use 60-2 gear signal plate to recognize the speed signal
Malfunction indicator light, fuel pump, A/C relay, fan, (speed sensor DG6).
ignition, injection (signal cylinder fuel cut off). Use the idle control of the bypass air path (idle
(4) Odometer display adjuster-step motor).
Running distance, running time Achieve idle torque closed loop control.
(5) Version information display Catalytic converter heat and protection function.
Frame number (VIN), ECU hardware number and ECU Limp home function.
software number. Flash code function etc
- 57 -
Section 3 M7 System Component Configuration, Principle and Trouble Analysis

3.1 Intake Pressure and Temperature Sensor
Sketch and pin
Fig.3-1 Intake Pressure and Temperature Sensor Fig.3-2 Intake Pressure and Temperature Sensor
Electrical Wiring Diagram
Pin: No.1 is grounded.

No.2 outputs temperature signal.
No.3 connects to 5 V.
No.4 outputs pressure signal.
3.1.1 Installation position Intake temperature sensing element is a negative

The sensor, consisting of two sensors which are intake temperature coefficient (NTC) resistance. Its resistance
manifold absolute pressure sensor and intake value varies according to the intake temperature. The
temperature sensor, is installed on the intake manifold. sensor transmits a voltage indicating pressure change to
the controller.
3.1.2 Operation principle
Intake manifold absolute pressure sensing element
consists of a piece of silicon chip on which etch a piece
of pressure diaphragm.
There are 4 piezoelectric resistors on the pressure
diaphragm, which form a Wheatstone bridge as a strain
element. Besides the pressure diaphragm, the silicon
chip also integrates with the signal processing circuit.
Silicon chip and a metal housing form an enclosed
reference space where the air absolute pressure is near
to 0. Therefore, a micro-electronics mechanism system
is created. The active surface on the silicon is subjected
to the pressure of approximate 0. While its back is
subjected to the intake manifold absolute pressure
introduced by a pipe, which is to be detected. Changing Fig 3-3 Intake Manifold Absolute Pressure and Intake
the intake manifold absolute pressure will make the Temperature Sensor Cross Section
silicon chip deform mechanically as the chip thickness 1. Seal Ring, 2. Stainless Steel Bushing 3. PCB Plate, 4.
is just several microns. Accordingly, the 4 piezoelectric Sensing Element 5. Case, 6. Pressure Carrier, 7.
resistors will deform and its resistance changes. After Welding Connection, 8. Adhesive Connection
the resistance is processed by the silicon chip signal
processing circuit, it will generate a voltage signal
which is in linear with the pressure.
- 58 -
3.1.3 Technical parameter
（1）Limit data
Factor Value Unit

Min. Typical Max.
Tolerant source voltage 16 V
Tolerant pressure 500 kPa
Tolerant storage temperature -40 +130 C
（2）Performance data
Factor Value Unit
Min. Typical Max.
Pressure test Range 20 115 kPa
Operation temperature -40 125 C
Operation source voltage 4.5 5.0 5.5 V
Current at US=5.0 V 6.0 9.0 12.5 mA
Load current of the output circuit -0.1 0.1 mA
Load resistance to the ground or battery 50 k
Reaction time 0.2 ms
Weight 27 g
（3）Transfer function for the pressure sensor can be affected by the components connectors mainly.
UA=(c1 pabs+c0)Us The material quality and size precision of the
In this formula, UA=signal output voltage (V) connectors matched on the wire harness are also the
US=Source Voltage (V) effect factors.
pabs=absolute pressure (kPa)
c0=-9.4/95 3.1.5 Trouble symptom and diagnosis method
c1=0.85/95 (1/kPa)  Trouble symptom: stall, poor idle etc.
In the above formula, under the atmospheric pressure,  Normal cause for the malfunction:
the signal output voltage of the pressure sensor is near 1. Abnormal high voltage or inverse large current
to the source voltage. during servicing.
If the source voltage is 5 V, the signal output voltage of 2. Vacuum component is damaged during repairing.
the pressure sensor is about 4 V when the throttle is full  Service precaution: High pressure air is limited to
open. shock the vacuum components during service.
(4) Limit data for the temperature sensor Check if the engine output voltage and current is
Storage temperature: -40/+130C normal when replacing the sensor as malfunction is
25Load capacity at 25°C: 100 mW found.
(5) Performance data for the temperature sensor  Simple measurement method:
Operation temperature: -40/+125C Temperature sensor: (connector removed) Switch the
Rated voltage: Operate in front-built resistance (1 k) digital multimeter to OHMMETER position, then
at 5 V, or operate in test current (1 mA). connect both probes to 1# 、 2# pin of the sensor
20C Rated resistance: 2.5 k  5% respectively. The rated resistance is 2.5 kΩ±5% at 20℃,
Temperature time coefficient in the air 63, v=6m/s: and other corresponding resistance values can be
45s measured according to above characteristic curve.
Simulative method can be used during the measurement.
3.1.4 Installation precaution Below are the details. Use the electric hair dryer to blast
This sensor is designed to install on the flat of the to the sensor (not too closed), and observe the change of
vehicle engine intake manifold. The pressure jointing the sensor resistance. It should decrease at this
time.Pressure sensor: (connector connected) Switch
pipe and temperature sensor project from the intake the digital multimeter to DIRECT VOLTAGE position,
manifold and the atmosphere is sealed by an O ring. black probe is grounded, and the red one is connected to
If the sensor is mounted on the vehicle by an 3 #, 4# pin separately. When idling, the reference
appropriate way (pump the pressure from the intake voltage of the 3# pin should be 5 V, and 4# pin voltage
manifold, pressure jointing pipe tilts down etc.), it is is about 1.3 V (the actual value is related to the vehicle
necessary to make sure that no condensation water is on type). In the unload status, open the throttle slowly, no
the pressure sense element. sharp change occurred on 4# pin’s voltage. Open the
Drill hole on the intake manifold and hold according to throttle quickly, 4# pin’s voltage can reach about 4 V
the supplied illustration to secure a long-term seal and (the actual value is related to the vehicle type) instantly
erosion resistance from the medium. and then decrease to about 1.5 V (the actual value is
related to the vehicle type).
The secure contact of the junction electronic connection
- 59 -
Fig 3-4 Coolant Temperature Sensor NTC Resistance Characteristic Curve
3.2 Throttle Position Sensor
Sketch and pin
Fig.3-5 Throttle Position Sensor Fig.3-6 Throttle Position Sensor Electrical Wiring
Diagram
Pin: Pal for a large open when the throttle turns counterclockwise (see the throttle from sensor side in the direction of
throttle shaft): No. 1 is grounded, No. 2 is connected to a 5 V power supply.
Pal for the large open when the throttle turns clockwise (see the throttle from sensor side in the direction of throttle
shaft): No. 1 is connected to a 5 V power supply, No. 2 is grounded, NoO.3 outputs signal.
3.2.1 Installation position

It is mounted on the throttle body.
The sensor is a linear output angle sensor and consists of two arch sliding resistors and two sliding arms. The spindle
of the sliding arm is connected to the throttle shaft in the same axial line. 5 V source voltage U S is applied to both
sides of the sliding resistor. When the throttle rotates, sliding arms rotate with it and also slide on the sliding resistors
and consider the potential UP of the contact point as the output voltage to project. In fact, the sensor severs as an
angle potentiometer which outputs the voltage signal that is proportional to the throttle position.

（1） Limit data
Factor Value Unit

Mechanical angle between the two extremity 95 Degree
positions
Electrical available angle between the two 86 Degree
extremity position
Allowable sliding arm current 18 A
Storage temperature -40/+130 C
Allowable vibration acceleration 700 m/s2
- 60 -
（2） Performance data
Factor Value Unit

Min. Typical Max.
Total resistance (pin 1-2) 1.6 2.0 2.4 k
Sliding arm protective resistance
(sliding arm at 0, pin 2-3) 710 1380 
Operation Temperature -40 130 C
Source voltage 5 V
Voltage ratio in extremity position (RH) 0.04 0.093
Voltage ratio in extremity position (LH) 0.873 0.960
UP/US increase with the throttle angle 0.00927 1/degree
Weight 22 25 28 g
3.2.4 Installation precaution
 For the leakage in the throttle shaft seal after running a long time, it is suggested that the throttle valve shaft
should be installed with a 30 degrees deviation from the vertical direction.
 Allowable tightening torque for screw is 1.5 Nm-2.5 Nm.
3.2.5 Trouble symptom and diagnosis method
 Trouble symptom: poor acceleration etc.

 Normal cause for the malfunction: man-made trouble.
 Service precaution: pay attention to the installation position.
 Simple measurement method:
(Connector removed) Switch the digital multimeter to OHMMETER position, and then connect both probes to 1#, 2#
pin of the sensor respectively. The resistance is 2 kΩ±20% at normal temperature. The two pens of the meter are
connected to 1# and 3# pin. Turn the throttle and its resistance changes linearly according to the openness of the
throttle. For 2#, 3# pins it is in the opposite condition.
NOTE: Examine if there is a jump when observing the change of the resistance.
(Connector connected) Turn on ignition switch but do not start the engine. Switch the digital multimeter to DIRECT
VOLTAGE position, black probe is grounded, and the red one is connected to 2 # pin. At this time, there should be a
5 V reference voltage. Connect to the 3# pin when the throttle fully closes, the voltage is about 0.3 V (the actual value
depends on the vehicle model). The voltage is about 3 V when the throttle fully opens (the actual value depends on
the vehicle model).
3.3 Coolant Temperature Sensor
Sketch and pin
Meter
Fig.3-7 Coolant Temperature Sensor Fig.3-8 Coolant Temperature Sensor Electrical Wiring
Diagram
Pins: There are 3 pins on this sensor, one is connected to the meter, and the others are connected to the electronic
controller.

It is mounted on the water outlet of the engine.
- 61 -

This sensor is a negative temperature coefficient (NTC) thermostat, and its resistance decreases with the rising of the
coolant temperature. But the relationship between the resistance and temperature is not linear. NTC thermostat is
mounted on a copper surface. See the below illustration.
Configuration Characteristic curve
Resistance Value R
1. Electrical Connector
2. Housing
3. NTC resistor
Temperature
Fig.3-9 Coolant Temperature Sensor Cross Section Fig.3-10 Coolant Temperature Sensor Performance Curve

(1) Limit Data
Factor Value Unit

Rated voltage Operate only by the ECU
20Rated resistance at 20°C 2.55% k
Operation temperature range -30 to +130 C
Max. measurement current passing the sensor 1 mA
Allowable vibration acceleration 600 m/s2
(2) Performance data
No. Resistance (k) Temperature

Temperature tolerance1C Temperature tolerance0C （C)
Min. Max. Min. Max.
1 8．16 10．74 8．62 10．28 -10
2 2．27 2．73 2．37 2．63 +20
3 0．290 0．354 0．299 0．345 +80

The coolant temperature sensor is installed on the cylinder block, with the copper heat conducting bushing inserted
into the coolant.Using the hexagon head of the bushing with thread on it can tighten the coolant temperature sensor
into the thread hole on the cylinder block easily. Max. allowable tightening torque is 20 N∙m.

 Trouble symptom: difficult to start etc.
(connector removed) Switch the digital multimeter to OHMMETER position, then connect both probes to 1#、3# pin
of the sensor respectively. The rated resistance is 1.825-2.155 kΩ at 25℃, and other corresponding resistance values
can be measured according to above characteristic curve. Simulative method can be used during the measurement.
Below are the details. Put the sensor functional area into the boiling water (the soaking time should be enough) and
observe the change of the sensor resistance. At this time it should decrease to 300 Ω-400 Ω (actual value depends on
the boiling temperature).
- 62 -
3.4 Oxygen Sensor

Sketch and pin
Fig 3-11 Oxygen Sensor
1 Cable 2 Butterfly Washer 3 Insulation

Bushing
4 Protective Sleeve 5 Heating Element
Clamping Joint
6 Heating Bar 7 Contact Pad 8 Sensor
Seat
9 Ceramic Probe 10 Protective Pipe
Fig 3-12 Oxygen Sensor Cross Section
Main Relay
Oxygen Sensor
Fig.3-13 Oxygen Sensor Fig.3-14 Oxygen Sensor Electrical Wiring Diagram
All the oxygen sensors are equipped with cable. There is an electronic connector on the other end of the cable. There
are 4 pins on the electrical connector of the oxygen sensors produced by our company.
No.1 is connected to the heating power positive (white).
No.2 is connected to the heating power supply negative terminal (white).
No.3 is connected to the signal negative terminal (grey).
No.4 is connected to the signal positive (black).
NOTE: The oxygen sensor shown in fig.3-13 and ECU pin connection may be adjusted according to the
allocation. For the details of the ECU pin number, please refer to the wire harness schematic diagram.

It is mounted on the front of the exhaust pipe.
The sensing element of the oxygen sensor is a ceramic tube with an opening. The tube wall periphery is surrounded
by the engine exhaust and its inside is open to the atmosphere. The sensing ceramic tube wall is a kind of solid
electrolyte and an electrical heating tube is built in it. See fig.3-12.
The operation of the oxygen sensor is achieved by converting the oxide ion density differences between the outside
and inside of the sensing ceramic tube into the voltage signal output. When the sensing ceramic tube temperature
reaches 350℃, it features as solid electrolyte. The oxide ion can pass through the ceramic tube freely due to the
special material. According, convert the density difference into the potential difference and generate an electrical
signal to output using above performance. If the mixture gas is richer, the density difference between the outside and
inside of the ceramic tube is great, potential difference is greater; a large amount of oxide ion moves from outside to
inside, and the output voltage is higher (approximate 800 mV-1000 mV). If the mixture gas is leaner, the density
difference between the outside and inside of the ceramic tube is small, potential difference is
- 63 -
Output Voltage
Excessive Air Coefficient
Fig 3-15 Oxygen Sensor Performance Curve at 600C
Smaller, only a few oxide ion moves from inside to outside, and the output voltage is lower (approximate 100 mV).
Signal voltage changes sharply near the stoichiometric air-fuel ratio (λ=1). See the above illustration.

(1) Limit data
Factor Value Unit

Min. Typical Max.
Storage temperature -40 +100 C
Ceramic tube end 200 850 C
Operation Housing hexagon head 570 C
Temperature Cable metal retaining ring and bond 250 C
cable
Connecting plug 120 C
Max. allowable Exhaust from the ceramic tube end 930 C
temperature when
energizing the
heating element Housing hexagon head 630 C
(10 minutes at a
time at most,
accumulative total
is 40 hours at Cable metal retaining ring and bond 280 C
most) cable
Allowable temperature variation rate of the ceramic tube 100 K/s
end
Ceramic element allowable temperature when condensation 350 C
water is gathered on the exhaust side
Random vibration 800 m/s2
(peak)
Housing allowable Harmonic vibration 0.3 mm
vibration (vibration displacement)
Harmonic vibration 300 m/s2
(vibration acceleration)
350Continuous direct current at 350C Absolute A
value10
Max. continuous alternate current at the exhaust 20 A
temperature350C、f1Hz
Allowable fuel additive Unleaded gasoline, lead tolerance 0.15g/L
Oil consumption and oil combustion The allowable value and data must be confirmed
by proper tests performed by the customers.
Guideline value: 0.7L/1, 000 km
- 64 -
Factor New Follow 250 stand test

Exhaust temperature when meeting the performance data 350C 850C 350C 850C
At =0.97 (CO=1%), 840±70 710±70 840±80 710±70
Sensing element voltage (mV)
At =1.10, 20±50 55±30 20±50 40±40
Sensing element voltage (mV)
Sensing element internal resistance (k)  1．0 0．1 1．5 0．3
Reaction time (ms) <200 <200 <400 <400
(600 mV to 300 mV)
Reaction time (ms) <200 <200 <400 <400
(300 mV to 600 mV)
(3) Sensor electrical data

Factor Value Unit
Insulation resistance between the Room temperature, heating element de-energizes 30 M
new heating element and sensor Exhaust temperature: 350C 10 M
connector Exhaust temperature: 850C 100 k
Rated voltage 12 V
Plug source voltage Continuous operation voltage 12 to 14 V
Operation voltage for maintaining 1% of entire life 15 V
at most (exhaust temperature850C)
Operation voltage lasting 75 seconds at most 24 V
(exhaust temperature350C)
Test voltage 13 V
Heating power when the operation voltage is 13 V and thermal balance is achieved 12 W
(exhaust temperature: 350C, exhaust flow rate: about 0.7 m/s)
Heating current when the operation voltage is 13 V and thermal balance is achieved 5 A
(exhaust temperature: 350C, exhaust flow rate: about 0.7 m/s)
Fusible link of the heating circuit 8 A
(4) Service life

The service life of the oxygen sensor depends on the lead in the gas, see the below chart.
Lead in gas (g/L) Life (km)
0.6 30000
0.4 50000
0.15 80000
0.005 (unleaded gasoline) 160000

 The oxygen should be installed on the exhaust pipe to secure a position which represents the emission content
and can meet the specified temperature limit. Installation position should be close to the engine as possible. The
thread is provided on the exhaust pipe for tightening the oxygen sensor, see the below illustration.
Fig 3-16 Oxygen Sensor Installation Position
- 65 -
 Oxygen sensor installation posture

The oxygen sensor should be installed at a angle of 10 degrees from the level surface with the sensor tip facing down
to avoid the condensation water accumulation between the sensor case and sensing ceramic tube during the cold start.
See the below illustration.
Fig 3-17 Oxygen Sensor Installation Posture
 Requirement for the exhaust pipe: it should be heated rapidly, which locates on the front of the oxygen sensor. If
necessary, the exhaust pipe should be designed to tilt down to avoid the condensation water accumulation in the front
of the sensor.
 Do not heat the cable metal retaining ring (oxygen sensor side) improperly, especially when the engine stops.
 Do not apply washer fluid, oily liquid or volatile solid on the oxygen sensor plug.
 The thread of the oxygen sensor is M181.5.
 The size of the hexagon head wrench of the oxygen sensor is 22-0.33.
 The oxygen sensor tightening torque is 40 to 60 N∙m.

 Trouble symptom: poor idle, poor acceleration, illegal exhaust, more oil consumption etc.
 Normal cause for the malfunction:

1. The moisture enters into sensor, temperature changes sharply and the probe is broken.
2. The oxygen sensor is ―poisoned‖. (Pb, S, Br, Si)
 Service precaution: Do not apply washer fluid, oily liquid or volatile solid on the oxygen sensor during
repairing.
(connector removed) Switch the digital multimeter to OHMMETER position, then connect both probes to 1# (white)、
2# (white) pin of the sensor respectively. The resistance is 2.5~4.5  at normal temperature.
(connector connected) During idling, Switch the digital multimeter to DIRECT VOLTAGE position until the oxygen
sensor temperature reaches 350℃ (operation temperature). Connect both probes to 3# (grey), 4# (black) pin of the
sensor respectively. At this time, the voltage should fluctuate between 0.1-0.9 V rapidly.
3.5 Inductive Speed Sensor
Sketch and pin
Speed sensor
Fig.3-18 Inductive Speed Sensor Fig.3-19 Inductive Speed Sensor Electrical Wiring
Diagram
- 66 -
1. Shield Line 2. Permanent Magnet

3. Sensor Housing 4. Mounting Bracket
5. Soft Magnet Core 6. Coil
7. Air gap 8. 60-2 Ring Gear
Fig 3-20 Inductive Speed Sensor Cross Section
Pin: There are two kinds of inductive speed sensor connectors produced by our company for the M979.8. See the
below illustration.
Accordingly, there are two definitions for the pins. The connector shown in the fig. 3-26 is applied in this system.
Fig. 3-21 Fig. 3-22
No.1 is connected to the shield. No.3 is connected to the shield.

No.2 and No.3 are connected to the signal line. No.1 and No.2 are connected to the signal line.

It is mounted on the flywheel plan at the rear of the engine.

Inductive speed sensor matched with the signal plate is used to supply engine speed information and crankshaft top
dead center information in the distributorless ignition system. The inductive speed sensor consists of a permanent
magnet and the coil around the magnet. Pulse wheel is a gear plate which has 60 gears formerly, but 2 gears are
missed. Signal plate is installed on the crankshaft and rotates with it. When the gear tip closes up to the inductive
speed sensor tip to pass, the pulse wheel which is made of iron magnet material cuts the magnet line of the permanent
magnet in the inductive speed sensor, generates sensing voltage in the coil as a speed signal to output.
- 67 -

(1) Limit data
Factor Value Unit

Min. Typical Max.
Coil area -40 +150 C
Transition area Mixed Mixed C
Bearable Lead area -40 +120 C
temperature for Storage temperature -20 +50 C
PUR lead Ambient temperature without -40 +120 C
inductive speed operation
sensor (see the Long-term ambient temperature in -40 +120 C
below operation
illustration) Short-term 150 hours +150 C
ambient 380 hours +140 C
temperature in
operation
for lead area 150 hours +150 C
entire service 380 hours +140 C
life 1, 130 hours +130 C
Coil area -40 +150 C
Bearable Transition area Mixed Mixed C
temperature for Lead area -40 +130 C
H&S lead Storage temperature -20 +50 C
inductive speed Ambient temperature without -40 +130 C
sensor (see the operation
below Long-term ambient temperature in -40 +130 C
illustration) operation
Short-term ambient temperature in +150 C
operation
for lead area 500 hours +150 C
entire service 200 hours +160 C
life
Anti-vibration ability for 20 to 71 Hz Acceleration40 m/s2
each plane in 168 hours 71 to 220 Hz Amplitude0.2 mm
Allowable magnetic field strength for external field in 2 kA/m
opposite direction
Insulation resistance (10 s, New 1 M
test voltage 100 V) Expiry date for use 100 k
Withstanding voltage(1 to 3 seconds, 1, 200 V alternate) Attack through is not allowed
Lead Area
Transition Area
Coil Area
Fig.3-23 Three Temperature Areas for Speed Sensor

Factor Value Unit

Min. Typical Max.
Resistance at 20C in room temperature 731 860 989 
Inductance 310 370 430 my
Output voltage when crankshaft rotates at 416 rpm 1650 mV
- 68 -

 Inductive speed senor is only allowed to take out from the package material when it is about to be installed on
the vehicle or installed on the testing device.
 The inductive speed sensor is installed by pressing but not tapping.
 It is suggested a M612 bolt with partial micro-encapsulation should be used to fix the inductive speed sensor.
 Tightening torque is 82 Nm.
 Air gap between the inductive speed sensor and signal plate gear tip: 0.8 to 1.2 mm.
 Dimension d (see the following illustration): 4.7 mm.

Size
Fig 3-24 Speed Sensor Installation

 Trouble symptom: Unable to start etc.
 Service precaution: Pressing but not tapping should be used during servicing.
(connector removed) Switch the digital multimeter to OHMMETER position, then connect both probes to 2#、3# pin
of the sensor respectively. The rated resistance is 860 Ω±10% at 20℃.
(connector connected) Switch the digital multimeter to ALTERNATE VOLTAGE position, then connect both probes
to 2#、3# pin of the sensor respectively and start the engine. At this time, voltage should be output. (On-board
oscilloscope is suggested to use when checking)
Fig 3-25 Test Wave Diagram
- 69 -
3.6 Phase Sensor
Sketch and pin
Ground Point
Phase Sensor
Main Relay
Fig.3-26 Phase Sensor Fig.3-27 Phase Sensor Electrical Wiring Diagram
Pin: Mark ―1‖ indicates ground.

Mark ―2‖ indicates signal output.
Mark ―3‖ indicates connection to the power positive.

It is mounted on the camshaft end cover.
This sensor is produced according to the condition that Hall voltage is affected by changed magnetic field induction
strength in the Hall principle.
B
Hall Sensor Principle
A hall voltage UH will be generated in the right
current rotation direction when current I S passes
a semiconductor thin sheet. And the voltage value
is in proportion to the magnetic field induction B
(vertical to current IS) and current IS. Hall voltage
is affected by the changed magnetic field
induction strength B.
I U
S
H
Fig. 3-28 Hall Effect Schematic Diagram
Rotation direction
Phase signal wheel
Output signal
Fig. 3-29 Hall Element working scheme (1) Fig. 3-30 Hall Element working scheme (2)
- 70 -

Limit data
Factor Value Unit
Min. Typical Max.
Ambient temperature -30 +130 C
Installation clearance 0.1 1.8 Mm
Supply voltage 4.5 24 V

Only one hole in the sensor case is available for tightening.
 Trouble symptom: Illegal exhaust, oil consumption increase etc.
(Connector connected) Turn on ignition switch but do not start engine. Switch the digital multimeter to DIRECT
VOLTAGE position, then connect both probes to 3#、1# pin of the sensor respectively. Make sure that 12 V reference
voltage is generated at this time. Start the engine. It is possible to check if the 2# pin signal is normal with an
on-board oscilloscope at this time.
3.7 Electronic Control Unit (ECU)

Power Supply
Ignition Injector 1
5 V output 1 Injector 1
5 V output 1 Injector 1
Main Relay Injector 1
From Diagnosis K Line Malfunction Indication Signal
CAN1H
CAN1L Fuel Pump Relay
Crankshaft Sensor+ A/C Relay
Crankshaft Sensor- Fan 1
Knock Sensor A Step Motor A

Knock Sensor B Step Motor B
Step Motor C
Step Motor D
Intake Pressure Sensor
Upstream Oxygen Sensor
Throttle Position Oxygen Sensor Heating
Coolant Temperature Sensor Oxygen Sensor Heating
Intake Temperature Sensor Canister Control Valve
Downstream Oxygen Sensor Exhaust Gas Recirculation Control
A/C Pressure/Temperature Valve
Acceleration Sensor
Exhaust Gas Recirculation Position
Reserved Input Oil Consumption Output
Reserved Input Speed Output
Battery
Fan 2
Camshaft Signal Reserved
Vehicle Speed Reserved
Electrical Load 1 Reserved
A/C Switch Reserved
ABS
Electrical Load 2
Theft Deterrent Password Ignition control 1
Ignition control 2
Oxygen Sensor Heating
Oxygen Sensor Heating
Fig.3-31 ECU Electrical Principle Schematic Drawing
- 71 -
Fig.3-32 ECU Outline Drawing

It is mounted on the right side of passenger room.

(1) Function
• Multi-port sequential injection
• Ignition control
• Idle control
• Supply power to the sensor: 5 V/100 mA
• Closed loop control (with adaptive function)
• Canister control valve control
• A/C switch
• Engine malfunction indicator light
• Fuel ration trim
• Engine speed signal output (TN signal)
• Vehicle speed signal input
• Trouble self-diagnosis
• Receive engine load signal
etc.
- 72 -
(2) ECU pin definition:
Pin Connect to Type Pin Connect to Type

1 Downstream LSH heated oxygen Output 33 CAN high Input,
sensor (Optional)* output
2 Upstream heated oxygen sensor* Output 34 CAN low Input,
output
3 Ignition coil 1 Output 35 Step motor phase C Output
4 Downstream heated oxygen Output
sensor*
5 Ignition ground Ground 37 Canister control valve Output
6 Upstream LSH heated oxygen Output 38 Reserved Output
sensor (Optional)*
7 Ignition coil 2 Output 39 Sensor ground Ground
8 UBR Input 40 Sensor ground Ground
9 Engine speed output Output 41 Engine coolant temperature Input
10 KO/CBR input Input 42 Phase Sensor Input
11 ABS/IGN input Input 43 Electrical ground Ground
12 Electrical load 1 Input 44 A/C switch Input
13 PAC/TAC Input 45 Upstream oxygen sensor Input
14 Theft deterrent signal input Input 46 Speed signal B Input
15 Diagnosis K-line Output, 47 Speed signal A Input
input
16 UBD Input 48 Power ground Ground
17 Ignition switch Ground 49 Injection 2 Output
18 5 V output 2 Output 50 Injection 1 Output
19 5 V output 1 Output 51 UBR Input
20 MIL light Output
21 Step motor B Output 53 Reserved Output
22 Step motor A Output 54 Reserved Output
23 SVS light/exhaust gas Output 55 Reserved Output
recirculation valve
24 Electrical load 2 Input 56 KVA/TMOT output Output
25 Intake air temperature Input 57 Vehicle signal sensor Input
26 Throttle position sensor Input 58 Exhaust gas recirculation valve Input
position sensor
27 FLS/TOIL input Input 59 Intake pressure sensor Input
28 Acceleration sensor Input 60 Fuel pump relay Output
29 Downstream oxygen sensor Input 61 A/C compressor relay Output
30 Knock sensor A Input 62 Fan 1 Output
31 Knock sensor B Input 64 Injection 3 Output
32 Main relay Output
* The pin is reusable. The actual pin number is subject to the wire harness schematic diagram. (The blank indicates
there is no pin)
- 73 -
Limit data
Factor Value Unit

Min. Typical Max.
Normal operation 9.0 12 16.0 V
Battery voltage Limit function 6.0 to 9.0 12 16.0 to 18.0 V
26.0 V Maintain some functions, trouble 60 s
Limit and time for diagnosis can be performed
tolerant battery over 13.0 V Secure start function, trouble 60 s
voltage diagnosis can be performed
Operation temperature -40 +70 C
Storage Temperature -40 +90 C

 Be sure to avoid the static when installing
 Be sure to protect the plug pin

 Trouble symptom: unsteady idle, poor acceleration, unable to start, high idle, illegal exhaust, difficult to start,
A/C out of service, injector control out of service, flameout, etc.
 Normal cause for the malfunction: 1. The ECU inner components are burnt to fail as the external device
electrical over load. 2. The circuit board is corroded as water enters ECU etc.
 Service precaution: 1. Do not remove the ECU randomly during repairing. 2. Remove the ECU 5 minutes after
removing the battery terminal. 3. Pay attention to store the removed ECU. 4. Never install any wiring routes on the
ECU connecting line.

1. (Connector connected) Use engine data K-line to read engine trouble record.
2. (connector removed) Check if the ECU connecting line is good, and concentrate on checking if the ECU power
supply and ground line are normal.
3. Check if the external sensor operates normally, output signal is reliable and other lines are in good condition.
4. Check if the actuator operates normally and other lines are in good condition.
5. Replace the ECU to have a test at last.
3.8 Electrical Fuel Pump (Type EKP13.5)
Sketch and pin
Fig.3-33 Electrical Fuel Pump Fig.3-34 Electrical Fuel Pump Electrical Wiring Diagram
Pin: Two pins are on the electrical fuel pump, which are connected to the fuel pump relay. ―+‖ and ―-‖ are marked on
the fuel pump housing besides two pins, indicating a connection to the positive and negative respectively.
- 74 -
It is mounted in the fuel tank.
Electrical fuel pump consists of direct current motor, vane pump and end cover etc (integrating with check valve,
pressure relief valve and anti-solenoid interference component). See the following illustration.
The pump and motor are mounted in the same shaft and sealed in the same shield. The pump and motor in the shield
are full filled with gasoline around to radiate heat and lubricate by the fuel. The battery supplies power to the
electrical fuel pump through fuel pump relay that could energize the circuit of the electrical fuel pump only when is
engine started and runs. The fuel pump will stop operating automatically when the engine stops running due to the
malfunction.
Fig 3-35 Electrical Fuel Pump Cross Section
The maximum pressure of the electrical fuel pump outlet is determined by the pressure relief valve, which is between
450 to 650 kPa. But the pressure of the entire fuel system waves with the changing of the intake manifold pressure.
The difference between the system pressure and intake manifold pressure is determined by fuel pressure regulator.
Generally it is 300 kPa.
Electrical fuel pump has different flow according to the request of engine. For easy production, EKP13 series
electrical fuel pump with the same configuration adjusts the motor speed by adjusting the coil turns to regulate the
flow. So the electrical fuel pump for one vehicle model is not allowed to install on another vehicle randomly.
(1) Limit data
Factor Value Unit

Min. Typical Max.
Operation voltage 8 14 V (direct)
System pressure 300 kPa
Outlet pressure 450 650 kPa
Ambient temperature -40 +80 C
(for storage and transport)
Allowable fuel temperature -30 +70 C
Allowable vibration acceleration 20 m/s2

The flow of the electrical fuel pump is in proportion to the voltage under certain pressure of the fuel supply. Different
vehicle manufacturers apply different fuel pump
The weight for EKP 13.5 type electrical fuel pump is 295-305 g.
- 75 -
3.8.4 Installation precaution If you want to return the goods, please provide the fuel
pump with the supply list, inspection list and the
Electrical fuel pump should be stored in the enclosed packing label together. The returned fuel pump should
original packing box. After the pump is installed on the be packed in a specified way. If the fuel pump has been
vehicle, its max. allowable storage time is 6 months, used, clean it with the test liquid and dry it in the air.
and the period is 4 years as component. It is suggested Blow dry is not allowed. For safety, the fuel pump with
that manufacturer should recheck the performance data fuel is not accepted.
for the fuel pump if it exceeds above period. At the
storage place, the fuel pump must be protected not to be 3.8.5 Trouble symptom and diagnosis method
affected by atmosphere. Do not damage the original  Trouble symptom: great operation noise, poor
package during storage. acceleration, unable to start (difficult to start) etc.
EKP 13 series electrical fuel pump is only applied for
the fuel tank. Fuel inlet strainer whose hole dimension  Normal cause for the malfunction: using poor
is not greater than 60  or which is agreed with the quality fuel leads to: 1. colloid cumulated to form an
customer must be installed when installing the fuel insulation layer, 2. fuel pump bushing and armature are
pump. Be careful not to make the fuel spray injected locked, 3. fuel level sensor components are corroded.
from the vent injects to the fuel inlet strainer, fuel pump
bracket or fuel tank wall. Be careful when moving the  Service precaution: 1. Electrical fuel pump may
fuel pump. Firstly, be sure to protect the fuel inlet have different flow according to the engine request. The
strainer from the load and shock. The fuel pump should fuel pump with the same shape and could be installed
be taken out of the plastic packing carefully when it is may be not the appropriate one. The fuel pump
about to be installed. The protective cap can not taken components applied during the service should conform
off until the fuel pump is about to be installed. Never to the original ones. Wrong replacement is not allowed.
take off the fuel inlet strainer, or the foreign material 2. Do not operate the fuel pump in dry status to avoid
entered into the fuel pump inlet or strainer will lead to damage. 3. Be sure to clean the fuel tank and its pipe
damage to the fuel pump. and replace the fuel filter if fuel pump is needed to be
Clean the fuel pipe when installing it. The inside of the replaced.
fuel pipe must be cleaned. Only use a new fuel pipe
clamp. Confirm the correct position of the fuel pipe  Simple measurement method:
clamp, and follow the method recommended by the (Connector removed) Switch the digital multimeter to
producer. OHMMETER position, then connect both probes to two
Do not hold the fuel pump at the fuel pipe or fuel inlet pins of the fuel pump respectively, and measure the
strainer. internal resistance to ensure it is not 0 or infinity (no
Do not operate the fuel pump in dry status to avoid short or open).
damage. Do not use damaged fuel pump and that was
dropped off the ground. Repalce the fuel pump in the (Connector connected) Connect a fuel pressure gauge
fuel tank when fuel tank was dropped off the ground. into the fuel inlet pipe, start the engine, and observe if
Do not apply any pressure to the fuel inlet plate. the fuel pump operates. If it does not operate, check ―+‖
Mechanism stress should not exist in the caulking. The pin to see if it has power supply. If it operates, check if
clamping of the fuel pump should be operated in the the fuel pressure is about 260 kPa during idling. Then
specified range. See the following illustration. pull off the fuel pressure regulator vacuum pipe, check
if the fuel pressure is about 300 kPa.
Fuel Pump Clamping

Allowable Range
Mechanism stress
should not exist in
the caulking.
Fig. Fuel Pump Clamping Allowable Range
- 76 -
3.9 Magnetic Injector

Sketch and pin
Connect to Pin No.7 of the Main

Relay
Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4

Injector
Fig.3-37 Magnetic Injector Fig.3-38 Magnetic Injector Electrical Wiring Diagram
Pin: There are two pins in each injector. One pin marked with ―+‖ on one side of the case is connected to No. 87 pin
on the output side of the main relay and another pin is connected to ECU No.49, 50, 63, 64 pin.
1. O-ring
2. Strainer
3. Injector with Electrical Plug
4. Coil
5. Spring
6. Valve Needle with Coil
Armature
7. Valve Seat with Orifice Plate
Fig.3-39 Injector on the Fuel Distribution Pipe Fig.3-40 Magnetic Injector Cross Section

It is mounted on the intake manifold close to one side of the intake valve.
The ECU sends electric pulse to the injector coil to generate the magnetic field force. When the magnetic field force
increases to overcome the combination of the return spring pressure, needle valve gravity and friction force, the
needle valve begins to lift, and the injection starts. The pressure of the return spring closes the needle valve when the
injection pulse is cut off.
 Type for EV 6 magnetic injector:
-Enlonged type and standard type according to the length
-(single hole, single bundle), C (four holes, tapered) and E (four hole, double bundles) according to the spray shape
 Type selection is determined by the engine and intake manifold configuration.

（1） Limit data
Factor Value Unit

Min. Typical Max.
Storage temperature (original package) -40 +70 C
Allowable temperature for the injector in the vehicle +140 C
(Not operation)
Continuous -40 +110 C
- 77 -
Injector operation Short interval after the hot start +130 C

temperature (about 3 minutes)
Allowable fuel Continuous +70 C
temperature for Short interval (about 3 minutes) +100 C
injector inlet
Temperature at which the deviation of the fuel flow is up -40 +45 C
to 5% comparing that at 20C
Allowable O-ring leakage at -35 to -40C Moistened fuel is ok but not dripping around the
O-ring
Max. allowable vibration acceleration (peak) 400 m/s2
Supply voltage 6 16 V
Insulation resistance 1 M
Tolerant internal fuel pressure 1100 kPa
Tolerant bending stress 6 Nm
Tolerant axial stress 600 N
（2） Performance data
Factor Value Unit

Min. Typical Max.
Operation pressure (pressure difference) 300 kPa
20Injector resistance at 20°C 11．4 12．6 
used when installing. And injector positioning block and

（3） Allowable fuel position pin should be engaged in the corresponding slot
The injector can only use the specified fuel that on the positioning clamp separately.
conforms to the PRC National Standard GB ④ If there are two slots in the injector, be careful not to
17930-1999 Lead-Free Gasoline for Vehicle and engage incorrectly. See the installation position of the
National Environment Protection Standard GWKB original one.
1-1999 Hazardous Material Control Standard for  Install the injector with hands. Never tap it with a
Automobile Gasoline and the detergent is required to hammer etc.
add in the gasoline. It is noted that the gasoline will  O-ring must be replaced when removing and
deteriorate if it is stored for a long time. Especially for installing the injector. Do not damage the seal surface of
the taxi with a LPG and gasoline duel fuel engine, the the injector at this time.
gasoline is only used for starting if the LPG serves as  Do not pull out the supporting washer of O-ring
main fuel, so the daily consumption of gasoline is very from the injector. Avoid damage the injector inlet, O-
little. However, the fuel pump keeps operating in ring, retaining ring, orifice plate and the electric plug. If
driving, so the temperature in the fuel tank is very high. they are damage, do not use.
If the gasoline is stored in the tank of such auto, it is  Check the tightness of the fuel distribution pipe
easy to be oxidized and may block or even damage the assembly after injector installation has completed. No
injector. leakage is allowed.
3.9.4 Installation precaution  Remove the failed component by hands. Remove
 Confirm the BOSCH trade mark and product the injector clamp firstly and then pull out the injector
number. from the injector seat.
 Specified plug should be used in the specified Make sure the injector seat is clean after the removal to
injector. Do not mix them. avoid pollution.
 For easy installation, it is suggested to apply clean 3.9.5 Trouble symptom and diagnosis method
silica-free oil to the upper O-ring surface, which is  Trouble symptom: poor idle running, poor
connected to the fuel distribution pipe. Note that the acceleration, unable to start (difficult to start) etc.
injector interior and injection hole shall not be polluted  Normal cause for the malfunction: Lacking of
by the oil. maintenance leads to colloid cumulation in the injector
 Install the injector to the injector seat vertically interior to make the injector deteriorate.
and fix the injector to the seat with a clamp.  Service precaution: (refer to the installation
NOTICE: ① Injector clamp is divided to axial precaution)
positioning clamp and radial positioning clamp by the  Simple measurement method:
positioning manner. Do not use clamp of wrong type. (Connector removed) Switch the digital multimeter to
②For axial positioning injector installation, make sure OHMMETER position, and then connect both probes to
that the bayonet in the center of the clamp is engaged to both pins of the injector respectively. The rated
the slot of the injector completely, and the slot in both resistance is 11-16 Ω at 20℃.
sides of the clamp is engaged to the edge flange of the SUGGEST: Perform the cleaning analysis of the
injector seat. injector periodically with a special injector cleaning
③ For the injector with the axial positioning and radial tester.
positioning requirement, axial-radial clamp should be
- 78 -
3.10 Idle Actuator Step Motor

Sketch and pin
Fig. 3-41 Idle Actuator Step Motor Fig. 3-42 Idle Actuator Step Motor Electrical Wiring Diagram
Pin: Pin A is connected to ECU No. 22 pin

Pin B is connected to ECU No. 21 pin
Pin C is connected to ECU No. 35 pin
Pin D is connected to ECU No. 36 pin
It is mounted on the throttle block.
As a micro-motor, step motor consists of several steel stators forming a circle and one rotor, see the following
diagram. Each steel stator has one coil around. The rotor is a permanent-magnet, with a nut in its center. Currency
always runs through all the coils of the stators. If the current direction in one coil changes, the rotor will rotate by a
certain angle. A revolving magnetic field would be formed when the current direction in each stator coil are changed
in a proper order, which will make the rotor made of permanent-magnet rotate in a certain direction. If reversing the
order of the changes of current direction, the rotation direction of the rotor will reverse too. The nut in the center of
the rotor connects a screw rod. Because the screw rod can not to rotate, it can only move in axis direction. Therefore,
it is also called linear shaft. A plug at the end of the screw rod can retract or stretch so as to increase or decrease the
sectional area of the idle actuator bypass air intake path until block it. Whenever the current direction in certain coil is
changed, the rotor will rotate a certain angle, which is called step size. The step size value is equal to the number that
360 is divided by the number of stators or coils. The step size of this step motor is 15. Accordingly, the moving
distance of the screw rod in each movement is fixed. ECU controls the movement number of the step motor by
controlling the changing number of current direction in coils so as to adjust the sectional area of the bypass air path
and the air mass flow through it. In general, air mass flow is linear with step size. There is a spring behind the plug at
the end of screw rod. See following diagram. The force available in plug stretching direction is equal to the step
motor force plus that of the spring. While the force available in plug retracting direction is equal to the step motor
force minus that of the spring.
- 79 -
Fig. 3-43 Idle Actuator Step Motor Cross Section

(1) Limit data

Factor Value Unit
Min. Typical Max.
Operation temperature -40 +125 C
Max. allowable number that the step motor 2.0106 times
plug can touch seat

Factor Value Unit
Min. Typical Max.
Resistance of each coil at 25C 47.7 53 58.3 
Resistance of each coil in the range of 35 95（+125C) 
operation temperature （-40C)
Inductance of each coil to 1, 000 Hz at 25C 26.8 33.5 40.2 mH
Normal operation voltage 7.5 12.0 V
Possible operation voltage 3.5 14.0 V
Step size of step motor’s rotor 15 Degree
Pressure drop at both ends of bypass path when 60 kPa
it is open
Maximum axial force made by air pressure 6.28 N
difference

The idle actuator with step motor is installed on the throttle body cast, which forms the bypass path at both ends of
the throttle. See the following figure.
- 80 -
High
Voltage
Low Voltage
Fuel
Fig. 3-44 Installation Figure of Idle Step Motor
 Install it with 2 bolts (M50.814).

 Bolt tightening torque is 4.00.4 Nm.
 Install it with a spring washer, and apply adhesive.
 The shaft of idle actuator with step motor should not be in or below level surface to avoid condensation water.
 Do not apply any force in axial direction to attempt to press in or pull out the shaft.
Before the idle actuator with step motor is installed into the throttle body, its shaft have to be in the fully retraction
position.
 Trouble symptom: idle speed too high, idle stall, etc.
 Normal cause for the malfunction: bypass air path is partially blocked by dust, oil gas, etc. so that step motor
abnormally adjusts its idle speed.
 Service precaution: 1. Do not apply any force in axial direction to attempt to press in or pull out the shaft. 2.
Before installing the idle adjuster with step motor into the throttle, its shaft have to be in fully retraction position. 3.
Keep bypass air path clean and perform maintenance. 4. Perform self learning for step motor without delay after the
removal of battery or ECU.
The self learning method of M7 system: turn on ignition switch but do not start the engine immediately. Wait for 5
seconds and then start the engine. If poor idling of the engine is found, the above procedures should be repeated.
 Simple measurement method: (connector removed) Switch the digital multimeter to OHMMETER position, and
connect both probes to AD, BC pin of the adjuster respectively. The rated resistance is 53±5.3 Ω at 25℃.
- 81 -
3.11 Single Spark Ignition Coil
Sketch and pin
Fig. 3-45 Single Spark Ignition Coil Fig. 3-46 Single Spark Ignition Coil Electrical Wiring Diagram
NOTICE: There are two ignition coils in this system. Each secondary ignition coil connects two cylinders, that is,
Bank 1 and Bank 4 spark simultaneously, Bank 2 and Bank 3 spark simultaneously.
Pin definition:
Bank 1 and Bank 4 ignition coil
Low pressure side: No.1 coil primary winding pin is connected to main relay 87#.
No.1 coil primary winding pin is connected to pin 3# of ECU.
High pressure side: Two secondary winding terminals are connected to spark plug of the same engine cylinder
through distributor respectively.
Bank 2 and Bank 3 ignition coil
Low pressure side: No.2 coil primary winding pin is connected to main relay 87#.
No.2 coil primary winding pin is connected to pin 7# of ECU.
High pressure side: Two secondary winding terminals are connected to spark plug of the same engine cylinder
through distributor respectively.

It is mounted on the engine or vehicle body.
The ignition coil consists of primary winding, secondary winding, iron core and outer housing, etc. When one
primary winding is grounded, it has been charging. Once the primary winding circuit is cut off by ECU, charging is
stopped. At the same time high-voltage electricity is sensed on the secondary winding and makes spark plug
discharge. Different from ignition coil with distributor, both ends of ignition coil secondary winding connect one
spark plug, so the two spark plugs simultaneously spark. Electricity in the two primary winding is ON and OFF
alternately. Accordingly, two secondary winding alternately discharge.
Performance data
Factor Value Unit

Min. Typical Max.
Primary resistance 0.77 0.95 
Coil static parameter Primary inductance 2.25 2.75 my
Secondary resistance 7.57 10.23 K
Secondary inductance 15.30 20.70 H
Coil normal temperature (25℃±5℃) secondary output voltage chart
Power supply voltage Time for continuity Engine speed Secondary output voltage(kV)
(V) (mess) (r/min)
14±0.1 4.41 800±100 ≥34
4.41 2400±100 ≥34
3.84 4000±100 ≥34
3.32 5600±100 ≥32
2.94 7200±100 ≥27.5
- 82 -

 Trouble symptom: unable to start etc.
 Normal cause for the malfunction: too high current causing burn out or damaged under the external force, etc.
 Service precaution: it is prohibited to test ignition function by using "short spark test" during the repairing to
avoid the damage to electronic controller.

(Connector removed) Switch the digital multimeter to OHMMETER position, and then connect both probes to the
two pins of primary winding respectively. At 20℃, the resistance is 0.77-0.95 Ω; the resistance of secondary winding
is 7.57-10.23 kΩ.
3.12 Canister Control Valve
Sketch and pin
To the main relay 87#
Canister Control Valve
Fig. 3-47 Canister Control Valve TEV-2 Fig. 3-48 Canister Control Valve TEV-2 Electrical Wiring Diagram
Pin: Canister control valve only has two pins. One is connected to the pin No.87 at the main relay output end and the
other is connected to the pin No.37 of ECU.

It is mounted in the vacuum line of canister to intake manifold.
1 From Fuel Tank

2 Canister
3 Atmosphere
4 Canister Control Valve
5 To intake Manifold
6 Throttle
∆P=Pu (ambient pressure) – Ps (intake manifold)
Fig 3-49 Canister Control Valve Cross Section Fig. 3-50 Installation Figure of Canister Control Valve
Canister control valve consists of solenoid coil, armature and valve etc. There is a strainer in the entrance. The air
flow through canister control valve, in one hand, is related to the duty ratio of the electric pulse that ECU output to
canister control valve, and in the other hand, it is related to the pressure difference between inlet and outlet of the
canister control valve. Canister control valve is closed when there is no electric impulse.
- 83 -
The flow of different type of canister control valve differs at the duty ratio of 100%, namely, fully open. The
following figure shows two typical flow curves. According to the figure, under the same pressure difference of 200
mbar and with the valve open, the flow of canister control valve is 3.0 m3/h (type A) and 2.0m3/h (type B). (This
model is type B)
Fig. 3-51 Flow chart of Canister Control Valve
Type A
Type B
Flow
Pressure Difference
(1) Limit data
Factor Value Unit

Min. Typical Max.
Operation voltage 9 16 V
Overvoltage for 1 minute 22 V
Minimum starting voltage 7 V
Minimum voltage drop 1.0 V
Allowable operation temperature -30 +120 C
Allowable operation temperature for a short time +130 C
Allowable storage temperature -40 +130 C
Tolerant pressure difference between the inlet and 800 mbar
outlet
Allowable number of turning ON and OFF 108
Allowable vibration acceleration of the product 300 m/s2
Leakage volume when pressure difference is 400 mbar 0.002 m3/h
Factor Value Unit

Min. Typical Max.
Rated voltage 13.5 V
+20C resistance 26 
Current under rated voltage 0.5 A
Frequency of control pulse 30 Hz
Typical Type A 7 ms
control pulse width Type B 6 ms
Flow volume when Type A 2.7 3.0 3.3 m3/h
pressure difference is Type B 1.7 2.0 2.3 m3/h
200 mbar and duty ratio
is 100%
- 84 -

For the connection of canister control valve, canister and intake manifold, see fig. 3-50.
 In order to avoid the transmission of solid-borne noise, it is recommended to install canister control valve on the
hose hanging in the air.
 Make sure that the air flow direction meets the requirement.
 Proper measures (filtering, purifying, etc) have to been taken to avoid foreign matter (such as particulate matter)
to enter the canister control valve from canister or hose.
 Therefore, it is recommended to install a protective filter in the outlet of canister (mesh size <50 m).

 Trouble symptom: functional failure, etc.
 Normal cause for the malfunction: foreign matter enters inside of the control valve causing rust or poor air
tightness, etc.
 Service precaution: 1. Make sure that the air flow direction meets the requirement. 2. Check canister condition
when the replacement of control valve is needed since the black particulate matter is found inside of valve, which
leads to the failure of the control valve. 3. Avoid any objects such as water, oil etc. to enter the valve during repairing.
4 In order to avoid the transmission of the solid-borne noise, it is recommended to install the canister control valve on
the hose hanging in the air.
(Connector removed) Switch the digital multimeter to OHMMETER position, and then connect both probes to the
two pins of canister control valve respectively. The rated resistance is 26±4 Ù at 20℃.
3.13 Fuel Pressure Regulator
Sketch
Fig. 3-52 Fuel Pressure Regulator Fig. 3-53 Fuel Pressure Regulator Cross Section

It is mounted on the fuel distribution pipe assembly.

As shown in figure 3-53, a flexible thin film made of rubber-fiber divides the fuel pressure regulator into two cavities:
upper cavity and lower cavity. The upper cavity is connected to the intake manifold with a hose and a joint at its side.
There is a spring in the upper cavity. The lower cavity is fully of fuel and the fuel from fuel distribution pipe enters
the lower cavity through fuel inlets around the bottom of the pressure regulator. The lower part of thin film is subject
to the fuel pressure of fuel distribution pipe and the upper part is subject to the pressure of intake manifold plus that
of the spring. The thin film can deform and guide valve seat to move, which makes the valve open or close. However,
since the deformation is so slight that spring force is regarded as fixed. Therefore, the open and close of the valve is
mainly determined by the pressure difference between the fuel pressure from lower cavity and the intake manifold
pressure from the upper cavity. Suppose the valve is closed originally. Then since the engine load decrease and the
drop of intake manifold pressure, or since the fuel pressure increase, which leads to the increase of above pressure
difference, finally the thin film is lifted by fuel pressure and the valve opens. Then, fuel returns to the fuel tank
through fuel return port in the center of pressure regulator and fuel pressure drops until the valve is closed. And this
keeps the pressure difference between fuel distribution pipe and intake manifold unchanged in general. This is also
the basic prerequisite for the application of fuel quantities electronically control. In fact, when the fuel flow increases,
there is a slight increase linearly in the pressure difference. When the absolute pressure of intake manifold changes,
there will be also a slight fluctuation in the pressure difference.
- 85 -
(1) Limit data
Factor Value Unit

Min. Typical Max.
Leakage volume when pressure difference is 280 kPa 9 cm3/min
Allowable temperature of continuous operation -40 +110 C
Maximum allowable fuel temperature +85 C
-30C maximum allowable pressure drift (reversible) -2% +5%
+85C maximum allowable pressure drift (reversible) -5% +2%
Maximum allowable acceleration peak 600 m/s2
Maximum allowable pressure pulsating quantity at 100 kPa
the inlet
Factor Value Unit

Min. Typical Max.
Rated pressure difference at flow volume of Q=80 l/h 294 300 306 kPa
Operation pressure variation value when the flow 17.5 kPa
volume changes between 15 and 140 l/h
Flow volume range 10 280 L/h
Slop of performance curve 0.12 kPa/ L/h
(3) Fuel requirement

Fuel pressure regulator can be applied to the fuel stipulated by the PRC National Standard GB 17930-1999 Lead-Free
Gasoline for Vehicle and National Environment Protection Standard GWKB 1-1999 Hazardous Material Control
Standard for Automobile Gasoline.
Fuel pressure regulator also can be applied to the gasoline with the volume percentage of methanol or ethanol below
15%.

 Lightly dip the O-ring into clean, silicone-free engine oil or other lubricants approved by BOSCH.
 Do not deform the pressure regulator valve during its removal and installation.
 When pressure regulator vale is removed and reused, it is necessary to replace the O-ring with a new one. If the
regulator valve is subject to the pressure of over 1, 500 kPa, replace it.
 The pressure regulator valve that has been used in burst test or life test can not be used in the vehicle again.

 Trouble symptom: fuel pressure too low or too high, difficult to start, etc.
 Normal cause for the malfunction: lack of maintenance for a long time, resulting in: 1. strainer blockage, 2.
massive leakage caused by particulate foreign matters, 3. mechanical damage from personal action, etc.
 Service precaution: during the repairing: 1. Never attack membrane with high pressure air. 2. Never clean it with
strongly corrosive liquid. 3. Never make it deformed by external force.
 Connect the fuel pressure gauge to fuel inlet pipe, start the engine, and run the engine at idle condition, check if
the fuel pressure is around 260 kPa. Pull out the vacuum pipe on fuel pressure regulator to see if the fuel pressure is
around 300 kPa.
- 86 -
3.14 Steel Fuel Distribution Assembly
Sketch
Fig. 3-54 Fuel Distribution Pipe Assembly

It is mounted between air inlet pipe and cylinder body.

Fuel distribution pipe assembly consists of fuel distribution pipe (KVS-S), injector (EV) and fuel pressure regulator
(DR). It is used to store and distribute fuel.

(1) Limit data
Factor Value Unit

Min. Typical Max.
Operation temperature when fuel distribution pipe and -40 +80 C
O-ring is connected correctly
Maximum operation temperature under condition of +130 C
soakage for 15 minutes
Maximum allowable peak of vibration acceleration 300 m/s2
For system pressure, refer to the technical parameter of pressure regulator valve. For fuel requirement, refer to the
technical parameter of injector. For airtightness, it is required that there is no oil leakage under operation pressure.
The inside diameter of fuel rubber pipe is Φ8.0±0.2.

 Connect fuel inlet and outlet pipe and rubber pipe with a clamp securely, and choose the clamp that matching the
rubber pipe to make sure the connection of fuel inlet pipe and rubber pipe is tight.
 Make sure there is no crack, damage, pit, burr and corrosion on the fuel inlet pipe wall.
 Before the assembly of fuel distribution pipe assembly, lubricate lower O-ring of the injector with clean
lubricant oil.
The airtightness of fuel distribution pipe can be tested by pressure drop method: perform test for O-ring of fuel
distribution pipe injector, the limit value of leakage test is ≤1.5 cm3/min at 4.5 bar.
Section 4 M7 System Performs Inspection and Diagnosis Procedure According to

Trouble Code
NOTE: 1. Perform inspection when current steady trouble is confirmed. Otherwise, it will lead to wrong diagnosis.
2. ―Multimeter‖ mentioned below refers to digital multimeter. Never perform inspection for electronic
injection system by using pointer type multimeter.
3. When inspecting the vehicle with theft deterrent system, if the ―following step‖ is the replacement of ECU,
program the ECU after replacement.
4. If trouble code indicates that the voltage of certain circuit is too low, it means that there may be a short to
ground or open in the circuit. If trouble code indicates that the voltage of certain circuit is too high, it means that there
may be a short to power supply in the circuit. If trouble code indicates certain circuit is malfunction, it means that
there may be an open in the circuit or there are many malfunctions in different lines.
- 87 -
Troubleshooting help: 1. If the trouble code can not be cleared, the malfunction is steady trouble.
If the malfunction is occasional, the priority should be given to check the connection of wire
harness to see if it is loose.
2. Inspection has been completed according to the steps above, and no abnormal condition has
been found.
3. Do not ignore the influence from the condition of vehicle maintenance, cylinder pressure,
mechanical ignition timing, etc to the system during the inspection.
4. Replace ECU, and perform the test.
If trouble code can be cleared, malfunction occurs on the ECU. If trouble code still can not be
cleared, restore the original ECU, and repeat above procedures and perform inspection again.
Instructions for scan tool or tester mode: OBD system can provide much information related to malfunction
diagnosis, and this information is of high value for references when inspecting the electronic injection system.
According to the definition of ISO/DIS15031-5 (International Standard of Automotive Industry), the information
related to OBD system is provided in 9 different services/modes and can be obtained by using diagnostic equipment
which meets the requirement of ISO/DIS15031-4. The main functions of each model are as follows:
- 01 Read the current diagnostic data of power system
- 02 Read the freeze frame data
- 03 Read the DTCs of systems related to emission.
- 04 Clear and reset the diagnostic information related to emission.
- 05 Read the result of oxygen sensor test
- 06 Read the result of specific monitoring system OBD
- 07 Read the current DTC or the monitoring DTC of OBD system during last driving cycle
- 08 Component test (without forcible requirement)
- 09 Read the identification number of vehicle and software
What needs to note is that the content read by scan tool or diagnostic equipment belongs to one of the modes above,
though different scan tool or diagnostic equipment may different in design and usage.
After the malfunction is confirmed, its DTC then will display in mode 3. All the DTCs that occur in current driving
cycle or occurred in last driving cycle will display in mode 7.
The following are the DTC meaning, corresponding diagnostic strategies and possible cause of malfunction, and the
strategies to deal with troubles, which are used in M7.8 system currently. They can be considered as a reference
during the repairing
All the ECU pins mentioned below in this program is based on the practical wiring diagram.
Trouble code: P0030 Open in the Upstream Oxygen Sensor Heating Control Circuit
Procedure 1: Use tester to read ―Mode 3‖ and ―Mode 7‖

Display indication 1 Display indication 2
Mode 3 Mode 7 Mode 3 Mode 7
Abnormal Normal Normal Abnormal
P0030 P0030
Service tip: Service tip:
The malfunction is confirmed and may be The malfunction is not confirmed and may be
resulted from the following problems intermittent problems, then check the following
1) Open circuit between the ECU terminal and items
the upstream oxygen sensor terminal 2 1) Measure the resistance between the ECU
2) Open circuit between the upstream oxygen socket connector and the upstream oxygen
sensor terminal 1 and the main relay sensor terminal 2, and determine whether it is
3) Open circuit between the terminal 1 and normal
terminal 2 of the upstream oxygen sensor 2) Measure the resistance between the upstream
oxygen sensor terminal 1 and the main relay,
determine whether it is normal
3) Measure the resistance between the terminal
1 and terminal 2 of the upstream oxygen sensor,
determine whether it is normal
- 88 -
Trouble Code: P0031 Short to Ground in the Upstream Oxygen Sensor Heating Circuit

P0031 P0031
1) Short to ground in the circuit to ECU items
terminal 1) Measure and check if the ground resistance
of the ECU terminals circuit is normal
Trouble Code: P0032 Short to Power Supply in the Upstream Oxygen Sensor Heating Circuit

P0032 P0032
1) Short circuit between the circuit to ECU items
terminal and the upstream oxygen sensor 1) Measure and check if the voltage values of
terminal 1 ECU are normal
2) Short circuit between the circuit to ECU 2) Measure the resistance between the ECU
terminal and other power supply circuits terminal and the upstream oxygen sensor
terminal 1
Trouble Code: P0036 Open in the Downstream Oxygen Sensor Heating Circuit

P0036 P0036
1) Open circuit between the ECU terminal and items
the downstream oxygen sensor terminal 2. 1) Measure the resistance between the ECU
2) Open circuit between the downstream socket connector and the downstream oxygen
oxygen sensor terminal 1 and the main relay sensor terminal 2
3) Open circuit between the terminal 1 and 2) Measure the resistance between the
terminal 2 of the downstream oxygen sensor downstream oxygen sensor terminal 1 and the
main relay
3) Measure the resistance between the terminal
1 and terminal 2 of the downstream oxygen
sensor
- 89 -
Trouble Code: P0037 Short to Ground in the Downstream Oxygen Sensor Heating Circuit

P0037 P0037
1) Short to ground in the circuit to ECU items
terminal 1) Measure and check if the ground resistance
of the ECU terminals circuit is normal
Trouble Code: P0038 Short to Power Supply in the Downstream Oxygen Sensor Heating Circuit

P0038 P0038
terminal and the downstream oxygen sensor 1) Measure and check if the voltage values of
terminal 1 the ECU terminals are normal
2) Short circuit between the circuit to ECU 2) Measure the resistance between the ECU
terminal and other power supply circuits terminal and the downstream oxygen sensor
terminal 1
Trouble Code: P0053 Upstream Oxygen Sensor Heating Inherent Resistance is Inaccurate
Diagnostic instruction for oxygen sensor heater: the system identifies and determines whether the heating output is
correct by measuring the heater resistance of the sensor. Under some unfavorable condition, the heated sensor will be
damaged by condensation, especially at the cold start stage.
Therefore, the primary catalytic converter sensor is heated directly after the start of the engine. While the secondary
catalytic converter sensor is heated only when theoretical temperature in the catalytic converter is above 308℃.

P0053 P0053
The malfunction is confirmed and may be If the malfunction is not confirmed by the
resulted from the following problems system, please wait for the final diagnosis
1) Upstream oxygen sensor heating function result.
fails, replace oxygen sensor.
- 90 -
Trouble Code: P0054 Downstream Oxygen Sensor Heating Inherent Resistance is Inaccurate
Diagnostic instruction for oxygen sensor heater: the system identifies and determines whether the heating output is
correct by measuring the heater resistance of the sensor. Under some unfavorable condition, the heated sensor will be
damaged by condensation, especially at the cold start stage.
Therefore, the primary catalytic converter sensor is heated directly after the start of the engine. While the secondary
catalytic converter sensor is heated only when theoretical temperature in the catalytic converter is above 308℃.

P0054 P0054
resulted from the following problems system, please wait for the final diagnosis
1) Downstream oxygen sensor heating function result.
fails, replace oxygen sensor.
Trouble Code: P0105 Intake Pressure Sensor Signal is not Changing.

P0105 P0105
The malfunction is confirmed and may be The malfunction is not confirmed and maybe
resulted from the following problems the ice has been melted, then check the
1) The intake pressure sensor is iced or blocked following items
2) The intake pressure sensor is deteriorated 1) Melt the ice in the sensor under ambient
seriously temperature and then install the sensor again.
Use tester ―mode 1‖ to read the pressure after it
is started.
Trouble Code: P0106 ―Intake Pressure Sensor Signal is Unreasonable‖

P0106 P0106
resulted from the following problems intermittent problems Check the following
1) The sensing element in pressure sensor is air items:
leak 1) Since the pressure sensor is free voltage
2) The pressure sensor is damaged style, it can not be diagnosed by reading the
3) The installation position of pressure sensor is pressure parameter in the tester, therefore, wait
air leak for the final diagnosis result from the system.
4) There is a characteristic deviation in pressure
sensor
- 91 -
Trouble Code: P0107 ―Intake Pressure Sensor Circuit Low Voltage‖

P0107 P0107
1) ECU detects that there is a short to ground in items
the sensor signal circuit 1) The resistance between ECU terminal and
ground
Trouble Code: P0108 ―Intake Pressure Sensor Circuit High Voltage‖

P0108 P0108
1) ECU detects that there is a short to power items
supply in the sensor signal circuit 1) The voltage of ECU terminal
Trouble Code: P0112 Intake Temperature Sensor Signal Low Voltage

P0112 P0112
1) Short to ground in the sensor signal circuit to items
ECU terminal 1) Measure the resistance between the sensor
signal circuit of ECU terminal and ground
Trouble Code: P0113 Intake Temperature Sensor Signal High Voltage

P0113 P0113
1) Short to ground in the sensor signal circuit to items
ECU terminal 1) Measure and check if the sensor signal
circuit voltage of ECU terminal is normal
- 92 -
Trouble Code: P0116 ―Indicating Temperature of Engine Coolant Temperature Sensor is Unreasonable‖

P0116 P0116
resulted from the following problems system, please wait for the final diagnosis result
1) The water temperature sensor is damaged
and needs to be replaced.
Trouble Code: P0117 Engine Coolant Temperature Sensor Circuit Low Voltage

P0117 P0117
terminal and ground 1) Measure the resistance between ECU
terminal and ground.
Trouble Code: P0118 Engine Coolant Temperature Sensor Circuit High Voltage

P0118 P0118
terminal and other power supply circuits 1) Measure and check if the voltage values of
the ECU terminals are normal
Trouble Code: P0122 Throttle Position Sensor Circuit Voltage is below the Minimum Value

P0122 P0122
1) Short to ground in the ECU terminal items
1) Measure the resistance between ECU
terminal and ground
- 93 -
Trouble Code: P0123 Throttle Position Sensor Circuit Voltage is above the Maximum Value

P0122 P0122
terminal and other power supply circuits 1) Measure and check if the voltage values of
the ECU terminals are normal
Trouble Code: P0130 ―Upstream Oxygen Sensor Signal is Unreasonable‖
Introduction of malfunction cause: when the following conditions of the upstream oxygen sensor signal occur, it is
determined that the upstream oxygen sensor signal is unreasonable.
Upstream oxygen sensor signal maintains in the lower voltage range (0.1~0.4 V) for a long time while the voltage of
downstream oxygen sensor signal always stays above 0.5 V.
Upstream oxygen sensor signal maintains in the higher voltage range (0.6~1.5 V) for a long time while the voltage of
downstream oxygen sensor signal always stays below 0.1 V.
The upstream oxygen sensor signal circuit is coupled with the heating circuit.

P0130 P0130
The malfunction is confirmed and may be If the malfunction is not confirmed finally,
resulted from the following problems please wait for the final check of ECU
1) Check if the socket connectors of oxygen
sensor are right and normal.
2) Check if the upstream oxygen sensor signal
circuit is coupled with the heating circuit.
Trouble Code: P0131 ―Upstream Oxygen Sensor Circuit Low Voltage‖

P0131 P0131
1) Short to ground in the signal circuit to ECU items
terminal 1) Measure the resistance between the signal
circuit to ECU terminal and ground
- 94 -
Trouble Code: P0132 ―Upstream Oxygen Sensor Circuit High Voltage‖
Introduction of malfunction cause: The ECU measures the voltage of upstream oxygen sensor circuit after the engine
is started. When the signal voltage is above 1.5 V for a long time, it is determined that there is a short to power supply
in the upstream oxygen sensor signal circuit.

P0132 P0132
1) Short circuit between the signal circuit to items
ECU terminal and the oxygen sensor terminal 1) Measure the resistance between the signal
1. circuit to ECU terminal and the oxygen sensor
2) Short circuit between the signal circuit to terminal 1
ECU terminal and other power supply circuits 2) Measure the voltage of signal circuit to ECU
terminal
Trouble Code: P0133 Upstream Oxygen Sensor is deteriorated
Introduction of malfunction cause: The air fuel ratio of the air fuel mixture is switched between Lean and Rich.
Accordingly, the amplitudes of the oxygen sensor signal will fluctuate continuously. After the deterioration of the
oxygen sensor, its sensitivity to the mixture gas drops, which will cause the period of the signal fluctuation slower.
The ECU calculates the signal average period according to its corresponding algorithm. If the actual period is slower
than the critical value preset, it is determined that the sensor is deteriorated.

P0133 P0133
1) The sensor is deteriorated and needs to be
replaced
Trouble Code: P0134 ―Upstream Oxygen Sensor Signal Malfunction‖
Introduction of malfunction cause: The ECU measures the voltage of upstream oxygen sensor circuit after the engine
is started. When the signal voltage always fluctuates in the range of 0.4~0.6 V, the system determines there is an open
in the upstream oxygen sensor signal circuit.

P0134 P0134
1) Open circuit between the oxygen sensor and items
ECU terminal 1) Measure the resistance between ECU socket
2) Oxygen sensor socket connector has poor connector and oxygen sensor 4
contact (the pins are oxidized)
- 95 -
Trouble Code: P0136 Downstream Oxygen Sensor Signal Unreasonable
Instruction of malfunction cause: The upstream oxygen sensor signal circuit is coupled with the heating circuit.

P0136 P0136
1) Check if the socket connectors of oxygen
sensor are right and normal.
2) Check if the upstream oxygen sensor signal
circuit is coupled with the heating circuit.
Trouble code: P0137 Downstream Oxygen Sensor Signal Circuit Low Voltage

P0137 P0137
1) Short to ground in the signal circuit to ECU items
terminal 1) Measure the resistance between the signal
circuit to ECU terminal and ground
Trouble code: P0138 Downstream Oxygen Sensor Signal Circuit High Voltage
Introduction of malfunction cause: The ECU measures the voltage of downstream oxygen sensor circuit after the
engine is started. When the signal voltage is above 1.5 V for a long time, it is determined that there is a short to power
supply in the downstream oxygen sensor signal circuit.

P0138 P0138 P0138
1) Short circuit between the signal circuit to items
ECU terminal and the oxygen sensor terminal 1) Measure the resistance between the signal
1. circuit to ECU terminal and the oxygen sensor
2) Short circuit between the signal circuit to terminal 1
ECU terminal and other power supply circuits 2) Measure the voltage of signal circuit to ECU
terminal
- 96 -
Trouble code: P0140 Downstream Oxygen Sensor Circuit Signal Malfunction

Introduction of malfunction cause: The ECU measures the voltage of downstream oxygen sensor circuit after the
engine is started. When the signal voltage always fluctuates in the range of 0.4~0.6 V, the system determines there is
an open in the downstream oxygen sensor signal circuit.

P0140 P0140
1) Open circuit between the oxygen sensor and items
ECU terminal 1) Measure the resistance between ECU
2) Oxygen sensor socket connector has poor connector and oxygen sensor 4
contact (the pins are oxidized)
Trouble code: P0170 Air-fuel Ratio Closed Loop Control Self Learning Value Detected by the lower Line
is Unreasonable
Trouble code: P0171 Air-fuel Ratio Closed Loop Control Self Learning Value Detected by the Lower
Line is Leaner
Trouble code: P0172 Air-fuel Ratio Closed Loop Control Self Learning Value Detected by the Lower
Line is Richer
(NOTE: The inspection procedures are for the situation where the DTCs of intake pressure sensor, canister control
valve and oxygen sensor, etc. do not occur simultaneously. If the relative trouble code exists simultaneously, deal
with the other troubles firstly, and then check if the oil lines are normal.）
Trouble code: P0201 Open in the Cylinder 1 injector control circuit

Trouble code: Open in the P0202 Cylinder 2 injector control circuit

P0201 P0201
1） The injector coil is open or not items
2） The connection between the injector 1） The injector coil is open or not
connector terminal and the ECU terminal is 2） The connection between the injector
good or not connector terminal and the ECU terminal is
3 ） The connection between the injector good or not
connector terminal and the main relay is good 3) The connection between the injector
or not connector terminal and the main relay is good
or not
Trouble code: P0261 Short to Ground in the Cylinder 1 Injector Control Circuit
- 97 -

P0261 P0261
1) Short to ground in each drive circuit to ECU items
terminal 1) Measure the ground resistance in the ECU
terminal circuit
Trouble code: P0262 Short to Power Supply in the Cylinder 1 Injector Control Circuit

P0262 P0262
resulted from the following problems. resulted from intermittent problems, then check
1) Short to other power supplies in the ECU the following items
terminals circuit. 1) Measure the voltage in the ECU terminals
circuit
DTC: P0300 Multiple Cylinders Misfire May Occur

DTC: P0301 Cylinder 1 Misfire May Occur
Cause of the malfunction: Misfire means that combustion in the cylinders cannot stop or occur in a cylinder for
ineffective energy releasing of engine ignition (failed ignition), deviation of fuel injection (lean air-fuel mixture), low
cylinder compression pressure or other factors, which will cause emission deterioration or catalytic converter too hot
to damage. In terms of OBD system, it refers to a malfunction identified by the system when the number of misfires
is over the specified level.

Display Indication 1 Display Indication 2
P030x P030x
resulted from the following problems system, please wait for the final result.
1) Clean the injector(s)
2) Clean the inlet port(s)
3) Valve leaks
4) Ignition system malfunction（Inspect and
replace spark plug(s), distributor(s))
5) Worn cylinder(s)
- 98 -
DTC: P0317 Rough Road ABS Detection Signal Failure
Cause of the malfunction: The signal from ABS wheel speed sensor is abnormal, so it cannot detect the rough road.

P0317 P0317
resulted from the following problems resulted from intermittent problems, then check
1) Check the ABS wheel speed signal the following items
DTC: P0318 Rough Road Detection Sensor Signal Failure
Cause of the malfunction: Acceleration sensor failure may be determined if the detected acceleration was out of the
specified range; rough road shouldn’t be detected by the acceleration sensor after the vehicle has stopped for a period,
such as 10 seconds.
Otherwise, the system will determine that there is acceleration sensor failure.

P0318 P0318
1) Short to ground in the ECU terminals circuit the following items
2) Short or open to power supply in the ECU 1) Inspect the ground resistance in the ECU
terminals circuit terminals circuit
3) Loosen installation position or support of the 2) Measure the voltage in the ECU terminals
acceleration sensor circuit
4) The acceleration sensor is damaged 3) Inspect the installation position or support
conditions of the acceleration sensor
DTC: P0321 Speed Sensor Reference Point Failure
Cause of the malfunction: The 60-2 teeth speed test system is adopted. The 60-2 sensing ring gear is installed on the
flywheel, and it’s rotating (equal speed with crankshaft) with the flywheel causes magnetic flux changing in speed
sensor to create induced AC voltage, whose frequency is determined by the rotating speed. ECU signal circuit will
change the input sine wave into rectangular wave. Then reference position will be found if the ECU discovered that
the distance between the falling edges of two rectangular waves is longer than two gear pitches. The reference gear
pitch is corresponding physically to a position of a cylinder. The second falling edge after the reference gear pitch is
defined as the software reference signal (BM) in the system, and the crankshaft rotation angle between the distance of
the software reference point signal and TDC is fixed at 108°CA. So the system will receive a software reference point
signal per crankshaft revolution, and keep synchronization with crankshaft position according to the software
reference point signal, then to ensure precise fuel injection, air intake and ignition timing.
There is a crankshaft software reference point signal (BM) failure if one of the following occurs:
1. Detected crankshaft software reference point signal (BM) is often advanced or lag behind than expected position;
2. Rotation speed signal is detected but no crankshaft software reference point signal (BM);
3. Missing crankshaft software reference point signal (BM) frequently.
- 99 -

P0321 P0321
The malfunction is confirmed and may be This failure occurs due to intermittent short or
resulted from the following problems open in the circuit connection, and needn’t to
1) Intermittent short or open in the circuit perform a diagnostic check before final
connection confirmation. Please wait for the final result.
2) Installation position of crankshaft signal
rotor is deviated.
3) Installation position of rotation speed sensor
is deviated.
DTC: P0322 No Speed Sensor Pulse Signal (Open or Short)

Cause of the malfunction: When cranking the engine, the ECU monitors speed sensor signal and phase sensor signal
at the same time. If receiving phase sensor signals continuously but no speed sensor signal, the system will determine
that speed sensor signal is missing.

P0322 P0322
1) Open circuit between speed sensor and the the following items
ECU 1) Circuit resistance between speed sensor and
2) Short circuit between speed sensor and the the ECU
ECU 2) Circuit voltage between speed sensor and the
3) Speed sensor coil open ECU
3) The resistance of speed sensor coil
DTC: P0327 Knock Sensor Signal Circuit Low Voltage
Cause of the malfunction: Knock sensors are fitted onto the engine block and vibrate with different frequencies under
different engine conditions, generating various voltage signals. Different voltage signals not only reflect whether
spark knock occurs, but also indicate the background noise levels (Mechanical parts). While the engine and the knock
sensors operate normally, the background noise value fluctuates in proper range. Once the value is below the setup
value, the system will determine that there is a failure in the knock sensor signal circuit.

P0327 P0327
resulted from the following problems system, check the following items
1) Open or short to ground in the knock sensor 1) Check the resistance in the knock sensor
(terminal 1) circuit to the ECU terminal (terminal 1) circuit to the ECU
2) Open or short to ground in the knock sensor 2) Check the resistance in the knock sensor
(terminal 2) circuit to the ECU terminal (terminal 2) circuit to the ECU
- 100 -
DTC: P0328 Knock Sensor Signal Circuit High Voltage
Cause of the malfunction: Knock sensors are fitted onto the engine block and vibrate with different frequencies under
different engine conditions, generating various voltage signals. Different voltage signals not only reflect whether
spark knock occurs, but also indicate the background noise levels (Mechanical parts). While the engine and the knock
sensors operate normally, the background noise value fluctuates in proper range. Once the value is over the setup
value, the system will determine that the failure of mechanical parts occurred.

P0328 P0328
1) Some mechanical parts in the engine are
worn seriously. Please inspect them (such as
piston ring, piston pin, bearing bush, parts
clearances).
DTC: P0340 Phase Sensor Installation Position Incorrect
DTC: P0341 Phase Sensor Poor Contact
Cause of the malfunction: Hall element is used in the phase sensor to sense the trigger wheel rotating with the
camshaft together, so the phase sensor can monitor the positions of camshaft. The phase signals received by the ECU
should be alternately change at a regular cycle between high level and low level. If the ECU detects slow changes
between high level and low level or irregular changes, the system will determine there is a malfunction of phase
signal.

P0340 P0340
1) Phase sensor installation position is poor the following items
2) Phase sensor wire harness socket 1) Phase sensor installation position (such as
connector has poor connection angle, clearance to the trigger wheel)
2) The connection condition of Phase sensor
wire harness socket connectors (firm pins
engagement and oxygenation)
DTC: P0342 Phase Sensor Short to Ground
camshaft together, so the phase sensor can monitor the positions of camshaft. The phase signals received by the ECU
should be alternately change at a regular cycle between high level and low level. If the ECU detects continuous phase
signals at low level, the system will determine that short to ground occurs in the phase signal circuit.
- 101 -

P0342 P0342
1) Short in the circuit from phase sensor the following items
(terminal 3) to the ECU 1) Inspect the ground resistance in the ECU
2) Short to ground in the circuit to the ECU terminals circuit
2) Check the resistance in the phase sensor
(terminal 3) circuit to the ECU
DTC: P0343 Phase Sensor Power supply short circuit

camshaft, so the phase sensor can monitor the positions of camshaft. The phase signals received by the ECU should
change alternately at a regular cycle between high level and low level. If the ECU detects continuous phase signals at
high level, the system will determine that a power supply short circuit occurs in the phase signal circuit.

P0343 P0343
1) Short in the phase sensor (terminal 1) circuit the following items
to the ECU 1) Measure the voltage of the ECU terminals
2) Short in other power supply circuits to the 2) Check the resistance in the phase sensor
ECU (terminal 1) circuit to the ECU terminals
DTC: P0420 Three-way Catalytic Converter Oxygen Storage Capacity Deterioration (Emission Deterioration)
Cause of the malfunction: There is a direct correlation between the efficiency of t hree-way catalyst and its oxygen
storage capacity. The output value of the downstream oxygen sensor is an indication of the oxygen storage capacity
of the TWC. The bigger the value is, the worse the capacity and the efficiency of the t hree-way catalyst are. The
diagnosis system monitors the voltage vibration of downstream oxygen sensor to determine whether the deterioration
of TWC has occurred, when the vibrating range of voltages is out of specified limits.

P0402 P0402
resulted from the following problems system, please wait for the final result.
1) Low efficiency of the three-way catalytic
converter may result in emission
deterioration.
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DTC: P0444 Canister Control Valve Control Circuit Open

P0444 P0444
1) Open circuit between the ECU and the the following items
canister control valve terminal 2 1) Measure the resistance between the ECU
2) Open circuit between the canister control socket connector and the canister control valve
valve terminal 1 and the main relay terminal 2
3) Open in the solenoid coil between the 2) Measure the resistance between the canister
canister control valve terminal 1 and terminal 2 control valve terminal 1 and the main relay
3) Measure the resistance between the canister
control valve terminal 1 and terminal 2
DTC: P0458 Canister Control Valve Control Circuit Voltage Low

P0458 P0458
1) Short to ground in the circuit to the ECU the following items
1) Measure and check if the resistance of the
ECU terminals to the ground is normal
DTC: P0459 Canister Control Valve Control Circuit Voltage High

P0459 P0459
1) Short circuit between the ECU and the the following items
canister control valve terminal 1 1) Measure and check if the voltage values of
2) Short among the ECU terminals and other the ECU terminals are normal
power supplies circuits 2) Measure the resistances among the ECU
terminals and the canister control valve
terminal 1
DTC: P0480 Open in Cooling Fan Relay Control Circuit (Low Speed)
DTC: P0481 Open in Cooling Fan Relay Control Circuit (High Speed)
DTC: P0691 Short to Ground in the Cooling Fan Relay Control Circuit (Low Speed)
DTC: P0692 Short to Power Supply in the Cooling Fan Relay Control Circuit (Low Speed)
DTC: P0693 Short to Ground in the Cooling Fan Relay Control Circuit (High Speed)
DTC: P0694 Short to Power Supply in the Cooling Fan Relay Control Circuit (High Speed)
Cause of the malfunction: The circuit control module in the ECU measures the voltage in the cooling fan relay
control circuit after engine start. If the measurement result of the voltage or current meets the value in different failure
models, it will be determined as a malfunction in the relay circuit.
- 103 -

P0480 P0480
1) Open / short to ground / short to power the following items
supply between the ECU and the cooling fan 1) Measure the resistance between the ECU
relay socket connector and the relay terminal
2) Open between the cooling fan relay and the 2) Measure the resistance between the cooling
main relay fan relay and the main relay
3) Open in the solenoid coil of the cooling fan 3) Measure the resistance between the cooling
relay fan relay terminals
DTC: P0501 Vehicle Speed Sensor Signal Inaccurate
Cause of the malfunction: While the vehicle is driving by releasing the accelerator pedal with D gear, the ECU
monitors the engine speed and the vehicle speed. If the engine speed is high but the vehicle speed is displayed at zero
or absolutely low, the system will determine there is a malfunction of vehicle speed signal.

P0501 P0501
1) Short to ground or open between the ECU the following items
and vehicle speed sensor signal circuit 1) Measure the resistance between the ECU
socket connector and the vehicle speed sensor
signal circuit
2) Measure the circuit resistance of the ECU
terminal to the ground
DTC: P0506 Idling Control Speed Lower than Object Idling Speed
Cause of the malfunction: engine idling speed is dominated by the closed loop control. If the ECU performs idling
speed control for a moment, but the engine speed is still lower than object idling speed, the malfunction is
determined.

P0506 P0506
resulted from the following problems intermittent problems
1) Stepping motor stuck at small opening angle
2) Inspect the function of relative
components, such as throttle adjusting
screws, accelerator cable and throttle
operation
3) Throttle body is too dirty
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DTC: P0506 Idling Control Speed Higher than Object Idling Speed
Cause of the malfunction: engine idling speed is dominated by the closed loop control. If the ECU performs idling
speed control for a moment, but the engine speed is still higher than object idling speed, the malfunction is
determined.

P0507 P0507
resulted from the following problems intermittent problems
1) Inspect the function of relative
components, such as throttle adjusting
screws, accelerator cable and throttle
operation
2) Throttle body is too dirty
3) Stepping motor stuck at large opening angle
4) Inspect if the vent of positive crankcase
ventilation has dropped off or air leakage
DTC: P0508 Step Motor Drive Terminal Short to Ground

DTC: P0509 Step Motor Drive Terminal Power supply short circuit
DTC: P0511 Step Motor Drive Terminal Open
Cause of the malfunction: The circuit control module in the ECU continuously monitors the voltage in the idle step
motor drive circuit after engine start. If short to ground / short to power supply / open happens in one of the four
circuits, it will be determined as a malfunction in the step motor circuit.

P0508 P0508
1) Short to ground / short to power supply / items
open happens in one of the drive circuits of step 1) Measure the resistance or voltage between
motor to the ECU the drive circuit of each step motor to the ECU
and the ground
DTC: P0560 System Battery Voltage Signal Inaccurate

DTC: P0562 System Battery Voltage Low
DTC: P0562 System Battery Voltage High

P0560 P0560
1) The generator has been damaged and cannot items
generate electricity or Current in battery leaks 1) Inspect the power generation capacity of the
2) Open in the engine field circuit generator (measure the voltage of generator
3) The generator regulator has been damaged after start)
and cannot control the generated power
resulting in high voltage output.
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DTC: P0627 Open in the Fuel Pump Relay Control Circuit

DTC: P0628 Short to Ground in the Fuel Pump Relay Control Circuit
DTC: P0629 Short to Power Supply in the Fuel Pump Relay Control Circuit

P062X P062X
1) Open / short to ground / short to power items
supply between the fuel pump relay control 1) Measure the voltage or resistance in the fuel
circuit to the ECU and the fuel pump relay pump relay control circuit to the ECU
2) Open between the fuel pump relay and the 2) Measure the resistance between the fuel
main relay pump relay and the main relay
3) Open in the solenoid coil of the fuel pump 3) Measure the resistance between the fuel
relay pump relay terminals
DTC: P0645 Open in the A/C Compressor Relay Control Circuit

DTC: P0646 Short to Ground in the A/C Compressor Relay Control Circuit
DTC: P0647 Short to Power Supply in the A/C Compressor Relay Control Circuit

P064X P064X
supply between the A/C compressor relay 1) Measure the resistance or voltage in the A/C
control circuit to the ECU and the A/C compressor relay control circuit to the ECU
compressor relay 2) Measure the resistance between the A/C
2) Open between the A/C compressor relay and compressor relay and the main relay
the main relay 3) Measure the resistance between the A/C
3) Open in the solenoid coil of the A/C compressor relay terminals
compressor relay
DTC: P0650 MIL Drive Circuit Malfunction

P0650 P0650
supply in the MIL drive circuit to the ECU 1) Measure the resistance or voltage in the MIL
2) Open between the MIL and the main relay drive circuit to the ECU
3) MIL is burned out
- 106 -
DTC: P1651 SVS Indicator Drive Circuit Malfunction

P0650 P0650
supply in the SVS indicator drive circuit to the 1) Measure the resistance or voltage in the SVS
ECU indicator drive circuit to the ECU
2) Open between the SVS indicator and the
main relay
3) The SVS indicator is burned out
DTC: P2177 Air Fuel Ratio Closed Loop Control Learning Value Exceeding Upper Limit
DTC: P2178 Air Fuel Ratio Closed Loop Control Learning Value Exceeding Lower Limit
Operation and cause of the malfunction: Air fuel ratio of the air-fuel mixture should be controlled at 14.7:1 to keep
the best comprehensive efficiency of TWC to convert the HC, CO and NOx. Air fuel ratio maybe deviate the value
14.7:1 to a certain degree（lean or rich）for some factors, such as the defected engine components, particles in the pan,
sludge accumulating around the inlet port or the back surface of valve. The excessive deviation could lead to
emission deterioration and poor engine performance. The engine control system may perform correction and learning
to fuel injection according to the deviation degree and feature of air fuel ratio. When learning value reaches the
predetermined upper limit (air-fuel mixture lean or rich, and max fuel injection via correction), the malfunction is
determined.

P2177 or P2178 P2177 or P2178
1) Clean the clogged injector(s)
2) Air induction system or exhaust system leaks
3) Sludge accumulates around the inlet port or
the back surface of valve and needs to clean
4) Defected engine component(s)
5) Deviated valve clearance
6) Deviated pressure in the fuel system
DTC: P2195 Upstream Oxygen Sensor Deteriorated (Lean)

Cause of the malfunction: The signal deviation from upstream oxygen sensor may cause offset of air-fuel ratio, and
achieve correction by the end oxygen closed loop adjustment in a predetermined range. When the adjustment is over
the range, the system will determine there is a malfunction of upstream oxygen sensor deteriorated (Lean).

P2195 P2195
1) If the upstream oxygen sensor has been
deteriorated, it may cause excessive emission
- 107 -
DTC: P2196 Upstream Oxygen Sensor Deteriorated (Rich)
Cause of the malfunction: The signal deviation from upstream oxygen sensor may cause offset of air-fuel ratio, and
achieve correction by the end oxygen closed loop adjustment in a predetermined range. When the adjustment is over
the range, the system will determine there is a malfunction of upstream oxygen sensor deteriorated (Rich).

P2196 P2196
1) If the upstream oxygen sensor has been
DTC: P2270 Downstream Oxygen Sensor Deteriorated (Lean)

Cause of the malfunction: Normally, the downstream oxygen sensor signal fluctuates around the target value. If the
sensor voltage is persistent lean for certain period of time, the system will enrich the air-fuel mixture. The
malfunction will be determined if the sensor signal doesn’t become rich as expected.
DTC: P2271 Downstream Oxygen Sensor Deteriorated (Rich)
Cause of the malfunction: Normally, the downstream oxygen sensor signal fluctuates around the target value. If the
sensor voltage is persistent rich for certain period of time, the system will set the air-fuel mixture lean. The
malfunction will be determined if the sensor signal doesn’t become lean as expected.

P2270 or P2271 P2270 or P2271
1) If the downstream oxygen sensor has been
- 108 -
Section 5 Repair and Service Procedure by M7 Diagnosis System According to

Malfunction Symptoms
Before starting troubleshooting according to the malfunction symptoms of engine, be sure to perform basic
inspection:
1. Confirm the malfunction indicator lamp operates normally.
2. Confirm there is no troubleshooting history in the diagnostic tester.
3. Interview the customer to confirm the trouble and its occurrence condition.
Perform a visual check:

(1) Inspect if there is leakage in the fuel line.
(2) Inspect the vacuum tube for cracks, kinks and correct connection.
(3) Inspect the inlet ports for blocks, air leaks, crushing and damages.
(4) Inspect the high tension wire of ignition system for breaks and deterioration, and if the ignition sequence is
correct.
(5) Inspect if the earth contact point of harness is clean and fixed.
(6) Inspect the sensor and actuator connectors for looseness and poor contact
IMPORTANT HINT: If there is a malfunction mentioned above, do repair it at first. Otherwise, it will affect the
following troubleshooting and repair operations.
Troubleshooting help: 1. confirm that there is no malfunction history of the engine.

2. Interview the customer to confirm the trouble.
3. No abnormal condition occurs after completing above procedures.
4. Don’t overlook some factors’ influence to the system, such as maintenance, cylinder pressure, mechanical ignition
timing and fuel condition.
5. Replace the ECU and perform test.
If the symptom is disappeared, the ECU may be the location of malfunction. If the problem is still occurring, install
the original ECU, repeat the troubleshooting and repair procedures.
1. The engine doesn’t crank or cranks slowly when engine starts.

2. The engine can rotate by towing but cannot start successfully.
3. Warm engine starts difficultly.
4. Cold engine starts difficultly.
5. At a normal engine rpm, the engine starts difficultly at any time.
6. Engine starts normally, but idles rough at any time.
7. Engine starts normally, but idles rough when it warms up.
8. Engine starts normally, but idles rough after it warms up.
9. Engine starts normally, but idles rough or stalls with some loads (e.g. air conditioner is on).
10. Engine starts normally, but idle speed is too high.
11. The engine rmp speed cannot be enhanced or engine stall occurs when accelerating.
12. The engine rmp speed response is slow when accelerating.
13. The engine generates weak power and poor performance when accelerating.
1. The engine doesn’t crank or cranks slowly when engine starts.
Trouble Area: 1. Battery 2. Starter motor 3. Wire harness or ignition switch 4. Engine mechanical parts
- 109 -
Troubleshooting procedures:
Operation procedures Detection Next procedure

No.
result
Check the voltage between the two battery posts by Yes Next
1 multimeter, and confirm if it is approximate 8 - 12 V when
engine starts. No Replace the battery
Yes Next
After the ignition switch is turned ON, check if the voltage of
2 Repair or replace the
the positive post of starter motor is higher than 8 V. No
harness
Remove the starter motor, and check its operating condition, Repair or replace the
Yes
3 especially check if there is open circuit or block due to poor starter motor
lubrication.
No Next
If the malfunction only occurs in winter, check if the engine Apply appropriate
Yes
4 lubricant or gear case oil is improper resulting in excessive lubricant
resistance force for the starter motor.
No Next
Repair and reduce the
Yes internal engine
Check if the mechanical resistance force in the engine inside resistance
5 is excessive resulting that the starter motor doesn’t run or run
slowly. Repeat the above
No
procedure
2. The engine can rotate by towing but cannot crank successfully.
Trouble Area: 1. Empty fuel tank 2. Fuel pump 3. Engine speed sensor 4. Ignition coil 5. Engine mechanical
No. Operation procedures Detection result Next procedure

After connecting the fuel pressure gauge (at the front end
of the inlet tube of the fuel distribution pipe assembly) Yes Next
and cranking the engine, check if the fuel pressure is at
1
approximately 260 kPa in idle running; and then check if Repair the fuel supply
the fuel pressure is at approximately 300 kPa after pulling No
system
out the vacuum tube of fuel pressure regulator.
Connect EFI tester to the engine, observe the data ―Engine Yes Next
2 Speed‖ and check if there is speed signal output after Repair engine speed
engine cranking. No
sensor circuit
Pull out the distributor(s) of a cylinder and connect to Yes Next

spark plug. Keep a gap about 5 mm between the electrode
3
of spark plug and engine body. Then check if blue and Repair the ignition
white sparks jump across the gap after engine cranking. No
system
Troubleshoot the engine
Check every cylinder’s compression pressure and observe Yes
mechanical problem
4
if there is a cylinder with low pressure.
No Next
Connect EFI system connector and turn the ignition to Yes Troubleshooting help
ON, then check if the power supply of pin 16#, 17#, 8#,
5
51# is normal and check if the ground of pin 5#, 43#, 48# Repair corresponding
is normal. No
circuit
- 110 -
3. Warm engine starts difficultly.

Trouble Area: 1. Fuel containing water 2. Fuel pump 3. Coolant temperature sensor 4. Vacuum tube of fuel pressure
regulator 5. Ignition coil

After connecting the fuel pressure gauge (at the front end of the fuel
inlet tube of the fuel distribution pipe assembly) and cranking the Yes Next
1 engine, check if the fuel pressure is at approximately 260 kPa in idle
running. And then check if the fuel pressure is at approximately 300 Repair the fuel
No
kPa after pulling out the vacuum tube of fuel pressure regulator. supply system
Pull out the distributor(s) of a cylinder and connect to spark plug. Yes Next
Keep a gap about 5 mm between the electrode of spark plug and
2
engine body. Then check if blue and white sparks jump across the Repair the
gap after engine cranking. No
ignition system
Repair the
Start the engine and observe if it may start successfully after pulling circuit or
Yes
out the coolant temperature sensor connector. (Or Connect a 300 Ω replace the
3 sensor
resistance to the coolant temperature sensor connector instead in a
series, and observe if the engine may start successfully.）
No
Repair or
Check the vacuum tube of fuel pressure regulator for looseness or air Yes
4 replace
leakage.
No Next
Check fuel condition, and observe if it is a malfunction symptom Yes Replace fuel
5
after fuel filling. No Next
Troubleshootin
Connect EFI system connector and turn the ignition ON, then check Yes
g help
6 if the power supply of pin 16#, 17#, 8#, 51# is normal and check if
Repair
the ground of pin 5#, 43#, 48# is normal. No corresponding
circuit
4. Cold engine starts difficultly.

Trouble Area: 1. Fuel containing water 2. Fuel pump 3. Coolant temperature sensor 4. Injector 5. Ignition coil 6.
Throttle body and idle bypass air path 7. Engine mechanical

of the fuel inlet tube of the fuel distribution pipe Yes Next
assembly) and cranking the engine, check if the fuel
1 pressure is at approximately 260 kPa in idle running.
And then check if the fuel pressure is at approximately Repair the fuel supply
No
300 kPa after pulling out the vacuum tube of fuel system
pressure regulator.
Pull out the distributor(s) of a cylinder and connect to
spark plug. Keep a gap about 5 mm between the Yes Next
2 electrode of spark plug and engine body. Then check if
blue and white sparks jump across the gap after engine No Repair the ignition system
cranking.
Start the engine and observe if it may start successfully Repair the circuit or replace
after pulling out the coolant temperature sensor Yes
the sensor
3 connector. (Or Connect a 2500 Ω resistance to the
coolant temperature sensor connector instead in a series,
No Next
and observe if the engine may start successfully.）
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Wash and clean throttle

Lightly depress the accelerator pedal, and observe if the Yes body and idle bypass air
4 path
engine may crank.
No Next
Remove the injector and check it for leakage or block by Yes Failure changes
5
injector cleaning analyzer. No Next
Check fuel condition, and observe if it is a malfunction Yes Replace fuel
6
symptom after fuel filling. No Next
Check every cylinder’s compression pressure and Troubleshoot the engine
Yes
7 mechanical problem
observe if there is a cylinder with low pressure. No Next
Connect EFI system connector and turn the ignition ON, Yes Troubleshooting help
then check if the power supply of pin 16#, 17#, 8#, 51#
8
is normal and check if the ground of pin 5#, 43#, 48# is Repair corresponding
normal. No
circuit
5. At a normal engine rpm, the engine starts difficultly at any time.

Trouble Area: 1. Fuel containing water 2. Fuel pump 3. Coolant temperature sensor 4. Injector 5. Ignition coil
6. Throttle body and idle bypass air path 7. Intake air path 8. Ignition timing 9. Spark plug 10. Engine mechanical
Check air filter for clogging, and check intake air path Yes Repair inlet system
1
for air leakage. No Next
No
pressure regulator.
Pull out the distributor(s) of a cylinder and connect to
spark plug. Keep a gap about 5 mm between the Yes Next
3 electrode of spark plug and engine body. Then check if
blue and white sparks jump across the gap after engine No Repair the ignition system
cranking.
Check every spark plug in cylinders, and observe if its Yes Next
4
type and gap complies with specification. No Adjust or replace
Start the engine and observe if it may crank successfully Repair the circuit or replace
Yes
5 after pulling out the coolant temperature sensor the sensor
connector. No Next
Wash and clean throttle
Lightly depress the accelerator pedal, and observe if the Yes body and idle bypass air
6
engine may crank. path
No Next
7
8
Check every cylinder’s compression pressure and Yes
mechanical problem
9
observe if there is a cylinder with low pressure.
No Next
Check if the ignition sequence and ignition timing Yes Next
10
complies with specification No Check ignition timing
Connect EFI system connector and turn the ignition ON,

11 Yes Troubleshooting help
- 112 -
normal. No
circuit
6. Engine starts normally, but idles rough at any time.
Trouble Area: 1. Fuel containing water 2. Injector 3. Spark plug 4. Throttle body and idle bypass air path 5. Intake air
path 6. Idle adjuster 7. Ignition timing 8. Spark plug 9. Engine mechanical
1 for air leakage.
No Next
2 Check if the idle adjuster operates roughly. Yes Wash or replace
No Next
3 Check every spark plug in cylinders, and observe if its Yes Next
4 Check if the throttle body and idle bypass air path has Yes Wash
carbon. No Next
5 Remove the injector and check it for leakage, block or Yes Failure changes
little flow volume by injector cleaning analyzer. No Next
6 Check fuel condition, and observe if it is a malfunction Yes Replace fuel
Check every cylinder’s compression pressure and Yes Troubleshoot the engine
observe if there is a cylinder with high pressure. No Next
8
Yes Troubleshooting help

Check if the power supply of pins 8# and 51# is normal,
9
and check if the ground of pin 5#, 43#, 48# is normal. Repair corresponding
No
circuit
7. Engine starts normally, but idles rough when it warms up.

Trouble Area: 1. Fuel containing water 2. Coolant temperature sensor 3. Spark plug 4. Throttle body and idle bypass
air path 5. Intake air path 6. Idle adjuster 7. Engine mechanical

1
for air leakage. No Next
2
Wash corresponding
Remove the idle adjuster, and check if the throttle body, Yes
3 idle adjuster and idle bypass air path have carbon. components
No Next
Start the engine and observe if it idles rough when Repair the circuit or replace
Yes
4 engine warming up after pulling out the coolant the sensor
temperature sensor connector. No Next
Remove the injector and check it for leakage, block or Yes Failure changes
5
6
Check every cylinder’s compression pressure and Troubleshoot the engine
Yes
observe if there is a cylinder with high pressure.
No Next
Connect EFI system connector and turn the ignition ON,
Yes Troubleshooting help
8
No
normal. circuit
- 113 -
8. Engine starts normally, but idles rough after it warms up.
Trouble Area: 1. Fuel containing water 2. Coolant temperature sensor 3. Spark plug 4. Throttle body and idle bypass
air path 5. Intake air path 6. Idle adjuster 7. Engine mechanical

No.
result
1
for air leakage.
No Next
2
Wash corresponding
3 components
idle adjuster and idle bypass air path have carbon.
No Next
Start the engine and observe if it idles rough when Repair the circuit or replace the
Yes
4 engine warming up after pulling out the coolant sensor
temperature sensor connector. No Next
Remove the injector and check it for leakage, block or Yes Failure changes
5
6
Check every cylinder’s compression pressure and Yes
mechanical problem
7
observe if there is a cylinder with high pressure.
No Next
8
is normal and check if the ground of pin 5#, 43#, 48# is
normal. No Repair corresponding circuit
9. Engine starts normally, but idles rough or stalls with some loads (e.g. air conditioner).
Trouble Area: 1. Air conditioning system 2. Idle adjuster 3. Injector

No.
result
Wash corresponding
Remove the idle adjuster, and check if the throttle body, idle Yes
1 components
adjuster and idle bypass air path have carbon.
No Next
Observe if the engine power output increases when opening Yes Go to procedure 4
air conditioning. In other words, observe the changes of
2
ignition advance angle, injection pulse width and air intake
volume by EFI tester. No Next
Connect EFI system connector and disconnect the wire to Yes Next
3 the ECU pin 75#, Then Check if it is high level at the wire Repair the air conditioning
No
end after opening the air conditioning. system
Check if the pressure in the air conditioning system, Yes Next
4 magnetic clutch in the compressor and compression pump No Repair the air conditioning
of the air conditioning is normal. system
Remove the injector and check it for leakage, block or little Yes Failure changes
5
flow volume by injector cleaning analyzer. No Next
then check if the power supply of pin 16#, 17#, 8#, 51# is
6
normal and check if the ground of pin 5#, 43#, 48# is
- 114 -
10. Engine starts normally, but idles highly.
Trouble Area: 1. Throttle body and idle bypass air path 2. Vacuum tube 3. Idle adjuster 4. Coolant temperature sensor
5. Ignition timing

No.
result
Yes Adjust
1 Check if the accelerator cable is stuck or too tight.
No Next
Check the air intake system and vacuum tube for air Yes Repair inlet system
2
leakage.
No Next
Wash corresponding
3 components
No Next
Repair the circuit or replace
Start the engine and observe if it idles too fast after pulling Yes
4 the sensor
out the coolant temperature sensor connector.
No Next
Check if the engine ignition timing complies with Yes Next
5
specification. No Check ignition timing
6
11. The engine rmp speed cannot be enhanced or engine stall occurs when accelerating.
Trouble Area: 1. Fuel containing water 2. Intake air pressure sensor and throttle position sensor 3. Spark plug 4.
Throttle body and idle bypass air path 5. Intake air path 6. Idle adjuster 7. Injector 8. Ignition timing 9. Exhaust pipe

No.
result
Yes Repair inlet system
1 Check air filter for clogging.
No Next
No
pressure regulator.
3
Wash corresponding
4 components
No Next
Yes Next
Check if the intake air pressure sensor, throttle position
5 Repair the circuit or replace
sensor and corresponding circuits are normal. No
the sensor
6
7
- 115 -

8
Yes Next
9 Check if air passes through exhaust pipe easily. Repair or replace exhaust
No
pipe
10
12. The engine rmp speed response is slow when accelerating.

Throttle body and idle bypass air path 5. Intake air path 6. Idle adjuster 7. Injector 8. Ignition timing 9. Exhaust pipe

No.
result

No Next
No
pressure regulator.
Yes Next
Check every spark plug in cylinders, and observe if its
3
Wash corresponding
4 components
No Next
Yes Next
the sensor
6
7
8
Yes Next
No
pipe
10
- 116 -
13. The engine generates weak power and poor performance when accelerating.
Ignition coil 5. Throttle body and idle bypass air path 6. Intake air path 7. Idle adjuster 8. Injector 9. Ignition timing
10. Exhaust pipe

No.
result
Check if there is a malfunction, such as clutch slipping, low Yes Repair
1 tire pressure, stuck break, improper tire size and incorrect
No Next
four-wheel alignment.

No Next
After connecting the fuel pressure gauge (at the front end of
the fuel inlet tube of the fuel distribution pipe assembly) Yes Next
and cranking the engine, check if the fuel pressure is at
3
approximately 260 kPa in idle running. And then check if Repair the fuel supply
the fuel pressure is at approximately 300 kPa after pulling No
system
out the vacuum tube of fuel pressure regulator.
Pull out the distributor(s) of a cylinder and connect to spark Yes Next
plug. Keep a gap about 5 mm between the electrode of
4
spark plug and engine body. Then check if the sparks
strength is normal after engine cranking. No Repair the ignition system
Check every spark plug in cylinders, and observe if its type Yes Next
5
and gap complies with specification. No Adjust or replace
Wash corresponding
6 components
No Next
Yes Next
the sensor
8
9
Check if the ignition sequence and ignition timing complies Yes Next
10
with specification No Check ignition timing
Yes Next
No
pipe
12
- 117 -
Section 6 M7 System Tester Instruction for Use

In this chapter, we will take BYD ED300 which is produced by BYD as an example to explain the method of
diagnosing M7.8 system malfunctions with diagnostic tester. Please pay attention to that the display and functions
might be different subject to the new models.
The values and relative contents in this chapter are just as reference.
 General information for tester operation panel

• On the left side of this panel is LCD, which is used for display all of the Chinese information.
• On the right side are the operation keys as indicated below:
 Function instruction for keys

Numbers 0-9: Select the menu and enter the numbers act.
Directions↑↓←→:↑ and ↓are used to select the menu, ← and → to roll the pages. When enter the numbers,
↑ indicates the operation of adding 1, ↓subtracting 1 and ← clearing the front number. When performing
the component operation test, → means closing and → means active or opening.
Reset key RST: Reset the system. NOTE: Be careful when using this key. Press and hold 1-2 seconds before
releasing it.
Return / Exit key ESC: Return to the previous menu. Exit the current display. Exit the current setup objects.
Confirm key OK: Go to the next menu. Confirm to make operation.
F2: F1 display the help contents; F2 print the current page. These two keys can be used as auxiliary input key in
the specified conditions. Please see the hints on corresponding pages when entering the positive and negative
symbols.
- 118 -
 Tester function overview:

1. Self test
Mainly include: Read and clear the DTCs.
2. System parameter display
Mainly include: Display the main parameter, parameter and sensor signal voltage.
3. System condition
Mainly include: 10 condition displays (editing condition, cooling system, stable working state, dynamical working
state, emission control, oxygen sensor, idling, malfunction light, emergent operation and A/C etc).
4. Actuator test
Mainly include: 6 functions’ test (malfunction light, fuel pump, A/C relay, fan control, ignition test and single
cylinder oil cut off etc.).
5. Speedometer
Mainly include: Display the miles driven or months elapsed.
6. Version information
Mainly include: Display the frame number (optional), ECU hardware number and ECU software number.
 Tester instruction for use
1. Connect the diagnostic wire.
2. Turn on the ignition switch.
3. Enter the diagnostic function select screen.
Heading Column
Information Column
Help Column
4. Select the model to diagnose.

5. Enter the diagnostic model select screen.
6. Select the model FO needed to diagnose.
7. Enter the diagnostic system select screen.
8. Select engine management system.

9. Enter engine management system select screen.
10. Select the ―UAES-M7.8‖ system.
- 119 -
10.1 Read computer version.
Computer version information is a series data defined by the manufacturer. It is used to identify the basic information,
such as Vehicle Identification Number etc..
10.2 Read the trouble code
This function can display the malfunctions detected by the ECU in a specified code (trouble code). For the coding
specification of trouble codes, refer to the industry relative standards.
 If the system is normal,

BYD-ED300 will indicate malfunction. As shown in the figure below.
 If the system is abnormal,

―Information column‖ will list all of the trouble codes and corresponding malfunction information. As shown in the
figure below.
- 120 -
Each malfunction information consists of 4 parts. The first number is invalid. Then, what is followed is the trouble
code, such as "P0122". The letter ―P‖ indicates that the malfunction lies in the engine and combines a trouble code
with the followed 4 numbers ―0122‖, which is edited according to the relative standard. The third part is included in a
bracket and indicates the condition of this malfunction. There are three conditions, including present, history and
intermittent, present indicates the malfunction exist for a long time and cannot be cleared by the ―clear the trouble
code‖ function. ―history ― means the malfunction occurred previously and has been repaired during this operation.
You can clear it by the ―clear the trouble code‖ function. ―Intermittent‖ indicates the malfunction appears
occasionally which might caused by poor contact and can be cleared by the ―clear the trouble code‖ function. The last
part is the complete malfunction information description. If there is information not included in BYD-ED300, ―No
definition in the trouble code‖ will appear.
―Page: 1/2‖ on the upper right corner indicates there are 2 pages displaying the received malfunction information and
it is the first page displayed. Users could press [→] to turn to the second page and check the other information hinted
in the ―help column‖. You can also press [←] to return to the first page.
10.3 Clear the trouble code
This function is used to clear the history or intermit malfunctions recorded in ECU. If succeed, it will show as the
figure on the right. Repeat the operation for 2-3 times to make sure clear thoroughly.
10.4 Read the data stream

BYD-ED300 tester displays in two formats: normal and figure. The second one displays in the figure is a great
improvement for ED300 compared with the previous testers produced by BYD. You can switch between these two
displays according to the key hints in BYD-ED300 ―help column‖.
 Normal display
―Information column‖ displays as shown in the figure below. The current is the first page contents. You can press ←
and → to check the other data.
- 121 -
Figure display
BYD-ED300 figure display can show two figure trends in one page. On the left of the figure are the max., middle,
and min. values. At the same time, the relative text will show at the bottom of the figure.
The figure display adopts dotting from left to right timely, thus presents a dynamic process.
Paging hint ―Page: 4/4‖ will be displayed on the upper right corner of ―information column‖. Please see the operation
method above.
The figure displays in two formats.
The first one adopts dotting description. As shown in the figure below.
The second one adopts column description. As shown in the figure below.
You can switch between these two displays, refers to the hints in BYD-ED300 ―help column‖.
As shown in the normal way, the current display can also print out by the micro printer. Please see the operation
- 122 -
method in ―help column‖.

10.5 Component operation test
Component operation test can be controlled by 3 methods, including ―switch level‖, ―control level‖ and ―activation
level‖. As shown in the figure below.
The operations are different. Describe respectively as follows:
 switch level
Switch level means there are two conditions: ON or OFF. OFF
―★‖ indicates the current state. The current user required operation state displays on the right side: ON or OFF. You
can select the testing objects by ↑ and ↓ keys. Control the volume by ← and → keys. ← means OFF and → means
ON.
If you want to quit the current operation, press the ↑ and ↓ keys to select the other testing objects or press [ESC] to
exit the current page.
 Control level
Control level is some setup values. Users can adjust ECU inside values by setups to change the engine conditions.
―★‖ indicates the current adjustable objects. Users can press the ↑ and ↓ keys to select the required setup.
In the second line of ―help column‖ displays the current object setup range. The input value will show in the third line.
The fourth line hints you can press [OK] to setup the current object.
After inputting the values, press [OK] to setup. Then the result will be displayed in the fourth line.
If you want to quit the current operation, press the ↑ and ↓ keys to select the other testing objects or press [ESC] to
exit the current page.
- 123 -
 activation level
The operation of ―activation level‖ is similar to ―switch level‖. The display shown as follows:
For the details, refer to the operation method of ―switch level‖.
Note: Please be careful when apply ―component operation test‖. Please do not use this function by non-professional
or professional personnel. Otherwise, the engine system will be damaged by improper operation.
10.5 System reset
System reset will result in ECU automatic reset operation. If the system reset succeed, BYD-ED300 will appear reset
completes successfully.
- 124 -
Section 7 Accessories
7.1 Components Installing/Torque Specification Table
No. Component name Installing torque (N·m)
1 Intake pressure and temperature sensor 3.3
2 Coolant temperature sensor 20（Max）

3 Oxygen sensor 50±10
4 Throttle position sensor 2±0.5
5 Speed sensor 8±2
6 Phase sensor 8±0.5
7 Solenoid injector 6
8 Idle actuator 4.0±0.4
7.2 Electronic Injection System Maintenance Schedule
7.2.1 Family cars
Instruction:
1. This maintenance schedule is suitable for family cars.
2. Determine the interval to service the vehicle using either miles driven or months elapsed, whichever reaches the
specification first.
3. The maintenance schedule is presumed as normal usage and must be strictly observed.
x1000km 10 20 30 40 50 60 70 80
Items
Month 3 6 9 12 15 18 21 24
Ignition Coil I I I I
Ignition Cam I I I I
Ignition Cap I I I I
Ignition Wire I I I I
Spark Plug I I I R
Ignition Timing I I I I
Engine Idling Speed I I I I
Fuel Tank I C
Fuel Filter R R R R
Fuel Injector C* C* C* C*
Air Filter I R I R
EWD or Stepper Air Bypass C C C C
Throttle Body C C C C
Emission Check I I I I
Check by Diagnostic Tool I I I I
- 125 -
7.2.2 Taxies
Instruction:
1. This maintenance schedule is suitable for family cars.
2. Determine the interval to service the vehicle using either miles driven or months elapsed, whichever reaches the
specification first.
3. The maintenance schedule is presumed as normal usage and must be strictly observed.
x1000km 20 40 60 80 100 120 140 160

Items
Month 3 6 9 12 15 18 21 24
Ignition Coil I I I I I I I I
Ignition Cam I I I I I I I I
Ignition Cap I I I I I I I I
Ignition Wire I I I I I I I I
Spark Plug I R I R
Ignition Timing I I I I
Engine Idling Speed I I I I
Fuel Tank C C
Fuel Filter R R R R R R R R
Fuel Injector C* C* C* C* C* C* C* C*
Air Filter I R I R I R I R
Idle Speed Actuator EWD or
I C I C I C I C
Stepper Motor Air Bypass
Throttle Body I C I C I C I C
Emission Check I I I I
Check by Diagnostic Tool I I I I
Note: R- Replace
C- Clean
I Inspect (Replace the spare parts when find out failure in inspection.)
C*- The maintenance of fuel injector had better clean by a special tool --- fuel injector cleaner.
- 126 -
7.3 Trouble Code (PCODE) List
No. Trouble code Description (UAES)
1 P0030 Open in the Upstream Oxygen Sensor Heating Control Circuit

2 P0031 Short to Ground in the Upstream Oxygen Sensor Heating Circuit
3 P0032 Short to Power Supply in the Upstream Oxygen Sensor Heating Circuit
4 P0036 P0036 Open in the Downstream Oxygen Sensor Heating Circuit
5 P0037 Short to Ground in the Downstream Oxygen Sensor Heating Circuit
Short to Power Supply in the Downstream Oxygen Sensor Heating
6 P0038 Circuit
7 P0053 Upstream Oxygen Sensor Heating Inherent Resistance is Inaccurate
8 P0054 Downstream Oxygen Sensor Heating Inherent Resistance is Inaccurate
9 P0105 Intake Pressure Sensor Signal is not Changing (Frozen)
10 P0106 Intake Pressure Sensor Signal is Inaccurate
11 P0107 Short to Ground in the Intake Pressure Sensor
12 P0108 Short to Power Supply in the Intake Pressure Sensor
13 P0112 Intake Temperature Sensor Signal Low Voltage
14 P0113 Intake Temperature Sensor Signal High Voltage
15 P0116 Engine Coolant Temperature Sensor is Inaccurate
16 P0117 Engine Coolant Temperature Sensor Circuit Low Voltage
17 P0118 Engine Coolant Temperature Sensor Circuit High Voltage
18 P0122 Throttle Position Sensor Circuit Voltage is below the Minimum Value
19 P0123 Throttle Position Sensor Circuit Voltage is above the Minimum Value
20 P0130 Upstream Oxygen Sensor Signal is Inaccurate
21 P0131 Upstream Oxygen Sensor Circuit Low Voltage
22 P0132 Upstream Oxygen Sensor Circuit High Voltage
23 P0133 Upstream Oxygen Sensor is Deteriorated
24 P0134 Upstream Oxygen Sensor Circuit Signal Malfunction
25 P0136 Downstream Oxygen Sensor Signal is Inaccurate
26 P0137 Downstream Oxygen Sensor Signal Circuit Low Voltage
27 P0138 Downstream Oxygen Sensor Signal Circuit High Voltage
28 P0140 Downstream Oxygen Sensor Circuit Signal Malfunction
Air-fuel Ratio Closed Loop Control Self Learning Value Detected by the
29 P0170 lower Line is Unreasonable
30 P0171 Lower Line is Leaner
31 P0172 Lower Line is Richer
32 P0201 Open in the Cylinder 1 injector control circuit
- 127 -

36 P0261 Short to Ground in the Cylinder 1 Injector Control Circuit
37 P0262 Short to Power Supply in the Cylinder 1 Injector Control Circuit
44 P0300 Multiple Cylinders Misfire Occurs
45 P0301 Cylinder 1 Misfire Occurs
49 P0317 Rough Road ABS Detection Signal Failure
50 P0318 Rough Road Detection Sensor Signal Failure
51 P0321 Speed Signal Reference Point Failure
52 P0322 No Speed Sensor Pulse Signal (Open or Short)
53 P0327 Knock Sensor Signal Circuit Low Voltage
54 P0328 Knock Sensor Signal Circuit High Voltage
55 P0340 Phase Sensor Installation Position Incorrect
56 P0341 Phase Sensor Poor Contact
57 P0342 Phase Sensor Short to Ground
58 P0343 Phase Sensor Power supply short circuit
Three-way Catalytic Converter Oxygen Storage Capacity Deterioration
59 P0420 (Emission Deterioration)
60 P0444 Canister Control Valve Control Circuit Open
61 P0458 Canister Control Valve Control Circuit Voltage Low
62 P0459 Canister Control Valve Control Circuit Voltage High
63 P0480 Open in Cooling Fan Relay Control Circuit (Low Speed)
64 P0481 Open in Cooling Fan Relay Control Circuit (High Speed)
65 P0501 Vehicle Speed Sensor Signal Inaccurate
66 P0506 Idling Control Speed Lower than Object Idling Speed
67 P0507 Idling Control Speed Higher than Object Idling Speed
68 P0508 Step Motor Drive Terminal Short to Ground
69 P0509 Step Motor Drive Terminal Power supply short circuit
70 P0511 Step Motor Drive Terminal Open
- 128 -
71 P0532 A/C Pressure Sensor Circuit Voltage Low

72 P0533 A/C Pressure Sensor Circuit Voltage High
73 P0537 A/C Evaporator Temperature Sensor Circuit Voltage Low
74 P0538 A/C Evaporator Temperature Sensor Circuit Voltage High
75 P0560 System Battery Voltage Signal Improper
76 P0562 System Battery Voltage Low
77 P0563 System Battery Voltage High
78 P0602 ECU Code Failure
79 P0627 Open in the Fuel Pump Relay Control Circuit
80 P0628 Short to Ground in the Fuel Pump Relay Control Circuit
81 P0629 Short to Power Supply in the Fuel Pump Relay Control Circuit
82 P0645 Open in the A/C Compressor Relay Control Circuit
83 P0646 Short to Ground in the A/C Compressor Relay Control Circuit
84 P0647 Short to Power Supply in the A/C Compressor Relay Control Circuit
85 P0650 MIL Drive Circuit Malfunction
86 P0691 Short to Ground in the Cooling Fan Relay Control Circuit
87 P0692 Short to Power Supply in the Cooling Fan Relay Control Circuit
88 P0693 Short to Ground in the Cooling Fan Relay Control Circuit (High Speed)
Short to Power Supply in the Cooling Fan Relay Control Circuit (High
89
P0694 Speed)
90 P1651 SVS Indicator Drive Circuit Malfunction
Air Fuel Ratio Closed Loop Control Learning Value Exceeding Upper
91
P2177 Limit
Air Fuel Ratio Closed Loop Control Learning Value Exceeding Lower
92
P2178 Limit
93 P2195 Upstream Oxygen Sensor Deteriorated (Lean)
94 P2196 Upstream Oxygen Sensor Deteriorated (Rich)
95 P2270 Downstream Oxygen Sensor Deteriorated (Lean)
96 P2271 Downstream Oxygen Sensor Deteriorated (Rich)
7.4 Wire Harness Diagram
Please refer to the corresponding wire harness diagram for different models. Refer to the diagrams strictly when you
check the malfunction or perform maintenance.
- 129 -
Chapter 5 Fuel System

Section 1 Fuel System ........................................................................................................................................... 131
1.1 Fuel System Removal ............................................................................................................................. 131
1.2 Layout ..................................................................................................................................................... 133
1.3 System Schematic Diagram.................................................................................................................... 134
1.4 Inspection................................................................................................................................................ 135
Section 2 Fuel Injector ........................................................................................................................................... 136
2.1 Layout ..................................................................................................................................................... 136
2.2 Removal .................................................................................................................................................. 137
2.3 Inspection................................................................................................................................................ 138
2.4 Installation .............................................................................................................................................. 138
Section 3 Fuel Pump Assembly ............................................................................................................................. 140
3.1 Layout ..................................................................................................................................................... 140
3.2 Removal .................................................................................................................................................. 141
3.3 Inspection................................................................................................................................................ 142
3.4 Installation .............................................................................................................................................. 143
Section 4 Fuel Tank Assembly .............................................................................................................................. 145
4.1 Layout ..................................................................................................................................................... 145
4.2 Removal .................................................................................................................................................. 145
- 130 -
Section 1 Fuel System

1.1 Fuel System Removal
1.1.1 Preparation
1.1.1.1 Before inspecting or repairing the fuel system,
the battery negative terminal must be disconnected.
1.1.1.2 Never smoke or close to fire when inspecting Plastic Bag
or repairing the fuel system.
1.1.1.3 Prevent oil from spilling to the rubber or 1.1.3.1.4 Drain the remaining fuel in the fuel pump outlet
leather. nylon hose and filter outlet nylon hose assembly.
1.1.2 Release the fuel system pressure 1.1.3.1.5 Wrap the end of the removed fuel pump outlet
WARNING: nylon hose and filter outlet nylon hose assembly with a
The components of fuel system can be removed only plastic bag to prevent foreign material damaging it or
when the fuel system pressure is released. entering.
Although the fuel system pressure has been released,
please cover the fuel system line connector with a
piece of dry cloth or fabric material when
disconnecting to prevent fuel from spilling to your Correct
body or the engine compartment.
O-ring
Wrong
Fuel Rail Wrong
1.1.3.2 When removing or installing the fuel injector,

please follow the steps below:
1.1.3.2.1 Do not reuse the old O-ring.
1.1.3.2.2 Don’t damage the O-ring when replacing it with
a new one.
1.1.3.2.3 Before installing, apply grease or gasoline to the
1.1.2.1 Remove the rear floor service hole cover and new O-ring. Never use engine oil, gear oil or brake fluid.
disconnect the fuel pump socket connector.
1.1.2.2 Start the engine, then stop it. Fuel Rail
1.1.2.3 Confirm the engine has been stopped.
1.1.2.4 Open the fuel filler cap to release the air in Injector
fuel tank. Insulation
1.1.2.5 Disconnect the battery negative terminal. O-ring
Layer
1.1.3 Remove the fuel system
1.1.3.1 When remove the high-pressure line, fuel

will be spilled in bulk. So, please follow the steps
below: Cylinder Top
1.1.3.1.1 Put a fuel tanker under the vehicle to catch
all of the spilled fuel. 1.1.3.2.4 Install the fuel rail with fuel injector to the
1.1.3.1.2 Release the fuel system pressure (step 2). position of the cylinder head shown in the above
1.1.3.1.3 Disconnect the fuel pump outlet nylon hose illustration.
and filter outlet nylon hose assembly. NOTICE:
Before installing the fuel injector, make sure to apply
grease or gasoline to the fuel rail or cylinder head which
is contacting with the new O-ring.
- 131 -
1.1.3.3 When disconnecting the nylon pipe quick

joint, please follow the steps below:
1.1.3.4 When assembling the nylon pipe quick joint,

please follow the steps below:
1.1.3.4.1 Check if the connection of fuel pipe is damaged

1.1.3.3.1 Before disconnecting these nylon pipe or adheres to the mud or any foreign materials.
quick joints, check if there are foreign materials like
mud near the quick joint fuel pipe and clean it 1.1.3.4.2 After aligning the fuel pipe with the quick joint,
thoroughly. insert the quick joint into the fuel pipe until a click is
heard. Apply a little engine oil to the fuel pipe top end if
1.1.3.3.2 Make sure to disconnect these nylon pipe it is tough when assembling.
quick joints manually.
1.1.3.3.3 When the quick joint engages to the fuel

pipe tightly, hold the fuel pipe with one hand, push
and pull the quick joint with another hand, then pull
it out. Don’t use any tools during this step.
1.1.3.3.4 If there is any mud or foreign materials on

the seal surface of the disconnected fuel pipe
connector, clean it thoroughly.
1.1.3.3.5 Make sure the fuel pipe and quick joint are
not damaged and wrap them with a plastic bag to
prevent foreign materials from entering. 1.1.3.4.3 After assembling, push and pull the quick joint
lightly to check if it is connected securely.
1.1.4 Check fuel leakage

After repairing, check for the fuel system leakage.
- 132 -
1.2 Layout
Fuel Pump
Front Compartment
Distribution Box
Injector
- 133 -
1.3 System Schematic Diagram
Combination Meter and Instrument

Panel Distribution Block
Ignition Switch
Front Compartment Distribution Box
Fusible Links
Battery
- 134 -
1.4 Inspection 1.4.2.3 Disconnect the battery negative terminal.

1.4.2.4 Disconnect the fuel pump outlet nylon hose
1.4.1 Inspect the fuel pump and fuel leakage assembly from the fuel rigid pipe.
1.4.1.1 Use the intelligent tester. 1.4.2.5 Connect the 3 way connector and special pressure
1.4.1.1.1 Connect the intelligent tester to DLC3. gauge as shown in the illustration.
1.4.1.1.2 Turn the ignition switch to ―ON‖ position 1.4.2.6 Wipe off the spilled gasoline.
and turn on the intelligent tester. 1.4.2.7 Reconnect the battery negative terminal.
NOTICE: 1.4.2.8 Connect the intelligent tester to DLC3.
Don’t start the engine. 1.4.2.9 Measure the fuel system pressure.
1.4.1.1.3 Select the active test mode on the Fuel system pressure: 390 KPa-400 kPa
intelligent tester. If the pressure is higher, replace the pressure regulator.
HINT: If it is lower, check the fuel hose, fuel line connection,
For details, please refer to the intelligent tester fuel pump and pressure regulator.
operator's manual. 1.4.2.10 Disconnect the intelligent tester from DLC3.
1.4.1.2 After repairing, check for the fuel system 1.4.2.11 Start the engine.
leakage. 1.4.2.12 Measure the fuel pressure when idling.
1.4.2 Check the fuel pressure Fuel pressure: 390 kPa-400 kPa
1.4.2.1 Release the fuel system pressure. If the value is not within this range, check the fuel
1.4.2.2 Measure the battery voltage with a pressure regulator.
voltmeter. 1.4.2.13 Stop the engine.
Voltage: 12-14 V 1.4.2.14 Measure and check if the fuel pressure is within
the range below after 5 minutes since the engine has been
stopped.
Special tool (clamp) Fuel pressure: above 160 kPa.
If the value is not within this range, check the fuel pump,
Special tool (3 pressure regulator and fuel injector.
way connector) 1.4.2.15 After measuring the fuel pressure, disconnect the
battery negative terminal and carefully remove the 3 way
Special tool (pressure connector and special pressure gauge to prevent fuel
gauge) from spilling.
1.4.2.16 Reconnect the fuel pump outlet nylon hose to
the fuel rigid pipe.
Special tool (line) 1.4.2.17 Check for the fuel leakage (step 1).
Fuel Pipe
Special tool (quick joint)
- 135 -
Section 2 Fuel Injector

2.1 Layout
Air Cleaner Cap
Air Cleaner Element
Wire Harness
Engine Oil Inlet Nylon Hose
Fuel Rail
Fuel Injector
Tightening Torque
Non-reusable Part
- 136 -
2.2 Removal 2.2.4.1 Press the engine oil inlet nylon hose quick joint,
then pull it out from the fuel rail pipe connector.
2.2.1 Release the fuel system pressure NOTICE:
2.2.2 Disconnect the battery negative terminal Before operating, check if there is mud or any other
2.2.3 Remove the air cleaner cap foreign materials near the fuel pipe quick joint.
2.2.3.1 Remove the 4 clamps as shown in the fig.a. Take care! The O-ring which is used to seal the fuel pipe
2.2.3.2 Remove 2 clamps as shown in the fig. b, on the quick joint may be contaminated with mud.
then remove the air cleaner cap and air cleaner Don’t use any tools during this operation.
element. Make sure the fuel pipe and quick joint are not damaged
and wrap them with a plastic bag to prevent foreign
materials from entering.
When the fuel pipe engages the quick joint, push and pull
the quick joint lightly.
2.2.4.2 Disconnect 3 ignition coil connectors as shown in

the fig.c.
2.2.4.3 Disconnect 3 fuel injector connectors as shown in
the fig.d.
2.2.4.4 Disconnect 2 clamps and wire harness as shown
in the fig.e.
2.2.4 Remove the fuel rail
Pull
Push
2.2.4.5 Remove 2 bolts and 3 fuel rails with injector.

Push NOTICE:
When removing the fuel rail, be careful not to make the
fuel injector fall.
Nylon Hose Retainer
Nylon Hose O-ring O-ring

Quick Joint
2.2.4.6 Remove 3 injector cushions from the cylinder
head.
- 137 -
2.2.5 Remove the fuel injector assembly 2.4 Installation

2.4.1 Install the fuel injector assembly
New O-ring
2.4.1.1 Apply a coat of grease or gasoline to the new

Pull out 3 fuel injectors from the fuel rail. O-ring and install it to the injector.
2.4.1.2 Apply a coat of grease or gasoline to the fuel rail
2.3 Inspection which is contacting with the O-ring.
2.3.1 Inspect the fuel injector assembly

2.3.1.1 Inspect the resistance value of fuel injector.
2.3.1.1.1 Measure the resistance value between
terminals with an ohmmeter.
Resistance value: 11.4-12.6 Ù (at 20°)
If the value is not as specified, replace the fuel
injector.
2.3.1.2 Inspect the fuel injector capacity.
WARNING:
Never smoke when inspecting.
Capacity: 47～58 ml within 15 seconds.
The difference value of each injector: 15 ml or less. Push
If the injector capacity is not as specified, replace
the injector. Rotate
2.4.1.3 Rotate the fuel injector forward and backward,

then push it into the fuel rail.
NOTICE:
Don’t twist the O-ring.
After installing the fuel injector, check if it rotates
smoothly. If not, reinstall it with a new O-ring.
2.4.1.4 Adjust the fuel injector connector location and
make it face upward.
2.4.2 Install the fuel rail
2.3.1.3 Check the leakage.

Injector’s fuel is leak.
Fuel volume: one drop or less within 5 minutes.
- 138 -
2.4.2.1 Install 3 injector cushions on the cylinder

head.
Push
NOTICE:
Before operating, check if there is mud or any other
foreign materials near the fuel pipe quick joint.
2.4.2.2 Install the fuel rail and 3 fuel injectors When the fuel pipe engages the quick joint, push and pull
together into the cylinder head. the quick joint lightly.
NOTICE: 2.4.3 Install air cleaner cap assembly

When removing the fuel rail, be careful not to
make the fuel injector fall.
2.4.2.3 Install 2 bolts to fix the temporary fuel rail

on the cylinder head.
NOTICE:
After installing the fuel injector, check if it rotates
smoothly. If not, reinstall it with a new O-ring.
2.4.2.4 Tighten these 2 bolts in order to install the

fuel rail on the cylinder head.
Torque: 12 N*m
2.4.3.1 Install the air cleaner cap and air cleaner element
with a clamp as shown in the fig.a.
2.4.3.2 Tighten the 4 clamps as shown in the fig.b.
2.4.2.5 Install 3 ignition coil connectors as shown
in the fig.e. 2.4.4 Connect the battery negative terminal
2.4.2.6 Install 3 fuel injector connectors as shown 2.4.5.1 Use the intelligent tester.
2.4.5.1.1 Connect the intelligent tester to DLC3.
in the fig.f.
2.4.5.1.2 Turn the ignition switch to ―ON‖ position and
2.4.2.7 Install 2 clamps and wire harness as shown turn on the intelligent tester.
in the fig.g. NOTICE:
Don’t start the engine.
2.4.2.8 Push the engine oil inlet nylon hose quick 2.4.5.1.3 Select the active test mode on the intelligent
joint into the fuel rail connector until a click is tester.
heard. HINT:
For details, please refer to the intelligent tester operator's
manual.
2.4.5.2 After repairing, check for the fuel system
leakage.
- 139 -
Section 3 Fuel Pump Assembly

3.1 Layout
Rear Seat Cushion
Fuel Pump Connector Fuel Tank Service Hole Cover
Resilient Retainer
Fuel Pump
Seal Ring
Non-reusable Part
- 140 -
3.2 Removal 3.2.1.2.2 Remove the rear seat ring lock.

3.2.1 Remove the rear seat assembly
3.2.1.1 Remove the rear cushion assembly
3.2.1.1.1 Take off these 4 hooks to remove the rear
cushion.
3.2.2 Remove the rear floor service hole cover
3.2.1.1.2 Remove the rear cushion holder.
3.2.2.1 Remove the rear floor service hole cover.

3.2.2.2 Pull out the fuel pump terminal.
3.2.3 Release the fuel system pressure
3.2.4 Disconnect the battery negative terminal
3.2.5 Remove the fuel pump resilient retainer
3.2.5.1 Disconnect the fuel pump outlet nylon hose assembly at the
end of fuel pump.
3.2.1.2 Remove the rear seatback assembly

3.2.1.2.1 Remove 2 catch hooks, 2 bolts and 2 nuts shown
in the figure.
Nylon Hose Retainer
O-ring Rigid Pipe
Hold the nylon hose quick joint and pull it out from the
fuel pipe.
- 141 -
NOTICE: NOTICE:
 Before operating, check if there are mud  Before operating, check if there are mud or any
or any other foreign materials near the fuel pipe other foreign materials near the fuel pipe quick joint
quick joint  Take care the O-ring which is used to seal the
 Take care the O-ring which is used to fuel pipe on the quick joint is not contaminated with
seal the fuel pipe on the quick joint is not mud.
contaminated with mud.  Don’t use any tools during this operation.
 Don’t use any tools during this operation.  Make sure the fuel pipe and quick joint is not
 Make sure the fuel pipe and quick joint is damaged and wrap them with plastic bag to prevent
not damaged and wrap them with plastic bag to foreign materials enter.
prevent foreign materials enter.  When the fuel pipe engages to the quick joint,
 When the fuel pipe engages to the quick push and pull out the quick joint.
joint, push and pull out the quick joint. 3.2.5.4 Remove the fuel pump resilient retainer.
3.2.5.2 Disconnect the filter outlet nylon hose 3.2.6 Remove the fuel pump assembly
assembly at the end of fuel pump. 3.2.6.1 Remove the fuel pump assembly.
Hold the nylon hose quick joint and pull it out from NOTICE:
the fuel pipe. Don’t twist the oil level sensor float arm.
NOTICE: 3.2.6.2 Remove the fuel pump seal ring from the fuel
 Before operating, check if there are mud pump.
or any other foreign materials near the fuel pipe 3.2.7 Remove the oil level sensor assembly
quick joint
 Take care the O-ring which is used to
seal the fuel pipe on the quick joint is not
contaminated with mud.
 Don’t use any tools during this operation.
 Make sure the fuel pipe and quick joint is
not damaged and wrap them with plastic bag to
prevent foreign materials enter.

Slide
When the fuel pipe engages to the quick

joint, push and pull out the quick joint.
3.2.7.1 Disconnect the oil level sensor terminal as shown

in the fig.a.
3.2.7.2 Disconnect the clip (as shown in the fig.b), then
slid to remove the oil level sensor.
3.2.5.3 Disconnect the fuel evaporation nylon hose 3.3 Inspection
assembly at the end of fuel pump. 3.3.1 Inspect the fuel pump assembly
3.3.1.1 Pull out the fuel pump assembly terminal.
Hold the nylon hose quick joint and pull it out from
the fuel pipe.
- 142 -
3.1.1.2 Measure the resistance value of fuel pump NOTICE:

assembly. Don’t twist the oil level sensor float arm.
3.4.3 Install the fuel pump resilient retainer
3.4.3.1 Install the fuel pump resilient retainer.

3.4.3.2 Connect the fuel pump outlet nylon hose
assembly at the end of fuel pump.
Install the nylon hose quick joint into the fuel pump pipe
connector until a click is felt.
NOTICE:
Check if the fuel pump pipe connector is damaged or
Use ohmmeter to measure the resistance value there are foreign materials.
between terminal 1 and 2. After assembling, push and pull the quick joint to check
Resistance value: 0.2-0.3 Ù (at 20°) if it is connected securely.
3.1.1.3 Inspect the operate condition of fuel pump
assembly.
Connect the battery to the two terminals.
NOTICE:
 Please complete these inspections in a
short time (within 10 seconds) to prevent damaging
to the fuel pump.
 Keep the fuel pump far away from the
battery.
 The switch should always be on the
battery side.
3.1.1.4 Connect the fuel pump assembly terminal.
3.4 Installation
3.4.1 Install the oil level sensor assembly 3.4.3.3 Connect the filter outlet nylon hose assembly at
the end of fuel pump.
NOTICE:
 Check if the fuel pump pipe connector is
damaged or there are foreign materials.
 After assembling, push and pull the quick joint
to check if it is connected securely.
Slide
3.4.1.1 Slide until the clip engages into the position 3.4.3.4 Connect the fuel evaporation nylon hose
as shown in the fig.a. Install the oil level sensor. assembly at the end of fuel pump.
3.4.1.2 Connect the oil level sensor terminal as Install the nylon hose quick joint into the fuel pump pipe
shown in the fig.b. connector until a click is felt.
3.4.2 Install the fuel pump assembly NOTICE:
3.4.2.1 Install a new O-ring on the fuel pump.  Check if the fuel pump pipe connector is
3.4.2.2 Install the fuel pump assembly on the fuel damaged or there are foreign materials.
tank.  After assembling, push and pull the quick joint
to check if it is connected securely.
- 143 -
3.4.7 Install the rear seat assembly
Perform the installation in the reverse order of the

removal. Following precautions should be taken:
 Make sure the seat buckle switch socket
connector is connected properly.
 Remove the rear seat ring lock mounting bolt,
tightening torque: 21 N*m.
 Install the bolt and nut as shown in the figure,
3.4.4 Connect the battery negative terminal

NOTICE:
Check the fuel pump quick joint fuel leakage.
3.4.6 Install the rear floor service hole cover
3.4.6.1 Connect the fuel pump socket connector.

3.4.6.2 Install the rear floor service hole cover.
- 144 -
Section 4 Fuel Tank Assembly

4.1 Layout
4.2 Removal
4.2.1 Remove the rear seat assembly
4.2.1.1 Remove the rear cushion assembly
4.2.1.1.1 Take off these 4 hooks to remove the rear
cushion.
4.2.1.2.2 Remove the rear seat ring lock.
4.2.1.1.2 Remove the rear cushion holder.
4.2.2 Remove the rear floor service hole cover
4.2.1.2 Remove the rear seatback assembly

4.2.1.2.1 Remove 2 catch hooks, 2 bolts and 2 nuts
shown in the figure. 4.2.2.1 Remove the rear floor service hole cover.
4.2.2.2 Pull out the fuel pump socket connector.
4.2.3 Release the fuel system pressure
- 145 -
4.2.4 Remove the rear twist beam (see the section Ⅵ in chapter Ⅻ)
4.2.5 Remove the front exhaust pipe assembly
4.2.5.1 Remove the bolt and metal band.
4.2.5.2 Remove 2 bolts, 2 compression springs and cup gasket.
4.2.5.3 Remove the exhaust pipe hanger and the front exhaust pipe assembly.
4.2.6 Remove the filler pipe assembly 4.2.6.2 Disconnect the filler pipe from the oil filler
rubber bush.
4.2.6.1 Remove the service bolt connecting the filler pip 4.2.6.3 Loosen the clamp and disconnect the filler pipe
and vehicle body. and ventilation hose.
- 146 -
4.2.7 Disconnect the rigid pipe nylon hose Loosen the clamp and disconnect the fuel tank filler pipe
assembly and ventilation hose.
4.2.7.1 Disconnect the fuel pump outlet nylon hose 4.2.11 Remove the fuel tank heat insulator
assembly at the end of fuel rigid pipe.
4.2.7.2 Disconnect the fuel filter outlet nylon hose
assembly at the end of fuel filter.
4.2.7.3 Disconnect the fuel evaporation nylon hose
assembly at the end of fuel rigid pipe.
4.2.8 Remove the fuel tank assembly
Remove 3 bolts and fuel tank heat insulator.

4.3 Installation
4.3.1 Fuel tank heat insulator
4.2.8.1 Place a jack under the fuel tank.

4.2.8.2 Remove 4 bolts and fuel tank.
4.2.9 Remove the nylon pipe assembly at the end

of fuel pump.
4.2.9.1 Disconnect the fuel pump outlet nylon hose

4.2.9.2 Disconnect the fuel filter outlet nylon hose
4.2.9.3 Disconnect the fuel evaporation nylon hose
assembly at the end of fuel pump. Install the fuel tank heat insulator with 3 bolts, tightening
4.2.10 Remove the fuel tank filler pipe and torque: 8 N*m.
ventilation hose. 4.3.2 Install the filler pipe and ventilation hose to the
fuel tank
- 147 -
4.3.2.1 Install the filler pipe and ventilation hose to

the fuel tank with clamp as shown in the figure.
4.3.3.6 Connect the fuel evaporation nylon hose

NOTICE:
Check if the fuel pump pipe connector is damaged or
there are foreign materials.
4.3.3 Install the fuel pump assembly After assembling, push and pull the quick joint to check
4.3.3.1 Install a new O-ring on the fuel pump. if it is connected securely.
4.3.3.2 Install the fuel pump assembly on the fuel
tank.
NOTICE:
Don’t twist the oil level sensor float arm.
4.3.3.3 Install the oil pump resilient retainer.
4.3.3.4 Connect the fuel pump outlet nylon hose
Install the nylon hose quick joint into the fuel
pump pipe connector until a click is felt.
NOTICE:
Check if the fuel pump pipe connector is damaged
or there are foreign materials.
After assembling, push and pull the quick joint to
check if it is connected securely.
4.3.4 Install the fuel tank assembly

4.3.4.1 Install the fuel tank with 4 new bolts.
4.3.3.5 Connect the filter outlet nylon hose

Install the nylon hose quick joint into the fuel
pump pipe connector until a click is felt.
NOTICE:
Check if the fuel pump pipe connector is damaged Torque: 30 N*m
or there are foreign materials. 4.3.5 Install the filler pipe assembly
After assembling, push and pull the quick joint to 4.3.5.1 Insert the filler pipe into oil filler rubber bush.
check if it is connected securely.
- 148 -
4.3.5.2 Install the filler pipe and ventilation hose to 4.3.6 Install the front exhaust pipe assembly
the filler pipe assembly with clamp. 4.3.6.1 Measure the compression spring free length with
vernier caliper.
Min. length: 40.5 mm
If the length is not as specified, replace with a new
compression spring.
4.3.6.2 Replace a new cup grommet and tap it into the
three-way catalyst outlet pipe with a plastic hammer and
a small piece of wooden block.
NOTICE:
Please align the marked point on metal band to the
stamped groove.
Wooden
Block
Cup Grommet
NOTICE:
 Make sure the installation direction for cup
grommet is correct.
 Don’t damage the outer surface of cup grommet.
4.3.5.3 Install the filler pipe assembly with bolt.  The cup grommet is disposable.
Torque: 25 N*m  Don’t push the cup grommet into the three-way
catalyst outlet pipe with the front exhaust pipe.
(3) Install the front exhaust pipe assembly with 2 bolts
and 2 springs.
Torque: 45 N*m
(4) Install the hanger.
(5) Install the bolt and metal band.
Torque: 32 N*m
- 149 -
4.3.7 Install the rear twist beam assembly (see the

section Ⅵ in chapter Ⅻ)
4.3.8 Install the rear floor service hole cover
4.3.8.1 Connect the fuel pump socket connector.

4.3.8.2 Install the rear floor service hole cover.
4.3.9 Install the rear seat assembly
Perform the installation in the reverse order of the
removal. Following precautions should be taken: NOTICE:
Don’t start the engine.
Make sure the seat buckle switch socket connector is
connected properly. 4.3.12.3 Select the active test mode on the intelligent
The tightening torque for rear seat ring lock mounting tester.
bolt: 21 N*m. HINT:
For details, please refer to the intelligent tester
Install the bolt and nut as shown in the figure,
operator's manual.
4.3.12.4 After repairing, check the fuel system leakage.
4.3.10 Fill the fuel
4.3.11 Connect the battery negative terminal
Use the intelligent tester.
4.3.12.1 Connect the intelligent tester to DLC3.
4.3.12.2 Turn the ignition switch to ―ON‖ position and
turn on the intelligent tester.
- 150 -
Chapter 6 Cooling System

Section 1 Cooling System..............................................................................................................................................151
1.1 On-Vehicle Inspection.......................................................................................................................................151
Section 2 Eletric Fan System .........................................................................................................................................151
2.1 Layout ...............................................................................................................................................................151
2.2 System Electrical Wiring Diagram (EWD) ......................................................................................................152
2.3 On-vehicle Inspection .......................................................................................................................................153
2.4 Inspection ..........................................................................................................................................................153
Section 3 Coolant ...........................................................................................................................................................154
3.1 Replacement ......................................................................................................................................................154
Section 4 Radiator ..........................................................................................................................................................155
4.1 Layout ...............................................................................................................................................................155
4.2 Removal ............................................................................................................................................................157
4.3 Disassembly ......................................................................................................................................................160
4.4 Inspection ..........................................................................................................................................................160
4.5 Assemble ...........................................................................................................................................................160
4.6 Installation.........................................................................................................................................................161
- 150 -
Section 1 Cooling System principle of thermal expansion and contraction, the hot
coolant and steam will flow from radiator.
1.1 On-Vehicle Inspection
1.1.3.2 Make sure there is no rust or incrustant in the
1.1.1 Cooling system inspection
radiator cap or radiator filler hole. Make sure there is no
WARNING: Don’t open the radiator cap before
oil floating on the coolant level.
the engine and radiator cooled down thoroughly in
1.1.3.3 Install the radiator cap.
order to prevent burning. Depending on the
1.1.4 Check clogging condition of the fins
principle of thermal expansion and contraction, the
(1) If the fins are logging, clean it with water or vapor
hot coolant and steam will flow from radiator.
cleaner, then dry it up with the compressed air.
1.1.1.1 Fill coolant, close the radiator cap and
NOTICE: The inject direction must be vertical to the
connect a radiator cap tester.
main plate surface to prevent damage to the fins.
1.1.1.2 Start and warm up the engine.
1.1.1.3 Pressurize to 137 kPa, make sure there is no
If it is too narrow between the vapor cleaner and main
pressure leakage.
plate, then maybe break the fins. So please keep the
distances as follows.
Inject pressure (kPa) Inject distance (mm)

2.942 - 4.903 300
4.903 - 7.845 500
If the fins tilt, fix them up with screwdriver or pliers.

Don’t use ionized water.
If there is leakage, please check the hose, radiator

and water pump. If there is no coolant leakage,
please check the engine body.
1.1.1.4 Pressurize below 177 kPa.
1.1.2 Check the coolant level in sub tank
Normally, the coolant level should be between
"LOW" and ―FULL‖.
HINT: If the level is below ―LOW‖, then check if
there is leakage and fill the coolant to ―FULL‖.
1.1.3 Check the cooling performance
1.1.3.1 Open the radiator cap.
WARNING: In order to prevent getting burn, don’t
open the radiator cap before the engine and radiator
cooled down thoroughly. Depending on the
Section 2 Electronic Fan System

2.1 Layout
Engine Compartment
ALT fuse
Electric Fan Relay
Radiator fuse
Driving View
AM1 fuse
IG relay IG1 fuse
ECU-IG fuse
Fan Motor Engine Coolant
Temperature Sensor
- 151 -
2.2 Circuit Diagram
ECT Sensor
Front Compartment Distribution Box
Instrument Panel Distribution Box
Instrument Panel Distribution Box
Center Connector
IG Switch
Fusible Links
Cooling Fan Motor
Fusible Links
Battery
- 152 -
2.3 On-vehicle Inspection 2.3.2 Check the operate condition of electric fan under
2.3.1 Check the operate condition of electric fan the high temperature (over 93°)
under the low temperature (below 83°) 2.3.2.1 Start the engine and make the coolant temperature
2.3.1.1 Turn off the ignition switch. reaches to 93°.
2.3.1.2 Make sure the electric fan does not start. Hint: The coolant temperature can be measured from the
If started, please check the electric fan relay and coolant temperature sensor on the engine outlet.
engine coolant temperature sensor and if the circuit 2.3.2.2 Check the engine coolant temperature sensor.
between them is disconnected. 2.3.3 Check the fan motor
2.3.1.3 Remove the engine coolant temperature 2.3.3.1 Remove the fan motor.
sensor. 2.3.3.2 Connect the fan motor to the battery, make sure it
2.3.1.4 Make sure the electric fan rotates normally. rotates smoothly.
If not, please check the fuse, electric fan relay, 2.3.3.3 Use ammeter to measure the current of the circuit
ECM and electric fan. Moreover, check if there is which mentioned before.
short circuit between the electric fan relay and Specifications: With A/C switch 7.3-9.3 A (12V)
engine coolant temperature sensor. Without A/C switch 2.5-4.5 A (12V)
2.3.1.5 Install the engine coolant temperature 2.3.3.4 Install the fan motor.
sensor.
2.4 Inspection
2.4.1 Check the engine compartment
2.4.1.1 Check the resistance.
Use ohmmeter to measure the resistance of each wiring end in the circuit.
Measurement condition:
Measuring points Measurement value

G1 and E2 10 KÙ and more
G1 and E2 Below 1 Ù (Power supply voltage is applied between D3 and D6)
If the result is not the specified value, replace the engine compartment relay and junction end.
- 153 -
Section 3 Coolant
3.1 Replacement
3.1.1 Drain engine coolant
NOTICE: In order to prevent getting burn, don’t
open the radiator cap before the engine and radiator
cooled down thoroughly. Depending on the
principle of thermal expansion and contraction, the
hot coolant and steam will flow from radiator.
3.1.1.1 Remove the No.1 bolt and drain engine
coolant.
HINT: This bolt is located under the drive belt and

on the edge. 3.1.1.2 Remove the radiator cap.
Radiator Cap
Bolt 1
3.1.1.3 Move the radiator outlet hose from engine and shake radiator outlet hose for several times. If the level
bend it to drain coolant. becomes low, please fill coolant.．
3.1.2 Fill engine coolant 3.1.2.5 Install the radiator cap.
3.1.2.1 Install the radiator outlet hose on the side of 3.1.2.6 Fill coolant into the sub tank slowly until it
engine. reaches ―FULL‖.
3.1.2.2 Install the No.1 bolt. 3.1.2.7 Start engine till the electric fan works.
Torque: 20 N*m a. When engine temperature rises, please set as follows:
Manual air control system

Fan speed – position except the STOP
Settings position
Temperature – turn to ―WARM‖
A/C control switch - STOP
b. Warm up engine at the speed of 2000 to 2500 rpm till

the electric fan works.
3.1.2.8 When the engine is warming up, shake radiator
outlet hose for several times.
3.1.2.9 Stop the engine until the temperature of coolant
becomes low.
3.1.2.10 If the coolant level is below ―FULL‖, repeat
3.1.2.3 Fill coolant into the radiator until it is full. step 3.1.2.1 to 3.1.2.8 until the it reaches ―FULL‖.
Capacity: 4 L 3.1.2.11 Check coolant level inside the sub tank again.
NOTICE: Don’t use water instead of coolant. Fill coolant, if it is below ―FULL‖.
HINT: The use of improper coolant will damage the 3.1.3 Check for the coolant leakage condition
coolant system. 3.1.3.1 Fill coolant into the radiator, close radiator cap
Please use high-quality deionized glycol coolant. and connect a radiator tester.
3.1.2.4 Check coolant level inside the radiator and 3.1.3.2 Pressurize to 137 kPa, check the leakage.
- 154 -
Section 4 Radiator
4.1 Layout
Condenser Assembly
Washer
Clamp
Radiator Upper
Radiator Cover Support RH Support Pad Radiator Inlet Hose
Electrical Fan Wire Harness
Radiator Assembly Radiator Outlet Hose
Clamp
Radiator Lower
Support Pad
Water Tank Lower member
Radiator Cover Support LH

Front Bumper
Tightening Torque
Lower Bumper Frame

Non-reusable Part
- 155 -
Radiator Cap Assembly
Fan Assembly
Radiator Assembly
Radiator Upper Tank
O gasket
Radiator Core
Radiator Lower Tank O gasket
Tightening Torque Non-reusable Part
- 156 -
4.2 Removal
4.2.1 Drain engine coolant
NOTICE: In order to prevent getting burn, don’t open the radiator cap before the engine and radiator cooled down
thoroughly. Depending on the principle of thermal expansion and contraction, the hot coolant and steam will flow
from radiator.
4.2.1.1 Lift the vehicle to a proper height. Remove No.1 bolt and drain engine coolant.
HINT:
This bolt is located under the drive belt and on the edge.
4.2.1.2 Remove the radiator cap.
Radiator Cap
Bolt 1
4.2.1.3 Move the radiator outlet hose from engine and bend it to drain coolant.
4.2.2 Remove the bumper frame
4.2.2.1 Lift the vehicle to high working position, remove 9 bolts.
4.2.2.2 Remove 5 bolts and remove the bumper frame.
- 157 -
4.2.3 Remove the front bumper.
1 – Small Snap Button 2 – Combination Bolt 3 – Snap Button 4 – Rubber Head Bolt
4.2.3.1 Wind protective tape around the front bumper,

4.2.3.2 Remove 3 combination bolts and a snap button with wrench,
4.2.3.3 Disconnect 2 rubber head bolts and 2 small snap buttons with screwdriver,
4.2.3.4 Disconnect 4 claws on the left and right with screwdriver.
1 – Front Bumper Mounting Sleeve 2 - Screw
4.2.3.5 Remove 2 front bumper mounting sleeve,

4.2.3.6 Remove 3 screws,
4.2.3.7 Remove the front bumper.
4.2.4 Remove the water tank member support RH
4.2.5 Remove the water tank member support RH
4.2.6 Disconnect the fan motor power supply cord
- 158 -
4.2.6.1 Disconnect the fan motor power supply 4.2.9 Remove the condenser
cord and its connector. Remove 4 bolts, then remove the condenser from
radiator.
4.2.7 Remove the radiator inlet hose 4.2.10 Remove the water tank lower member
Remove the radiator inlet hose from radiator. Remove 6 bolts and water tank lower member.
4.2.8 Remove the radiator outlet hose 4.2.11 Remove the radiator
4.2.8.1 Disconnect the radiator outlet hose from the 4.2.11.1 Remove the radiator.
hose clip. NOTICE: Don’t remove condenser together with the
radiator.
4.2.11.2 Remove the sub tank hose from radiator.
4.2.8.2 Remove the radiator outlet hose from 4.2.11.3 Remove the bolt, open the clip and remove the
radiator. fan set from radiator.
- 159 -
4.2.11.4 Remove the radiator upper and lower 4.4 Inspection

support pads. 4.4.1 Inspect the radiator cap
NOTICE: If the radiator cap becomes dirty, clean it with
water.
Before using radiator cap, moisten the exhaust valve and
intake valve with water or coolant.
When proceed to step 4.4.1.1 and 4.4.1.2, make sure that
the test unit and horizontal are with the inclination of
more than 30°.
4.4.1.1 Use the radiator cap tester, draw the piston
slightly, then check if there is air drawn out of vacuum
valve.
Draw speed: three seconds per draw or faster.
NOTICE: Draw with a constant speed.
If there is no air coming from the vacuum valve, replace
4.3 Disassembly the radiator cap.
4.3.1 Open the main plate and mounting claw
(1) Open the main plate and mounting claw.
4.3.2 Remove the upper and lower tanks Radiator Cap Test
4.3.2.1 Tap the radiator support (or the inlet and
outlet of radiator hose).
or more
Radiator Cap
4.4.1.2 Measure the safety valve opening pressure with

tester.
Draw speed: one second per draw.
NOTICE: Draw with high speed only at the first time
(so as to close the vacuum valve). Reduce the draw speed
later.
4.3.2.2 Remove the O-ring. Standard opening pressure: 93 – 123 kPa
4.3.3 Check if the contacting surface damaged Min. opening pressure: 78 kPa
Check if the contacting surface damaged. If opening pressure is below the min. opening pressure,
HINT: If the groove on the contacting surface is replace the radiator cap.
damaged, reassemble the tank please. Use pliers to Hint: The max. reading of test unit is opening pressure.
fix all of the deformations. 4.5 Assemble
The damage or impairment of contacting surface 4.5.1 Install the upper and lower tanks
might result in leakage. Repair or replace is 4.5.1.1 Make sure there is no foreign material on the
necessary. contacting surface. Install the O-ring. Make sure the ring
is not twisted.
Mounting Claw HINT: When clean the contacting surface, slightly finish
with sandpaper. Don't rub and damage it.
Normal Twisted
Mounting Claw
NOTICE: The radiator should only be repaired for

twice. If the radiator has been repaired for twice,
Twisted
then you need to replace the radiator main plate.
O gasket
- 160 -
4.5.1.2 Tap the contacting surface with plastic 4.5.2.4 After tapping, make sure the height of main plate
hammer, make sure there is no gap between the is within the specified range.
contacting surface and tank.
4.5.2 Lock the upper main plate tightly
4.5.2.1 Slowly press the main plate as shown in the
illustration. After several times, lock the main plate
by pressing the handle until get and hold the stop
screw.
4.5.3 Check the tank

Stop Bolt
4.5.3.1 Clog the radiator water inlet and outlet.
4.5.3.2 Flush compressed air into the radiator with its cap
tester.
Special tool
Water Tank
Test pressure: 177 kPa
NOTICE: The pressure shouldn’t be over 177 kPa.
4.5.3.3 Immerse the radiator into water.
4.5.3.4 Check the leakage.
HINT: When install the tank on radiator, there will be air
maintaining between the tank and main plate. After
Mounting Claw immersing the radiator into water, the air will leak. So,
before testing the tank, immerse the radiator into water
until the air disappears.
4.5.2.2 Don’t tap the convex near the interface (1),
slot (2) and groove (3).
Upper Tank
Main Plate
Grommet
4.6 Installation
4.5.2.3 Don’t tap these points indicated in the fig. 4.6.1 Install the radiator
with tool. Use vise and prevent damaging to the 4.6.1.1 Install the 2 upper and 2 lower support pads to the
main plate. radiator.
- 161 -
4.6.1.2 Install the electric fan set to the radiator, 4.6.3 Connect the condenser
install the clip properly and tighten the bolt. 4.6.3.1 Connect the condenser with 2 bolts.
Torque: 7.5 N*m Torque: 9.8 N*m
4.6.1.3 Install the sub tank to radiator. 4.6.4 Install the radiator outlet hose
4.6.1.4 Position the radiator assembly onto tank 4.6.4.1 Connect the radiator outlet hose with steel band
lower member. resilient clamp.
4.6.2 Install tank lower member, tighten 6 bolts. 4.6.4.2 Fasten the electric fan hose clip.
Torque: 5.5 N*m
- 162 -
4.6.5 Install the radiator inlet hose 4.6.7.4 Shake the radiator inlet and outlet hose manually
4.6.5.1 Connect the radiator inlet hose with steel to stable the coolant level. If the level becomes low,
band resilient clamp. please fill coolant.
4.6.7. 5 Install the radiator cap.
4.6.7. 6 Fill coolant into the sub tank slowly until it
reaches ―FULL‖.
4.6.7.7 Warm up engine till the electric fan works.

a. When engine temperature rises, please set as follows:
Manual air control system

Fan speed – position except the
Settings STOP position
Temperature – turn to ―WARM‖
A/C control switch - STOP
b. Warm up engine at the speed of 2000 to 2500 rpm till

4.6.6 Connect the fan motor power supply cord the electric fan works.
4.6.6.1 Connect the fan motor power supply cord 4.6.7.8 When the engine is warming up, shake radiator
and fasten the power supply clip. outlet hose for several times.
4.6.7.9 Stop the engine until the temperature of coolant
becomes low.
4.6.7.10 If the coolant level is below ―FULL‖, repeat step
4.6.7.1 to 4.6.7.8 until it reaches ―FULL‖.
4.6.7.11 Check coolant level inside the sub tank again.
Fill coolant, if it is below ―FULL‖.
4.6.8 Cooling system inspection

WARING: In order to prevent getting burn, don’t open
the radiator cap before the engine and radiator cooled
down thoroughly. Depending on the principle of thermal
expansion and contraction, the hot coolant and steam will
flow from radiator.
4.6.8.1 Fill coolant, close the radiator cap and connect a
4.6.7 Add engine coolant radiator cap tester.
4.6.7.1 Connect radiator outlet hose on the side of 4.6.8.2 Start and warm up the engine.
the engine. 4.6.8.3 Pressurize to 137 kPa, make sure there is no
4.6.7.2 Install the No.1 bolt. pressure leakage.
Torque: 20 N*m If there is leakage, please check the hose, radiator and
4.6.7.3 Add coolant into the radiator till full. water pump. If there is no coolant leakage, please check
Capacity: 4.0 L the engine body.
NOTICE: Don’t use water instead of coolant.
Hint: The use of improper coolant might damage
the coolant system.
Use the special coolant or equal-quality deionized
glycol coolant.
4.6.8.4 Pressurize below 177 kPa.

4.6.9 Install the tank member column RH
4.6.10 Install the tank member column LH
4.6.11 Install the front bumper cover plate
- 163 -
1 – Small Snap Button 2 – Combination Bolt 3 – Snap Button 4 – Rubber Head Bolt
4.6.11.1 Wind protective tape around the front bumper,

4.6.11.2 Install 3 combination bolts and a snap button with wrench,
4.6.11.3 Install 2 rubber head bolts and 2 small snap buttons,
4.6.11.4 Secure 4 claws on the left and right,
1 – Front Bumper Mounting Sleeve 2 - Screw
4.6.11.5 Install 2 front bumper mounting sleeve,

4.6.11.6 Install 3 bolts,
4.6.11.7 Complete the installation of the front bumper.
4.6.12 Install the engine compartment under cover plate
4.6.12.1 Tighten 5 bolts, install the engine under cover plate.
4.6.12.2 Tighten 9 bolts.
- 164 -
Chapter 7 Exhaust System
Section 1 Layout ........................................................................................................................................... 166
Section 2 Removal ........................................................................................................................................ 167
Section 3 Installation .................................................................................................................................... 167
- 165 -
Section 1 Layout
Hanger
Hanger
Muffler with Exhaust Pipe Assembly
Metal Band
Hanger
Cup Grommet
Front Exhaust Pipe
Oxygen Sensor
Holder
Spring
Tightening Torque
- 166 -
Section 2 Removal Section 3 Installation

1. Remove the oxygen sensor 1. Install the muffler with exhaust pipe assembly
(1) Disengage the oxygen sensor holder (1) Install 2 No.4 hangers and the muffler with exhaust
(2) Remove the oxygen sensor pipe assembly.
2 Remove the front exhaust pipe assembly 2. Install the front exhaust pipe assembly
(1) Loosen the bolt, open the metal band (1) Measure the spring free length with vernier caliper.
(2). Remove 2 bolts, 2 springs and cup grommet. Min. free length: 40.5 mm
(3). Remove the No.4 hanger and remove the front If less, replace the spring.
exhaust pipe assembly
3. Remove the muffler with exhaust pipe assembly (2) Replace a new cup grommet and tap it into the
(1). Remove 2 No.4 hangers and remove the muffler three-way catalytic converter outlet pipe with a plastic
with exhaust pipe assembly hammer and a small piece of wooden block.
Ä¾¿
Wooden Block
é
Cup Grommet
ÍëÐÎÃÜ·âµæ
NOTICE: Make sure installation direction is correct.

Don’t damage the outer surface of cup grommet.
The cup grommet is disposable.
Don’t push the cup grommet into the three-way
catalytic converter with the front exhaust pipe.
- 167 -
(3) Install the front exhaust pipe assembly with 2 bolts 3. Install the oxygen sensor
and 2 springs.
Torque: 45 N*m (1) Install the oxygen sensor.
(4) Install the No.4 hanger. Torque: 44 N*m
(5) Install the bolt and band.
Torque: 32 N*m (2) Connect the oxygen sensor holder.
NOTICE: Please align the marked point on band to the
stamped groove.
4. Check the exhaust leakage condition
- 168 -
Chapter 8 Transmission Case

Part 1 Disassembly and Inspection ........................................................................................................................ 170
Section 1 Disassembly (Fig.1-1-1) and Detail (Table 1-1-1) For the Front Case Peripheral Components.......... 170
Section 2 Disassembly Diagram of the Rear Case Peripheral Components ......................................................... 173
Section 3 Transmission Case Assembly Disassembly Diagram ........................................................................... 174
Section 4 Case Set Disassembly Diagram ............................................................................................................. 175
Section 5 Main Shaft Set Inspection and Disassembly ......................................................................................... 177
Section 6 SUB Shaft Set Inspection and Disassembly .......................................................................................... 180
Section 7 Differential Inspection and Disassembly .............................................................................................. 183
Section 8 Manual Shift Assembly Disassembly and Inspection ........................................................................... 185
Section 9 Shift Lever Fork Disassemly ................................................................................................................. 187
Part 2. Assemble and Inspection............................................................................................................................ 189
Section 1 Manual Shift Assembly Assemble ........................................................................................................ 189
Section 2 Fork Installation ..................................................................................................................................... 191
Section 3 Differential Installation.......................................................................................................................... 193
Section 4 SUB Shaft Installation ........................................................................................................................... 195
Section 5 Main Shaft Installation .......................................................................................................................... 199
Section 6. Rear Case Installation ........................................................................................................................... 203
Section 7 Front Case Installation ........................................................................................................................... 204
Section 8 Closing ................................................................................................................................................... 205
- 169 -
Part 1 Disassembly and Inspection

Section 1 Disassembly (Fig.1-1-1) and Detail (Table 1-1-1) For the Front Case
Peripheral Components
Fig. 1-1
Table 1-1
1 Separating arm return 11 Release fork 21 Cable bracket

spring
2 Return spring support 1 12 Split washer 22 Bolt
bolt
3 Wire nail bracket bolt 13 Dust cover 23 Support 2
gasket
4 Return spring support 1 14 Separating arm oil seal 24 Hexagon flange bolt
5 Separating arm unit 15 Support 3 25 Speed sensor body
6 Bolt 16 Spring washer 26 O-ring
7 Engine speed sensor 17 Nut 27 Speed sensor driven
gear
8 Separating arm torsion 18 Bolt spring washer and plate 28 Spring
spring washer subassembly
9 Torsion spring stopper 19 Gasket 29 8 MM washer
bracket
10 Self aligning clutch 20 Cable bracket bolt 30 Snap spring
release bearing
- 170 -
NOTICE: Put the transmission case on two 1.4 Remove the support 2 (23), bolt (22) and gasket
wooden blocks which are enough to bear, in (16).
order to prevent damage when the case touches
ground.
1.1 Remove the engine speed sensor (7) and bolt
(6).
1.5 Remove the release bearing snap spring and self

aligning clutch release bearing (10).
1.2 Disassemble the separating arm return spring

(1).
1.6 Loosen the separating arm torsion spring (8).
1.3 Remove the return spring support 1 bolt (2),

wire nail bracket bolt gasket (3) and return spring
support 1 (4).
1.7 Remove the separating arm split washer (12).
- 171 -
1.8 Take out the separating arm unit (5), take off 1.11 Remove the bolt set (17) and the support 3 (15).
the release fork (11), torsion spring stopper Remove the cable bracket bolt (20), cable bracket
bracket (9) and separating arm torsion spring (8) gasket (19) and the cable bracket (16).
sequentially.
1.12 Remove the speed sensor set (A) and bolt (24).
1.9 Remove the separating arm oil seal (14).
1.10 Take off the dust cover (13).
- 172 -
Section 2 Disassembly Diagram of the Rear Case Peripheral Components

Hexagon head bolt and spring
1
washer subassembly
2 Socket connector set
3 Return spring support 2
4 Manual shift assembly
5 Back-up light switch set
6 Damper spring
7 Gasket
Filler plug, drain plug, oil gauge
8
plug
Filler plug sheet, drain plug sheet,
9
oil gauge plug gasket
10 Check ball set
11 Reverse shaft stopper bolt gasket
12 Reverse shaft stopper bolt
13 Wire nail bracket set
14 Wire nail bracket gasket
15 Bolt
16 Support 1
17 Gasket
18 Bolt
2.1 Remove the filler plug, drain plug, oil gauge plug (8) .3 Remove the back-up light switch set (5) with special
and gasket (9). tool.
2.2 Remove the back-up light switch set wire harness 2.4 Remove the check ball set (10).
(5).
- 173 -
2.5 Remove the 4 hexagon head bolt and spring Section 3 Transmission Case
washer subassembly (1), return spring support 2
(3), socket connector set (2), manual shift Assembly Disassembly Diagram
assembly (4) and interior damper spring 3.1 Remove 5 closing bolts (1) on the front case in
sequentially. order.
2.6 Remove the reverse shaft stopper bolt (12) 3.2 Alternately remove 8 closing bolts (2) on the rear
and gasket (11). case and take off the transmission rear case (3).
2.7 Remove the support set (13), bolt (15) and 3.3 Remove the reverse idler gear shaft (4) and
gasket (14) from case.
reverse idler gear (5).
2.8 Remove the support 1 (16), bolt (18) and 3.4 Remove 2 bolts (6), take off the reverse shaft
gasket (17). fork set (7).
17
- 174 -
3.5 Remove the main shaft (8), sub shaft set (9) Section 4 Case Set Disassembly
and gearshift (10).
Diagram
4.2 Remove the magnet (2) from front case.
3.6 Take out differential transmission set (11).
4.3 Remove the front case main shaft oil seal (3)
with special tool.
4.4 Remove the tapered bearing outer ring (4) on the

front case countershaft with special tool (A).
- 175 -
4.5 Take the oil guide plate (5) out of case. 4.9 Remove the front case differential transmission
tapered bearing outer ring (8) with special tool (C).
4.6 Remove the oil seal spring (6) with special 4.10 Remove the main shaft adjusting shim (9) from
tool. rear case.
4.11 Remove the tapered bearing outer ring (10) on

4.7 Remove the rear case differential the rear case countershaft with special tool (D).
transmission oil seal with special tool (B).
4.12 Remove the sub shaft adjusting shim (11) from

4.8 Remove the front case differential rear case.
transmission oil seal (7) with special tool.
- 176 -
Section 5 Main Shaft Set Inspection and Disassembly
Deep Groove Ball Bearing Main Shaft
3rd Needle Roller Bearing
3rd Gear
3rd Synchronizer Ring
Synchronizer Hub SnapSpring
Slider
Snap Spring 31.8*38.8 (option) Synchronizer Hub SnapSpring
4th Synchronizer Hub
4th Synchronizer Ring
3rd,4th Synchronizer Sleeve

Washer
4th Needle Roller Bearing
Washer
4th Gear
Snap Spring 30*36 (option)
th th
Main Shaft 4 , 5 Distance Ring
5th Gear 5th Synchronizer Hub

Slider
5th Synchronizer Sleeve
Deep Groove Ball Bearing
- 177 -
5.1 Inspect the main shaft 3rd gear clearance with 5.5 The inspection for the 5th gear radial clearance.
feeler gauge (A). Standard: 0.015 - 0.058 mm
Standard: 0.10-0.35 mm
5.2 Move the main shaft 4th and 5th gear upward 5.6 Remove the deep groove ball bearing (1), 5th
and downward manually as shown in the figure synchronizer (2) and 5th gear (3).
to inspect the axial clearance.
Standard: 0.10 - 0.50 mm
Special tool
5.3 Move the 3rd gear left and right as shown in 5.7 Disassemble the 5th synchronizer.
the figure manually to inspect its radial
Synchronizer Sleeve
clearance.
Standard: 0.015 - 0.058 mm Synchronizer Snap Spring
Synchronizer Hub
Slider
Synchronizer Snap Spring
5.8 Remove the 5th needle roller bearing (4).

th
5.4 The inspection for the 4 gear radial
clearance.
Standard: 0.015 - 0.058 mm
- 178 -
5.9 Take off the washer (5). 5.14 Take off the 4th synchronizer ring (10).
5.10 Remove the snap spring (6) with snap 5.15 Take off the washer (11).
spring pliers (30*36).
5.11 Remove the 4th and 5th distance ring (7). 5.16 Remove the snap spring (12) with snap spring
pliers.
5.12 Take off the 4th gear (8).

5.17 Use special tool to remove the 3rd gear (13)
together with the 3rd and 4th gear synchronizer (14).
Special tool
5.13 Take off the 4th needle roller bearing (9). 5.18 Remove the main shaft bearing (15) with
special tool.
Special tool
- 179 -
Section 6 SUB Shaft Set Inspection and Disassembly

Taper Roller Bearing
1st, 2nd Needle Roller Bearing

34*39*22.6 (option) Sub Shaft
1st Gear
1st Synchronizer Ring
1st, 2nd Synchronizer Hub

Synchronizer Hub Snap Spring
Slider
2nd Synchronizer Ring
Snap Spring
31.8*38.8 1st, 2nd Synchronizer Sleeve
(option)
Washer
2nd Gear
1st, 2nd Needle Roller

Bearing 34*39*22.6 (option)
3rd Gear
3rd, 4th Distance Ring

54th Gear
th
4 Gear
Sub Shaft 5th Snap Spring

31.8*38.8 (option)
- 180 -
6.1 Remove the sub shaft taper roller bearing (1) 6.5 Measure the radial clearance of sub shaft 2nd
with special tool as shown in the figure. gear as shown in the figure.
NOTE: Make sure apply the force on the inner Standard: 0.015 - 0.056 mm
ring of bearing, when remove the taper roller
bearing.
Special tool
6.6 Secure the sub shaft, then remove the stopper

st
6.2 Measure the axial clearance of sub shaft 1 snap spring (2) as shown in the figure.
gear with feeler gauge.
6.7 Put the sub shaft on special tool as shown in the

figure and remove the sub shaft 4th gear (3) and 5th
6.3 Measure the axial clearance of sub shaft 2nd gear (4) together with press.
gear with feeler gauge.
6.8 Remove the sub shaft 3rd and 4th gear distance
6.4 Measure the radial clearance of sub shaft 1 st ring (5).
gear as shown in the figure.
Standard: 0.015 - 0.056 mm
- 181 -
6.9 Put the gear on special tool as shown in the 6.14 Put the sub shaft on special tool and remove the
figure and remove the sub shaft 2nd gear (6) and 1st gear (12) and 1st, 2nd synchronizer (13) assembly
3rd gear (7) with press. together with press.
Special tool
6.10 Take off the sub shaft 2nd needle roller

bearing (8). 6.15 Take off the 1st needle roller bearing (14).
6.11 Take off the washer (9).

6.16 Remove the taper roller bearing (15) on the
other end of sub shaft with special tool.
NOTE: Square the bearing with press and make sure
apply the force on its inner ring.
Special tool
6.12 Take off the sub shaft 2nd gear synchronizer

ring (10).
6.17 Disassemble the 1st and 2nd synchronizer

assembly.
Synchronizer Hub Snap
Spring Synchronizer Hub
6.13 Remove the snap spring (11) with snap

spring pliers.
1st, 2nd Sleeve

Slider
- 182 -
Section 7 Differential Inspection and Disassembly
Differential Right Bearing
Vehicle Sensor Drive Gear
Planetary Ball Sheet (2)

Straight Pin
Planetary (2)
Planetary Shaft
Differential Case
Side Gear (2)
Side Gear Ball Sheet (2)
Main Speed Reduction Driven Gear
Differential Bolt (6)
Differential Left Bearing
- 183 -
7.1 Remove the differential transmission left and 7.4 Slightly tap the differential transmission driven
right bearings with screw extractor special aided gear with plastic hammer, then take it off.
tool.
Note: It is necessary to apply the force on the
bearing inner ring.
7.5 Remove the straight pin (4) on the planetary

shaft with special tool.
7.2 Remove the speed sensor drive gear (2).
7.3 Remove 6 differential transmission bolts (3) 7.6 Take out the planetary shaft (5), planetary (6),
with wrench. side gear (7), planetary adjusting shim (8) and side
gear adjusting shim (9) sequentially.
- 184 -
Section 8 Manual Shift Assembly Disassembly and Inspection
Shift Shaft Set
Dust Cover
Shift Shaft Fork

Shift Shaft Oil Seal
Shift Arm Cover

Clamping Retainer 1
Select Spring Collar Shift Shaft Set

Gear Interlock Carrier
Select Spring
Shift Lever Fork

Nylon Bush
Resilient Pin
Clamping Retainer 2
- 185 -
8.1 Remove the resilient pin (1) on shift lever 8.6 Remove the shift shaft fork bolt (7) with wrench
fork with special tool. and take off the select lever fork (8) and shift shaft
set accordingly.
8.2 Remove the clamping retainer 2 (2). 8.7 Remove the clamping retainer 1 (9).
8.3 Remove the shift lever fork (3) and gear 8.8 Take off the shift shaft set (10) and dust cover
interlock carrier (4) accordingly. (11) accordingly.
8.4 Take off the select spring (5). 8.9 Remove the nylon bush (12) with tools.
8.5 Take off the select spring collar (6). 8.10 Remove the oil seal (13) with special tool.
- 186 -
Section 9 Shift Lever Fork Disassemly
5th Gear Shift Fork

Clamping Retainer
5th Shift Lever
1st and 2nd Shift Lever

3rd and 4th Shift Lever
Straight Pin 1
3rd and 4th Gear Shift Fork

Spring
Resilient Pin
1st and 2nd Gear Shift Fork Bolt
5th Gear Shift Fork

1st and 2nd Gear Shift Fork
Resilient Pin
Reverse Block
Straight Pin 2
Clamping Retainer (2)
Bolt
- 187 -
9.1 Remove the clamping retainer (1) (2) on the bottom 9.4 Take off the 5th reverse gear fork (7) and spring (8).
of 3rd and 4th gear fork shaft and 5th reverse fork shaft Remove the straight pin (9) connected 5th gear shift fork
with tool. and fork shaft and 5th gear shift fork (10).
9.2 Keep these two fork shaft on the same level. 9.5 Remove the clamping retainer (11) on the upper end
Remove reverse block (3) and take straight pin 2 (4) out of 3rd and 4th gear fork shaft with tools. Remove the bolt
of it. (12) which is connected the 3rd and 4th gear shift fork
and fork shaft and take off the 3rd and 4th gear shift fork
(13).
9.3 Remove the straight pin 1 (5) in the 5 th reverse fork.

Remove the clamping retainer (6) on the upper end of
fork shaft with tools. 9.6 Remove the bolt (14) which is connected the 1 st and
2nd gear shift fork and fork shaft, then take off the 1st
and 2nd gear shift fork (15). Remove the bolt (16)
connected the 1st and 2nd gear shift fork and fork shaft
and take off the 1st and 2nd gear fork (17).
- 188 -
Part 2. Assemble and Inspection

Section 1 Manual Shift Assembly Assemble
NOTICE: Before reassembling, check if the bearing rotates smoothly and the damage condition of inner and outer
rings. If hardly rotate, large noise and bad damage occur, replace a new bearing assembly. All of the used oil seals
need to be replaced.
Shift Shaft Set
Dust Cover
Shift Shaft Fork Shift Shaft Oil Seal
Shift Arm Cover

Clamping Retainer 1
Shift Shaft Set

Select Spring Collar
Gear Interlock Carrier
Select Spring
Shift Lever Fork
Nylon Bush
Resilient Pin
Clamping Retainer 2
1.1 Apply a proper coat of grease to the shift shaft oil 1.2 Apply a proper coat of grease to the shift shaft oil
seal (1) inner and outer rings. Install them into the seal (2) inner and outer rings. Install them into the
shift arm cover with special tool. shift arm cover with special tool.
- 189 -
1.3 Install the nylon bush (3) 1.8 Fit the select spring collar (11).
1.4 Wrap the shift shaft set (5) with dust cover (4) 1.9 Fit the select spring (12).
and install the shift shaft set into shift arm cover
(6).
1.10 Install the shift lever fork (13) and gear

1.5 Fit the clamping retainer 1 (7) with special interlock carrier (14) in the direction indicated in
clamping tools. the figure. Pay attention to the direction of part
when installing.
1.11 Install the resilient pin (15) with special tool.

1.6 Assemble the shift shaft and shift shaft fork
(8).
1.12 Fit the clamping retainer 2 (16) with special

tool.
1.7 Assemble the shift shaft (9) and shift shaft fork
(10) in position as shown in the figure. Tighten the
shift shaft bolt (tightening torque: 38 N*m).
- 190 -
Section 2 Fork Installation
5th Gear Shift Fork

Clamping Retainer
5th Shift Lever
1st and 2nd Shift Lever

3rd and 4th Shift Lever
Straight Pin 1
3rd and 4th Gear Shift Fork

Spring
Resilient Pin
1st and 2nd Gear Shift Fork Bolt
5th Gear Shift Fork

1st and 2nd Gear Shift Fork
Resilient Pin
Reverse Block
Straight Pin 2
Bolt
- 191 -
2.1 Cover the 1st and 2nd shift lever with the 1st and 2nd 2.4 Install the spring (11), 5th gear shift fork (12) on the
gear shift fork. Align the pin hole with the hole in the 1 st 5th shift lever (13), then install the clamping retainer (14)
and 2nd shift lever. Install the resilient pin (3) with with special tool. Install the straight pin 1 (15).
special tool. Pay attention to the bolt holes in the 1st and
2nd gear shift fork and make sure the direction is correct.
Then install the 1st and 2nd gear shift fork (2) on the 1st
and 2nd gear shift fork (4) and tighten the bolt (5)
(tightening torque: 16 N*m).
2.5 Arrange the 3rd and 4th gear fork set (16) and 5th gear
fork set (17) as shown in the figure. Install the reverse
block (18), align the pin hole and install the straight pin
2 (19).
2.2 Install the 3rd and 4th gear shift fork (6) on the 3rd
and 4th shift lever (7). Align the fork hole with the fork
shaft threaded hole and pay attention to the direction.
Tighten the bolt (8) (Tightening torque: 16 N*m).
Finally, install the clamping retainer (9) on the fork
shaft with special tool.
2.6 Install the clamping retainer (20)(21) which are on

the bottom of set with tools.
2.3 Install the 5th gear shift fork (10) on the 5th shift
lever (11), align the pin hole and install the resilient pin
(12) with tools.
- 192 -
Section 3 Differential Installation
Differential Right Bearing
Vehicle Sensor Drive Gear
Planetary Ball Sheet (2)

Straight Pin
Planetary (2)
Planetary Shaft
Differential Case
Side Gear (2)
Side Gear Ball Sheet (2)
Main Speed Reduction Driven Gear
Differential Bolt (6)
Differential Left Bearing
- 193 -
3.1 Select a proper side gear ball gasket (1). Install side 3.5 Assemble the main speed reduction driven gear (8).
gear (2), planetary (3) and planetary ball sheet (4) on NOTICE: Put the inner ring chamfer downward.
the differential case (5).
3.6 Assemble 6 differential bolts (9) with special tool.

3.2 Insert planetary shaft (6) into the hole and align the Tightening torque: 124 N*m
pin hole.
3.7 Install the speed sensor drive gear (10) on the

3.3 Inspect the clearance of side gear with special tool corresponding locations of differential case and fit the
(A). differential bolt (11) into position.
3.8 Assemble the bearing (12) on the other end of

3.4 Put the straight pin (7) into corresponding holes and differential.
install it into position with tools.
- 194 -
Section 4 SUB Shaft Installation

1st, 2nd Needle Roller Bearing

34*39*22.6 (option) Sub Shaft
1st Gear
1st Synchronizer Ring
Synchronizer Hub
Slider

Snap Spring 31.8*38.8
(option) 2nd Synchronizer Ring
Washer 1st, 2nd Synchronizer Sleeve
3rd Gear 2nd Gear 1st, 2nd Needle Roller

Bearing 34*39*22.6 (option)
3rd Gear
3rd, 4th Distance Ring
4th Gear
Sub Shaft 5th Snap Spring

27.2*37.7 (option)
- 195 -
4.1 Before assembling, apply grease on the shaft inner 4.5 Assemble the 1st and 2nd synchronizer assembly (5)
ring. Then assemble the taper roller bearing (1) on the with special tool, pay attention to the direction and fit it
sub shaft bottom with special tool. Make sure apply the into position.
force on the inner ring of bearing.
Special tool
Special tool
4.2 Apply grease on the needle roller bearing, then 4.6 Select a proper snap spring (6).
install the 1st gear needle roller bearing (2).
4.3 Assemble the sub shaft 1st gear (3). 4.7 Install the snap spring (6) with special tool.
4.8 Measure the axial clearance of 1 st gear with feeler

4.4 Install the 1st synchronizer ring (4) on the 1st gear gauge.
unit taper. Standard: 0.10 - 0.35 mm
If the result is out of the specified range, go to the 3rd
step and reinstall the 1st gear.
- 196 -
4.9 Measure the thrust clearance of 1 st gear with special 4.13 Install the 2nd gear (10).
feeler gauge.
Standard: 0.015 - 0.056 mm
step and reinstall the 1st gear.
4.14 Assemble the 3rd gear (11) with special tool.
4.10 Install the washer (7).
SST
4.15 Measure the axial clearance of 2nd gear with feeler

gauge.
If the result is out of the specified range, go to the 13th
4.11 Apply grease on the 2nd gear needle roller bearing, step and reinstall the 2nd gear.
then install the 2nd gear needle roller bearing (8).
4.12 Install the 2nd synchronizer ring (9). 4.16 Measure the radial clearance of 2nd gear with
special feeler gauge.
Standard: 0.015 - 0.056 mm
step and reinstall the 2nd gear.
- 197 -
4.17 Install the 3rd and 4th distance ring (12). 4.20 Assemble the sub shaft 5th snap spring (15).
4.18 Install the 4th gear (13) with special tool and pay 4.21 Assemble the sub shaft 5th snap spring (15) with
attention to the gear direction. special tool.
4.19 Install the 5th gear (14) with special tool and pay 4.22 Assemble the taper roller bearing (16) on the top
attention to the gear direction. end of sub shaft with special tool and make sure apply
the force on the inner ring of bearing.
Special tool
- 198 -
Section 5 Main Shaft Installation
Deep Groove Ball Bearing Main Shaft
3rd Needle Roller Bearing
3rd Gear
3rd Synchronizer Ring
Slider
Snap Spring 31.8*38.8 (option)
Synchronizer Hub
Washer 3rd,4th Synchronizer Sleeve

Washer
4th Gear
Snap Spring 30*36 (option)

th th
4 , 5 Distance Ring

31*36*20
5th Gear Synchronizer Hub

Slider
5th Synchronizer Sleeve
Deep Groove Ball Bearing
- 199 -
5.1 Assemble the main shaft front deep groove ball 5.5 Assemble the synchronizer assembly (5) with
bearing (1) with special tool. special tool.
Special tool
5.2 Apply grease on the needle roller bearing, then 5.6 Assemble the 3rd and 4th synchronizer snap spring (6)
install the 3rd gear needle roller bearing (2). (31.8*38.8).
5.3 Install the 3rd gear (3). 5.7 Install the snap spring (6) with special tool.
5.4 Install the 3rd synchronizer ring (4) on the 3rd gear 5.8 Measure the axial clearance of 3 rd gear.
unit taper. Standard: 0.10 - 0.35 mm
step.
- 200 -
5.9 Measure the radial clearance of 3 rd gear with special 5.13 Install the 4th gear on the 4th synchronizer ring
feeler gauge. taper.
Standard: 0.015 - 0.058 mm
step.
5.14 Put the steel ball (11) into corresponding hole.
5.10 Install the 4th synchronizer ring (7).
5.15 Install the 4th and 5th distance ring (12) and make
sure the groove can be engaged in the steel ball.
5.16 Assemble the snap spring (13) (30*36).

5.12 Apply grease on the needle roller bearing, then
install the 4th gear needle roller bearing (9).
- 201 -
5.17 Assemble the 4th snap spring (13) with special tool.
5.21 Apply grease on the needle roller bearing, then
install the 5th gear needle roller bearing (15).
5.18 Measure the axial clearance of 4th gear with special

feeler gauge.
Standard: 0.1 - 0.55 mm 5.22 Install the 5th gear (16).
step.
5.23 Install the 5th synchronizer ring (17) on the 5th gear
unit taper.
5.19 Measure the radial clearance of 4th gear with
step.
5.24 Assemble the 5th synchronizer assembly (18) with

special tool, pay attention to the gear direction.
Special tool
- 202 -
5.25 Assemble the main shaft top end deep groove ball Section 6. Rear Case Installation
bearing (19) with special tool. 6.1 Assemble the rear case differential bearing outer
ring (1) with special tool.
Special tool
Special tool
6.2 Install oil groove (2) on the rear case.

5.26 Measure the axial clearance of 5th gear with special
feeler gauge.
If the result is out of the specified range, go to the 22nd
step.
6.3 Install the assembled adjusting shim (3) on the rear

case.
5.27 Measure the radial clearance of 5th gear with

Standard: 0.015 - 0.058 mm
If the result is out of the specified range, go to the 22nd
step. 6.4 Assemble the rear case sub shaft bearing outer ring
(4) with special tool.
Special tool
6.5 Apply grease on the oil seal outer ring and assemble
the rear case differential oil seal with special tool.
Special tool
- 203 -
Section 7 Front Case Installation 7.4 Apply little grease on the oil seal outer ring and
assemble the main shaft oil seal (4) with special tool.
7.1 Install the deflector (1) and make sure the deflector
oil hole against the case oil groove.
7.5 Install the magnet (5).
7.2 Assemble the front case sub shaft bearing outer ring
(2) with special tool.
Special tool
7.3 Assemble the front case differential bearing outer

ring (3) with special tool.
Special tool
- 204 -
BYD F0 Maintenance & Repair Manual l
Section 8 Closing 8.4 Remove the rear case and install the sub shaft.
8.1 Install the differential set (1).
8.2 Install the rear case and tighten all of the closing 8.5 Install the rear case and tighten all of the closing
bolts (2). bolts (3).
8.3 Move the differential with special tool and measure 8.6 Move the differential with special tool and measure
its moving torque. the moving torque of differential and sub shaft.
Standard: new bearing (0.78-1.57 N*m) Standard: new bearing (2.79-5.56 N*m)
Running-in bearing (0.49-0.98 N*m) Running-in bearing (1.73-3.47 N*m)
If the result is out of the specified range, replace the If the result is out of the specified range, replace the
differential adjusting shim on the rear case until it is differential adjusting shim on the rear case until it is
qualified. qualified.
Special tool Special tool
- 205 -
8.7 Remove the rear case and install the fork set (4), 8.10 Install the reverse camshaft set and tighten the bolt
main shaft set (5) and sub shaft set (6) together into the (9).
front case. Bolt torque: 17 N*m
8.11 Apply an even seal packing on the front case

contacting surface.
8.8 Measure the distance between the case contacting

surface and main shaft top end bearing (A). Then,
measure the depth of rear case and reserve a proper
clearance.
Standard: 0.00-0.1 mm (clearance fit)
8.12 Install 8 closing bolts (10).

Bolt torque: 29 N*m
8.13 Install 5 closing bolts (11) on the engine contacting

8.9 Install the reverse gear (7) and reverse gear shaft surface.
(8). Bolt torque: 29 N*m
- 206 -
8.14 Install the reverse shaft stopper bolt (12). 8.18 Install the back-up light switch set (17) with
Tightening torque: 37 N*m special tool.
8.15 Apply grease on the rear case shift assembly

contacting surface. 8.19 Sort out the back-up light switch wiring harness
(18).
8.16 Install the shift assembly (13), return spring

support 2 (14) and back-up light switch socket 8.20 Install the oil plug (19).
connector holder (15). Bolt torque: 39 N*m
8.17 Install and tighten the stopper bolt (16). 8.21 Install the cable bracket (20) and tighten the bolt
Bolt torque: 37 N*m (21).
Bolt torque: 17 N*m
- 207 -
8.22 Install bracket 3 (22) on the cable bracket. 8.25 Apply little grease on the oil seal outer ring and
Bolt torque: 11 N*m install the separating arm oil seal with special tool.
Special tool
8.23 Install the dust cover (23). 8.26 Install the separating arm set (28), torsion spring
(29), torsion spring holder (30) and separating arm fork
(31).
8.24 Install the big shaft bush (24) and small shaft bush
(25) of separating arm and apply grease on (26) and
(27).
8.27 Install the retainer (32).
- 208 -
8.28 Install the separating arm torsion spring (33) 8.31 Install the speed sensor (36).
properly as shown in the figure. Bolt torque: 11 N*m
8.29 Apply little grease on the release bearing inner ring 8.32 Install the return spring (37).
and install the release bearing (34).
8.33 Install the bracket 1 (38) and install the bracket 2

8.30 Install the return spring support 1 (35). (39) wire nail bracket (40) on the front side.
Bolt torque: 11 N*m Bolt torque: 11 N*m
- 209 -

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BYD F0 Maintenance & Repair Manual

Section 6. Rear Case Installation ........................................................................................................................... 203

1.1 Main Parameters

The main parameters of the BYD371QA Engine are as follows:

1.2 Service Technical Data

Piston pin hole diameter 18 00..011

Fit clearance of the piston and

Valve stem diameter Intake valve: 50.0035 mm

Valve guide inner diameter 5 00..03

1.3 BYD371QA/QB Engine Tightening Torque Table

Section 2 Drive Belt

2.1.1 Loosen the bolt A firstly.

During installing, install the belt and tighten the bolt B

2.3 Drive belt adjustment

Section 3 Valve Clearance

3.1.1 Confirm that engine has cooled down.

3.1.6 Measure the valve clearance.

Install the cylinder head cover in the order shown in the

3.1.7 Turn the crankshaft 360°. Check the other 4

3.1.9 Install the ignition coil;

HINT: When measuring, insert the feeler gauge to

3.2.2 Check if the mark on the 2 camshaft

Blue Mark Blue Mark

3.2.6 Remove the inner hexagon tapered screw plug.

3.2.3 Turn the crankshaft clockwise approximately

HINT: If the keeper can not move, turn the hexagon

3.2.7 While turning the hexagon square on the

NOTICE: When removing the cam bearing cap, move

3.2.8 Take out of the screwdriver. Insert the special

NOTICE: When removing the screwdriver and

3.2.11 Remove the camshaft.

These above steps are for pressing back the plunger

3.2.10 Remove the bolt and cam bearing cap in the

3.2.12 Remove the lifter to be changed. A New Lifter Thickness

Lifter (to be changed) thickness = 5.25 mm

Group No. Thickness Group No. Thickness Group No. Thickness

3.2.15 Install the lifter.

3.2.16.7 Turn the intake camshaft clockwise with a

Intake Camshaft Exhaust Camshaft

NOTICE: If the marks are not aligned, turn the

Section 4 Timing Chain 4.1.4 Remove the crankshaft position sensor.

4.1.5 Remove the crankshaft pulley.

4.1.2 Remove the water pump inlet hose in the order

4.1.6 Remove the oil pan.

4.1.3 Remove the cylinder head cover.

Blue Mark Blue Mark

4.1.11 Remove the tensioner plate bolt, and remove the

4.2.3 Turn the intake camshaft slightly to tension the

If the resistance is less than 10 MÙ, go to the step 7.

5.1 Spark Plug Removal and Installation

5.2.7 Clean the spark plug.

5.1.2 Remove the spark plug with a special wrench.

5.2 Spark Plug Inspection

5.3 Compression Pressure Inspection Section 6 Engine

Compression pressure MPa

6.1.8 Remove the oil receiver

6.1.4 Remove the generator

6.1.9 Remove the crankshaft pulley

6.1.6 Align the timing mark Special tool

6.1.10 Remove the timing cover body

6.1.7 Remove the oil pan

6.1.11.3 Remove the tensioner plate bolt, and remove

6.1.12 Remove the crankshaft sprocket. Be sure to