qq6 PDF

Service Manual for Chery
QQ6
(QR513 Transmission Case)
After Sales Service Department of Chery

Automobile Sales Co., Ltd
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CONTENTS
Foreword ........................................................................................................................................................... 2
Chapter One Introduction of QR513 Transmission........................................................................................... 3
I. Assembly Drawing of QR513 Transmission.......................................................................................... 3
II. Driving Characteristics of QR513 Transmission .................................................................................. 4
III. SN of QR513 Transmission ................................................................................................................ 4
1. Print position of SN of QR513 transmission................................................................................. 4
2. Composition and connotation of SN of QR513 transmission ....................................................... 4
IV. Specification of QR513 Transmission ................................................................................................. 6
V. Maintenance Instruction ....................................................................................................................... 7
Chapter Two Decomposition of QR513 Transmission...................................................................................... 8
I. Decomposition Process for QR513 Transmission ................................................................................. 8
1. Bleeding lubricant in transmission ................................................................................................ 8
2. Disassembly of external parts of transmission .............................................................................. 8
3. Separation of gear shift mechanism and transmission................................................................... 9
4. Disassembly of the connecting bolts for clutch and transmission housings................................ 10
5. Separation of transmission and clutch housings.......................................................................... 10
6. Separation of interior transmission parts and fork module from the housing ............................. 11
7. Separation of differential assembly and clutch housing .............................................................. 12
8. Disassembly of gearshift fork mechanism .................................................................................. 12
9. Disassembly of gearshift mechanism .......................................................................................... 13
10. Disassembly of input shaft ........................................................................................................ 13
11. Disassembly of output shaft ...................................................................................................... 15
12. Disassembly of differential ....................................................................................................... 15
13. Disassembly of release mechanism of clutch............................................................................ 16
14. Disassembly of transmission housing ....................................................................................... 17
Chapter Three Assembly and Regulation of QR513 Transmission ................................................................. 18
I. Assembly of QR513 Transmission....................................................................................................... 18
1. Assembly of differential assembly .............................................................................................. 18
2. Assembly of clutch housing ........................................................................................................ 19
3. Assembly of transmission housing .............................................................................................. 23
4. Assembly of gearshift mechanism assembly............................................................................... 23
5. Assembly of gearshift fork assembly .......................................................................................... 24
6. Regulation and assembly of input shaft assembly....................................................................... 24
7. Regulation and assembly of output shaft assembly..................................................................... 26
8. Assembly and regulation of transmission assembly.................................................................... 28
9. Disassembly of external accessories of transmission .................................................................. 31
10. Refilling and volume regulation of transmission lubricant ....................................................... 32
II. Tightening Torque Table for Fasteners ............................................................................................... 34
Chapter Four General Failures and Troubleshooting........................................................................... 35

Foreword
1. This service manual applies to use and maintenance of QR513 transmission
manufactured by Chery Automobile Co., Ltd.
2. Service Manual for QR513 Transmission describes relations among various
parts and assemblies of this transmission, which provide the maintenance
personnel with a reference when maintaining and repairing QR513 transmission.
3. Due to restrictions of the compiler’s level and other conditions, errors and
imperfections may exist in this service manual. During maintenance and use,
please inform us of any problem in and improvement idea on QR513
transmission and this service manual, so that we can correct and perfect this
service manual, for which we express our thanks herein.

Chapter One Introduction of QR513 Transmission
I. Assembly Drawing of QR513 Transmission
1 2
3 4
1. Input shaft 2. Clutch 3. Output shaft 4. Differential

II. Driving Characteristics of QR513 Transmission
This transmission achieves five forward gears and one reverse gear through three groups of
synchronizers and two shafts-input shaft and output shaft; all forward gears adopt conventional engagement
system while reverse gear adopts a gliding idler device. The synchronizers of the first and second gears are
installed on output shaft while the synchronizers of the third, fourth and fifth gears are installed on input
shaft. When the transmission is shifted to various gears, these synchronizers will engage with corresponding
gear hub to enable transmission of power, and then the driving gear of main decelerator will drive the driven
gear of main decelerator and differential assembly to rotate, which will drive the drive shaft to drive the
wheels to rotate.
III. SN of QR513 Transmission
1. Print position of SN of QR513 transmission
The print position of SN of QR513 series transmission is as shown in the figure:
Position of number
2. Composition and connotation of SN of QR513 transmission
SN of QR513 series transmission is consisted of model and leaving factory number of the transmission case.

1) Model of the transmission case
Model of the transmission case is composed of code QR, number of shift gears of the transmission,
maximum transmission torque, characteristic code and structure specification number.
A complete transmission case model is as follows:
□□ ○ ○○ □□ □
Structure specification number
Characteristic code
Maximum transmission torque (kg·m)
Number of shift gears of the transmission case
Code QR
Among which, ○ indicates an Arabic numeral while □ indicates a letter.
2) Leaving factory number
Leaving factory number is composed of endnote of assembly part number (for that without endnote, us
AA), character code of the year of production, character code of the month of production, sequence
number of this transmission case among the transmission cases manufactured in that month and start
stop sign “*”. See Table 1 and Table 2 for check list of character codes of the year and of the month.
Complete form of leaving factory number of a transmission case is as follows:
* □ □ □ □ ○○○○○ *
Sequence number among the product of the
same model manufactured in that month
Character code of the month
Character code of the year

Endnote of assembly part number
Among which, ○ indicates an Arabic numeral, □ indicates a letter and indicates an Arabic numeral or a
letter. The endnote locates at tail end of the part code, for a fundamental model, no endnote. The endnote
should be modified when modification is made to structure, dimension, material, heat treatment requirements
and surface treatment etc. of the part or assembly on the basis of original product. The English letter in the
code should be upper case letter (use in sequence with “A” as the first), in order to avoid confusion, do not
use “I”, “O” and “X”. When the modification does not affect interchangeability, use “A” as the first; when
the modification affects interchangeability, skip “A”, use “B” as the first.
Table 1 Character Codes Indicating the Years

Year Code Year Code
1999 X 2015 F
2000 Y 2016 G
2001 1 2017 H
2002 2 2018 J
2003 3 2019 K

2004 4 2020 L
2005 5 2021 M
2006 6 2022 N
2007 7 2023 P
2008 8 2024 R
2009 9 2025 S
2010 A 2026 T
2011 B 2027 V
2012 C 2028 W
2013 D 2029 X
2014 E 2030 Y
Table 2 Character Codes Indicating the Months
Month Code Month Code
January A July G
February B August H
March C September J
April D October K
May E November L
June F December M
3) Illustration
For example: QR513MHA MH5H00001 indicates the first transmission case with the model as
QR513MHA manufactured in August, 2005.
IV. Specification of QR513 Transmission
QR513 Series Transmission

Type Machine Gear Mesh
Model QR513MHA QR513MHB
Velocity Velocity
Gear shift Teeth Ratio Teeth Ratio
Ratio Ratio
First Gear 3.545 39/11 3.167 38/12
Second Gear 2.05 41/20 2.05 41/20
Third Gear 1.423 37/26 1.423 37/26
Fourth Gear 1.065 33/31 1.065 33/31
Fifth Gear 0.865 32/37 0.865 32/37
Reverse Gear 3.364 37/11 3.364 37/11
Main reduction ratio 4.056 73/18 75 16

Speedometer 0.806 29/36 0.806 29/36
Largest input torque 130 Nm
Lubricant oil type GL-4 75W-90
Volume of lubricant 1.8L
V. Maintenance Instruction
l In order to ensure maintenance quality of the transmission, when operating, please be careful
and ensure cleanness of each part of the transmission.
l Use appropriate tools or special tools.
l Strictly follow the specification to assembly or adjustment to maintain so as to ensure that the
transmission can accomplish a favorable working position.

Chapter Two Decomposition of QR513 Transmission
I. Decomposition Process for QR513 Transmission
1. Bleeding lubricant in transmission
First, drive the vehicle onto a maintenance platform or hoist the vehicle and keep it on a horizontal
plane, screw off the bleeding plug as shown by the arrowhead, and then use a clean container to
accommodate lubricant of the transmission to completely bleed the lubricant in the transmission.
Figure 1
2. Disassembly of external parts of transmission
Switch the transmission to NEUTRAL position; use an appropriate tool to remove the locating seat of
the fork shaft as shown in Figure 2; Connecting bolts for gearshift housing and transmission housing and the
screws for backup lamp switch and idler shaft.

Locating seat of fork shaft Assembly of locating
for all gears (3) seat of fork shaft Screws for idle gear shaft
Bolts-for gearshift housing and Backup lamp switch assembly

Transmission housing (5)
Figure 2
3. Separation of gear shift mechanism and transmission
Remove the gearshift mechanism assembly from the place as shown in Figure 3; as a result of sealant,
the disassembly process may be difficult, so, use such tools as a hand hammer etc. to knock on the bulge at
flank of housing of the gearshift mechanism, and then take out the whole gearshift mechanism assembly
until the two housings completely separate; remember to be slow when taking out the gearshift mechanism
assembly, so as to prevent the return spring as shown in the figure from dropping out inside the transmission;
during disassembly, be careful not to damage the junction planes of the two housings, so as to avoid oil leak
after re-assembly.
Gearshift mechanism assembly Return spring (remember to prevent
it from dropping out)

Figure 3
4. Disassembly of the connecting bolts for clutch and transmission housings
Use a tool to remove the connecting bolts for transmission and clutch housings as shown in Figure 4.
Remember to remove the bolts both inside and outside the clutch housing when disassembling, and a sleeve
with long connecting rod is required when removing the bolts inside the clutch.
Connecting bolts for transmission and clutch housings
Figure 4
5. Separation of transmission and clutch housings
After the bolts for transmission and clutch housings are removed, separate clutch housing and
transmission housing (Figure 5). as a result of sealant, the separation process may be difficult, so, use such
tools as a hand hammer etc. to knock on the bulge at flank of housing of the transmission, and then take out
the whole transmission housing until the two housings completely separate; during disassembly, be careful
not to damage the junction planes of the two housings, so as to avoid oil leak of the transmission after
re-assembly.
10

Transmission housing Clutch housing
Figure 5
6. Separation of interior transmission parts and fork module from the housing
After transmission housing and clutch housing are separated, keep the clutch housing flat at the place as
shown in Figure 6, remove the bolts for bracket of reverse gear rocker arm, take out the reverse gear rocker
arm assembly and the pin on idler drive, and then take out input shaft, output shaft and fork mechanism
together (when taking out, gently shake, meanwhile, press the driven gear of main decelerator along the
direction of arrowhead as shown in the figure to take out the assembly of input shaft, output shaft and idler
as well as fork mechanism); when taking out, remember to avoid interference between bearing retainer of
output shaft and big gear ring of differential and prevent the bearing retainer from damage.
Bolts for reverse gear rocker arm bracket (2 in total)
Reverse gear idler assembly
Reverse gear rocker arm
Figure 6
11

7. Separation of differential assembly and clutch housing
Separate differential assembly and clutch housing, and then simply take out the differential assembly as
shown in Figure 7.
Differential Assembly
Figure 7
8. Disassembly of gearshift fork mechanism
Use a hammer and a special tool to knock off all spring pins and then use a snap ring pliers or other
special tool to take the split washer off the fork shaft (when taking off the split washer, prevent it from
deformation), and then disassemble each part of the gearshift mechanism.
Split washer Spring pin
12

Figure 8
9. Disassembly of gearshift mechanism
As shown in Figure 9, remove the gearshift arm bracket bolts and reverse gear lockup mechanism bolts
first, use a hammer and a special tool to knock off all spring pins, use a special tool to remove the split
washer, and then disassemble each part of the gearshift mechanism.
Gearshift arm bracket bolts (2 in total)
Reverse gear lockup mechanism bolts (2 in total)
Split washer
Figure 9
10. Disassembly of input shaft
As shown in Figure 10, Use a special tool (such as bearing remover etc.) to remove the two bearings on
the input shaft first, use a special tool to remove the rear snap ring, and then take off the fifth gear
synchronizer assembly.
13

Bearing (when disassembling, be
careful and use a special tool) Rear snap ring Fifth gear synchronizer
Figure 10
After the fifth gear synchronizer assembly is removed, remove the remaining parts such as shift gears,
needle bearings and synchronizers in turn as shown in Figure 11; when disassembling, be sure to keep the
synchronizer of each gear concurrent with its corresponding synchronizer ring.
Figure 11
14

11. Disassembly of output shaft
The method and process for disassembly of output shaft are basically the same as those for input
shaft and the output shaft can be disassembled to the status as shown in Figure 12.
Figure 12
12. Disassembly of differential
As shown in Figure 13, use a special tool to take off the two bearings first, remove the bolts for driven
gear and differential housing, remove the driven gear, knock off the fixing pin of the planetary gear, and then
take out every part inside the differential (Figure 14).
Fixing pin of planetary gear Bolts for driven gear and differential housing (8 in total)
Figure 13
15

Figure 14
13. Disassembly of release mechanism of clutch
As shown in Figure 15, take off release bearing of the clutch first, remove the bolts for release fork, and
then draw the release shaft assembly off the clutch housing (during the drawing off process, be sure to
prevent the release return spring from ejection); also, remove the bush and dismount release mechanism of
the clutch from the clutch housing.
Release bearing of clutch Bolts for release fork Release fork Release arm
Bush Release return spring
16

Figure 15
Be sure to use special tool and be careful to remove the oil seal on the clutch housing, because
excessive deformation or damage of the oil seal may result in oil leak of the transmission. Use a special tool
to remove the two oil seals on the clutch housing, and then remove the remaining bushes, oil ducts and outer
rings of bearings as shown in Figure 16. Replacing with new oil seals after the former ones are removed is
recommended.
Oil seal Fork shaft bearing (3)
Outer ring of bearing Oil duct Figure 16
14. Disassembly of transmission housing
As shown in Figure 17, use a special tool to remove the oil seal of transmission housing, and then
remove oil drain channel, fork shaft bush and linear bearing.
17

Linear bearing Fork shaft bush
Oil seal Oil drain channel

Figure 17
Chapter Three Assembly and Regulation of QR513 Transmission
I. Assembly of QR513 Transmission
After disassembly, visually inspect parts for any abnormal condition such as deformation etc, and make
records; Replace the damaged parts, clean and wash all parts, then reassemble.
1. Assembly of differential assembly
Fit adjustment gaskets respectively at backsides of the two half axle gears, and then install the two half
axle gears together with their gaskets into the differential. When fitting adjustment gaskets for the half axle
gears, select the gasket with thickness as 1.2mm first. Fit spherical washers for the planetary gear, and then
simultaneously engage the two planetary gears with the two half axle gears (fit them to correct positions
while turning the gears). Insert the planetary gear shaft; note that the fixing pin hole on the shaft should align
correctly with that on the differential housing both in the position and along the direction. Measure the
clearance between the half axle gear and the planetary gear, and the normalized value should be
0.025~0.150mm; if the clearance does not conform to the normalized value, replace the adjustment gaskets
for the half axle gear, and then re-measure the clearance until it conforms to the standard with uniform
clearance at both sides. Drive down the fixing pin of planetary gear shaft from the fixing pin hole at the side
of differential housing with flange with the pin with end surface of the pin hole. Install driven gear of main
decelerator and ensure that the installation end surface of the gear fits well with the end surface of the
differential housing, and then fix the driven gear of main decelerator with bolts (apply sealant to full thread
18

of the bolt before installation); screw the bolts home with the torque as 130±5Nm cornerwise and alternately;
respectively press in an inner ring of front and rear bearings from each of both ends of the differential
housing and check if it has been pressed to the designated position. Note that the lubricant applied onto
adjustment gaskets for half axle gears, planetary gear gaskets, junction surface of planetary gear and
planetary gear shaft, junction surface of half axle gear and differential housing should be the same as that
used inside the transmission. Refer to Figure 18.
Adjustment gasket
Inner ring of for planetary gear
bearing (2) (2 sheets) Planetary gear (2) Planetary gear shaft Connecting bolt (8)
Fixing pin of planetary Adjustment gasket for half

Half axle gear (2) gear shaft axle gear (2 sheets)
Figure 18
2. Assembly of clutch housing
Use a hammer and a special tool to fit oil seal of input shaft with spring side of the oil seal up and
grease applied to lip of the oil seal. Use a special tool and a hamper to fit right side oil seal of differential
with end surface of the oil seal flush with the housing surface, and then apply grease to lip of the oil seal. See
Figure 19.
19

Right side oil seal of differential Special tool for installation
Oil seal of input shaft Special tool
Figure 19
First, install the oil duct of output shaft to its designated position as shown in Figure 20 (note that the
oil inlet and outlet of the oil duct should align with those on the housing), and then use a special tool to
respectively install the outer rings of the front bearing of output shaft and the differential bearing.
20

Special tool for installation Outer ring of
of outer ring of bearing output shaft Oil duct
Figure 20
The tool for installation of oil seal can be used to install the three bushes. When installing the bushes,
stagger the gap on the bush and that on the clutch housing (the two gaps can not coincide), as shown in
Figure 21.
Opening direction of installation position of
Special tool Bush Gap of bush clutch housing bearing
Figure 21
21

Wearing bush
Now start to install release bearing assembly and release bearing as shown in Figure 22. First, install
the two wearing bushes to their designated positions, and then put the release bearing through bush, release
return torsion spring, release fork (release fork and release bearing should be assembled properly in advance,
and then set the release bearing onto the housing) and bush in turn up to its designated position, finally,
tighten the release arm bolts (with torque as 20±2Nm). See Figure 23.
Release arm bolt (with tightening Release return

torque as 20±2Nm) Release fork torsion spring Release shaft assembly
22

Figure 23
3. Assembly of transmission housing
First, use a special tool to fit oil seal of the differential to its designated position (when fitting the oil seal,
care should be taken to prevent oil leak in the future, and replacement with new oil seal is recommended),
and then respectively install oil drain channel, bush (note: the installation process for this bush is the same
as that for the bush of clutch housing above), linear bearing etc. to their designated positions. See Figure 24.
Special tool for installation of oil seal Oil seal of differential Oil drain channel Bush Linear bearing
Figure 24
4. Assembly of gearshift mechanism assembly
Assembly of gearshift mechanism assembly is comparatively simple, which can refer to the disassembly
process of the gearshift mechanism assembly. Remember to check the amount of parts to prevent neglected
installation. Please refer to Figure 25 for tightening torque of the bolt.
23

Selector lever bracket
bolt (with tightening
torque as 25±2Nm)
Reverse gear locking
mechanism bolt (with
torque as 18±2Nm)
Figure 25
5. Assembly of gearshift fork assembly
Assembly of gearshift fork assembly is comparatively simple, which can be assembled with reference to
the disassembly drawing.
6. Regulation and assembly of input shaft assembly
Place the input shaft with its end with clutch spline down, and then set the third gear needle bearing
applied with the gear oil of the same designation as that used inside the transmission assembly onto the input
shaft. Set the third gear driving gear assembly in from upside of input shaft with the end with synchronizer
cone of the gear assembly up, and then check and make sure that the gear assembly can rotate freely. Set a
3/4/5 gears synchronizer ring in from upside of input shaft with conical surface of the synchronizer ring
applied with the gear oil of the same designation as that used inside the transmission assembly, and then
check and make sure that the synchronizer ring should envelop loosely on synchronizer cone of the third
gear driving gear assembly and can rotate relative to the synchronizer cone. Press 3/4 gears synchronizer
assembly onto the input shaft with the end surface of gear hub with two oil grooves down, turn the
synchronizer ring to make its guide block completely enter the groove corresponding to the gear hub, and
then make sure that the synchronizer ring is not locked. Fit front snap ring of input shaft; when fitting, try to
use the thicker snap ring, if really unsuitable, select the snap ring of next thinner level, and then check if the
snap ring has really enter the groove with the clearance between the snap ring and the groove not exceeding
0.05mm. Set a 3/4 gears needle bearing applied with the gear oil of the same designation as that used inside
the transmission assembly onto the input shaft from upside of the input shaft. Set a 3/4/5 gears synchronizer
ring applied with the gear oil of the same designation as that used inside the transmission assembly in from
upside of the input shaft. Set the fourth gear driving gear assembly in from upside of input shaft with the end
with synchronizer cone of the gear assembly down (the guide block of 3/4 gears synchronizer ring should
completely enter the groove corresponding to the gear hub), and then make sure that the gear assembly can
24

rotate freely. Set friction ball of gear, fender and clamp in from upside of input shaft, and then perform axial
orientation for the fourth gear driving gear. Set fifth gear needle bearing applied with the gear oil of the same
designation as that used inside the transmission assembly onto the input shaft from upside of the input shaft.
Set fifth gear driving gear assembly in from upside of input shaft with the end with synchronizer cone of the
gear assembly up, and then make sure that the gear assembly can rotate freely. Set a 3/4/5 gears synchronizer
ring in from upside of input shaft with conical surface of the synchronizer ring applied with the gear oil of
the same designation as that used inside the transmission assembly, and then check and make sure that the
synchronizer ring should envelop loosely on synchronizer cone of the fifth gear driving gear assembly and
can rotate relative to the synchronizer cone. Press fifth gear synchronizer assembly onto the input shaft with
the end surface of gear hub with oil groove down, turn the synchronizer ring to make its guide block
completely enter the groove corresponding to the gear hub, and then make sure that the synchronizer ring is
not locked. Fit rear snap ring of input shaft; when fitting, try to use the thicker snap ring, if really unsuitable,
select the snap ring of next thinner level, and then check if the snap ring has really enter the groove with the
clearance between the snap ring and the groove not exceeding 0.07mm. Simultaneously press front and rear
bearings of input shaft onto the input shaft with the side of front bearing of input shaft having word down
and the side of rear bearing of input shaft having word up, and then check and make sure that the outer rings
of the bearings can rotate freely. Refer to Figure 26.
Note: There are two friction balls between the bearing baffles (2 sheets). Be careful to install them in
full.
Input shaft 3/4 gears needle bearing Third gear driving gear assembly 3/4/5 gears synchronizer ring Rear bearing of input shaft
Gear baffle
Rear clip spring
5 gear synchronizer assembly
5 gear driving gear assembly
5 gear needle bearing
Front bearing of input shaft Clip-gear baffle
4 gear driving gear assembly
3/4 gears synchronizer assembly

Front clip spring
25

Gear fender Friction ball
Figure26
7. Regulation and assembly of output shaft assembly
With the end of output shaft with driving gear of main decelerator down, set first gear needle bearing in
onto output shaft from upside of the output shaft; before installation of the needle bearing, apply the gear oil
of the same designation as that used inside the transmission assembly on it. Set first gear driven gear
assembly in from upside of output shaft with the end with synchronizer cone of the gear assembly up, and
then check if the gear assembly can rotate freely. Set a 1/2 gears synchronizer ring assembly in from upside
of output shaft and the three finger jaws of balking ring of the synchronizer ring should completely enter the
three corresponding grooves on the first gear driven gear assembly; before installation of the synchronizer
ring assembly, apply the gear oil of the same designation as that used inside theClamp-gear
transmission assembly on
fender
three conical surfaces of the synchronizer ring; check and make
3/4 gears synchronizer assemblysure that the synchronizer ring assembly
envelops loosely on the synchronizer cone of the first gear driving and driven gears assembly and can turn a
certain angle relative to the synchronizer cone. Press 1/2 gears synchronizer assembly onto the input shaft
with the end of external gear of 1/2 gears hub sleeve with section down, turn the synchronizer ring to make
its guide block completely enter the groove corresponding Front snapgear
to the ring hub, and then make sure that the
synchronizer ring is not locked. Fit front snap ring of output shaft; when fitting, try to use the thicker snap
ring, if really unsuitable, select the snap ring of next thinner level, and then check if the snap ring has really
enter the groove with the clearance between the snap ring and the groove not exceeding 0.05mm. Set a 1/2
gears synchronizer ring assembly in from upside of output shaft; before installation of the synchronizer ring
assembly, apply the gear oil of the same designation as that used inside the transmission assembly on three
conical surfaces of the synchronizer ring. Set a second gear needle bearing onto output shaft from upside of
26

the output shaft; before installation of the needle bearing, apply the gear oil of the same designation as that
used inside the transmission assembly on it. Set second gear driven gear assembly in from upside of output
shaft with the end with synchronizer cone of the gear assembly down (the three grooves on the gear
assembly should completely envelop the three corresponding finger jaws on 1/2 gears synchronizer cone),
and then check and make sure that the gear assembly can rotate freely. Set the third gear driven gear in from
upside of output shaft with the end with boss of the gear up, and then check and make sure that the 1/2 gears
synchronizer ring assembly is not locked. Set 3/4 gears driven gear bush and then fourth gear driven gear in
from upside of output shaft, with the end with boss of the gear down. Set fifth gear driven gear in from
upside of output shaft with the end with boss of the gear up. When fitting, try to use the thicker snap ring, if
really unsuitable, select the snap ring of next thinner level, and then check if the snap ring has really enter
the groove with the clearance between the snap ring and the groove not exceeding 0.05mm. Simultaneously
press inner rings of front and rear bearings of output onto the output shaft. See Figure 27.
1/2 gears synchronizer ring assembly First gear driven gear assembly 1/2 gears needle bearing Output shaft Front bearing of output shaft
Needle bearing for 1/2 gears
1/2 gears synchronizer assembly
Front clip ring
2nd gear driven gear assembly
Rear bearing of output shaft rear snap ring Fifth gear driven gear Fourth gear driven gear Gear spacer Third gear driven gear
Figure 27
27

8. Assembly and regulation of transmission assembly
Place the clutch as shown in Figure 28 first, and then assemble the differential assembly to its
designated position.
Clutch housing assembly Differential assembly
Figure 28
Assemble gearshift fork assembly, input shaft assembly and output shaft assembly together as shown in
Figure 29, and then install them together onto clutch housing assembly. When assembling, wrap front end
spline of input shaft with polyvinyl chloride adhesive tape to prevent damage to oil seal. After installation,
turn each gear to ensure favorable engagement.
Gearshift fork assembly Input shaft assembly Output shaft assembly
Use tape to wrap the spline
Figure 29
28

Install the assembled idler assembly (assembly of idler assembly is comparatively simple, please refer
to its disassembly process) onto clutch housing, and then install reverse gear fork mechanism assembly with
tightening torque of the two reverse gear rocker arm bracket bolts as 25±2Nm. Clean the junction part of
clutch and transmission housings and apply sealant (oil resistance silicone sealant, HZ1213Q/320222
YAP02-92) on it, and then install the magnet. See Figure 30.
Reverse gear fork mechanism assembly Idler assembly
Apply sealant on junction part

of clutch and transmission
housings
倒档摆臂支架
螺栓（拧紧力
矩 25±2Nm）
Magnet
Figure 30
29

Assemble transmission housing and clutch housing together and then fasten them with connecting bolts.
Before fastening, apply thread locking glue (262 type anaerobic adhesive) on the bolts properly. Tighten
the diagonal bolts first as possible to ensure favorable fastening and sealing effects, and the tightening torque
for the bolts are 25±2Nm. Note: the two connecting bolts at oil drain hole are a little longer than other
connecting bolts, and the bracket should be installed first. See Figure 31.
Connecting bolt of transmission and clutch housings (13)

Reverse gear rocker arm bracket bolt
(with tightening torque as 25±2Nm)
The two connecting

bolts are longer
Bracket
Figure 31
To install the assembled gearshift mechanism assembly onto the transmission, clean the junction part of
gearshift housing and transmission housing and apply sealant on it (oil resistance silicone sealant,
HZ1213Q/320222 YAP02-92), align one end of gearshift shaft with the linear bearing inside the transmission
and align the locating hole on gearshift housing with the locating pin on transmission housing, and then
tighten the connecting bolts of gearshift housing and transmission housing with the tightening torque as
25±2Nm. See Figure 32.
30

Connecting bolts of gearshift housing and transmission housing
(5, tightening torque: 25±2Nm)
Figure 32
9. Disassembly of external accessories of transmission
Respectively install locating seats of 1/2 gears fork shaft and 3/4/5 gears fork shaft. Before installation,
apply thread fastening glue (262 type anaerobic adhesive) on the thread, and the tightening torque for the
bolts are 20±2Nm. Note: the locating seat of 1/2 gears fork shaft is longer than that of 3/4/5 gears fork
shaft. Then install locating seat of gearshift shaft, before installation, apply thread fastening glue (262 type
anaerobic adhesive) on the thread, and the tightening torque for the bolts are 32±2.5Nm; and install backup
lamp switch assembly, before installation, apply thread fastening glue (262 type anaerobic adhesive) on
the thread, and the tightening torque for the bolts are 20±2Nm. See Figure 33.
Locating seat of 1/2 gears fork shaft
Locating seat of 3/4/5 gears fork shaft
Locating seat of gearshift shaft (with

tightening torque as 32±2.5Nm)
Switch assembly of backup light

(with tightening torque as
20±2Nm)
31

Figure 33
Follow by installation of screw of reverse gear idler shaft. Align the screw of reverse gear idler shaft
with the threaded hole on the idler shaft, and then tighten it with the tightening torque as 38±2.5Nm; after
that, tighten bleeding plug with tightening torque as 44±3Nm; finally, install oil limit plug onto the
transmission, but do not tighten it then. See Figure 34.
Screw of reverse gear idler shaft (with Bleeding plug (with tightening torque
tightening torque as 38±2.5Nm) as 44±3Nm)
Oil-Limiting Plug
Figure 34
10. Refilling and volume regulation of transmission lubricant
After the transmission is installed onto the vehicle, park the vehicle on a flat road surface, then use the
tool for refilling to refill transmission lubricant. The lubricant refilled should at least conform to API GL-4
SAE 75W-90 specification. Refill through installation hole of speed sensor as shown in Figure 35 with the
refilling volume as 1.8L. after refilling, open the oil limit plug to regulate the lubricant to specified volume,
and then tighten the oil limit plug with the tightening torque as 44±3Nm.
32

Installation hole of speed sensor Oil limit plug (with tightening torque as 44±3Nm)
Figure 35
After the above steps, assembly and regulation to the transmission assembly are accomplished.
33

II. Tightening Torque Table for Fasteners
Position Tightening torque (N.m)

Reverse gear rocker arm bracket bolt 25±2
Connecting bolts for clutch and 25±2
transmission housings
Reverse gear idler shaft screw 38±2.5
Connecting bolts for gearshift and 25±2
transmission housings
Gearshift shaft locating seat assembly 32±2.5

Reverse switch assembly 20±2
Fork shaft locating seats of gears 20±2
Bleeding\oil limit plug 44±3

Clutch release fork bolt 20±2
Clutch release arm bolt\nut 20±2
Selector Lever Bracket Bolt 25±2
Main decelerator driven gear bolt 130±5

Reverse gear lockup mechanism bolt 18±2
34

Chapter Four General Failures and Troubleshooting
Failure Possible reason Troubleshooting
status
Damaged input or/and output shaft bearing(s) Replace the
bearing
Excessive Gear tooth faces damaged due to knocking, burr Repair or replace
or or pit corrosion existing, or poor contact between the gear
abnormal them.
noise Incorrect gear shaft position and clearance Check and adjust
Low oil level, insufficient lubrication Fill oil to the
specified level
Foreign matter(s) existing in the assembly Check and remove
Excessively worn or damaged oil seal(s) Replace
Uneven sealant smearing or damaged seal Replace the seal
Oil leakage gasket(s) gasket(s) or sealant
Failure to timely recondition junction surface(s) Check and repair
damage due to knocking
Damaged differential bearing Replace
Improper clutch adjustment and incomplete Adjustment
Difficult to release.
implement Improper gearshift transmission system Check and adjust
gear shift adjustment or movement obstruction occurring
Synchronizer ring(s) fails to work Replace
Gear Worn synchronizer gear sleeve(s) or tooth cone Replace related
jump surface(s) of gear junction components
Improper gearshift transmission system Check and adjust
adjustment
No gear Loose gearshift transmission system Overhauling
Loose gearshift arm of transmission Repair
Abnormall Metal impurities contained in transmission oil Replace
y damaged Insufficient lubrication or unqualified Replace
bearing(s) transmission oil
Using of unqualified bearing(s) Replace
35

Service Manual for Chery
QQ6
(UMC EFI for 473F Engine)
After Sales Service Department of Chery

Automobile Sales Co., Ltd.

CONTENTS
CHAPTER ONE DISASSEMBLY AND INSTALLATION OF ELECTRONIC FUEL
INJECTION SYSTEM.......................................................................................................................4
I. Disassembly and Installation of Components of Electronic Fuel Injection System ..................4
CHAPTER TWO PRINCIPLE OF ELECTRONIC FUEL INJECTION SYSTEM ...................6
I. Overhaul of System Components ..............................................................................................6

1. Intake Air Temperature Pressure Sensor ...........................................................................6
2. Tachogenerator of Engine .................................................................................................8
3. Phase Sensor ...................................................................................................................10
4. Water Temperature Sensor ..............................................................................................10
5. Knock Sensor ..................................................................................................................12
6. Electric Throttle Body.....................................................................................................12
7. Oxygen Sensor ................................................................................................................13
8. Fuel Pump Assembly ......................................................................................................16
9. Injector ............................................................................................................................17
10. Ignition Coil ..................................................................................................................19
11. Spark Plug.....................................................................................................................21
12. Carbon Canister Solenoid Valve Control ......................................................................22
13. Electronic Accelerator Pedal.........................................................................................24
14. Three-way Catalytic Converter .....................................................................................24
15. Fan Control ...................................................................................................................25
16. Position Sensor of Double Brake Pedal ........................................................................26
17. Clutch Position Sensor ..................................................................................................26
18. A/C Control...................................................................................................................27
CHAPTER TWO FUNDAMENTAL PRINCIPLE FOR FAILURE DIAGNOSIS OF

ELECTRONIC FUEL INJECTION SYSTEM .............................................................................28
1. Failure Information Records...................................................................................................28

2. Failure State ............................................................................................................................28
3. Failure Types ..........................................................................................................................28
4. Failure Frequency Counter .....................................................................................................28
5. Limp Home.............................................................................................................................29
6. Failure Alert............................................................................................................................29
7. Readout of Failure ..................................................................................................................29
8. Clearing Failure Information Records ....................................................................................30
9. Failure Locating......................................................................................................................30
10. Failure Code Table................................................................................................................30
11. The Steps for Implementation of Failure Diagnosis According to Failure Information
Records .......................................................................................................................................35
11.1 Electronic Throttle Failure..........................................................................................35
11.2 Knock Sensor failure...................................................................................................36
11.3 Air Pressure Sensor Failure ........................................................................................37

11.4 Front Oxygen Sensor Failure ......................................................................................38
11.5 Rear Oxygen Sensor Failure .......................................................................................40
11.6. Coolant Temperature Sensor Failure .........................................................................42
11.7 Failure in Driver Stage of Injector ..............................................................................43
11.8 Failure in Driver Stage of Canister Control Valve......................................................44
11.9 Failure in Driver Stage of Malfunction Indicator Lamp (MIL) ..................................45
11.10 Failure in Driver Stage of 1#, 2# Coils of Step Motor ..............................................46
11.11 Craftshaft Position Sensor Failure ............................................................................47
11.12 Craftshaft Position Sensor Failure ............................................................................48
11.12 Ignition Coil Failure..................................................................................................49
11.13 Accelerator Pedal Position Sensor Failure................................................................50
11.14 Double Brake Swtich ................................................................................................51
11.15 Theft-proof Control System Failure..........................................................................52
12. Steps for Implementation of Failure Diagnosis by Engine Symptom...................................53
12.1 Perform Preliminary Inspection First before Following the Steps for Implementation
of Failure Diagnosis by Engine Symptom. .........................................................................53
12.2 The Engine Does not Rotate or Rotates Slowly when Starting...................................55
12.3 When Starting, Engine Can be Dragged to Rotate but Can not Start with Success. ...56
12.4 Warm Starting Difficulty ............................................................................................58
12.5 Engine Speed is Normal, but it is Difficult to Start at any Time. ...............................60
12.6 Cold Starting Difficulty ..............................................................................................62
12.7 Unsteady Idle Speed at Any Time ..............................................................................64
12.8 Unsteady Idle Speed during Warming up Process ......................................................66
12.9. Unsteady Idle Speed after Warming up .....................................................................67
12.10 Unsteady Idle Speed or Extinguish with Load (A/C etc.).........................................69
12.11 Periodic Unsteadiness (Have to Perform Self-study again after ECU is Power off) 70
12.12 Too High Idle Speed (Have to Perform Self-study again after ECU is Power off) ..72
12.13. Engine Revolution Speed is too Low or Flameout ..................................................73
12.14 Slow Response when Accelerating ...........................................................................75
12.15 Poor Performance and Disability when Accelerating. ..............................................77
12.16 Unable to Reach the Maximum Revolution when Accelerating...............................79
12.17 When Releasing Accelerator Pedal after Acceleration, Unsteady Idle Speed Occurs
at Instant, even Extinguishes...............................................................................................81
12.18 A/C System Failure...................................................................................................83
13. Safety Precautions for System Maintenance.........................................................................84
13.1 Safety Precautions for Diagnosis and Maintenance of Gasoline Injection Electronic
Control System ...................................................................................................................84

Chapter One Disassembly and Installation of Electronic Fuel
Injection System
I. Disassembly and Installation of Components of Electronic Fuel
Injection System
1. Disassembly and installation of engine control unit (ECU).
2. Position and disassembly of intake air pressure sensor.
3. Position and disassembly of camshaft position sensor.
4. Remove fixing hoop of intake hose.

5. Remove the four fixing bolts of electronic throttle body.
Pull out the connector and take out the electronic throttle body.
6. Use a screwdriver to press down the fixed clip of the injection

nozzle connector and then pull out the connector.
7. Use a screwdriver to press down the fixed clip of the knock

sensor connector and then pull out the connector.
8. The water temperature sensor is behind the thermostat seat.
9. Pull out the connector of the ignition primary coil by hand.
10. Pull out the connector of the engine tachogenerator by hand.

Chapter Two Principle of Electronic Fuel Injection System
I. Overhaul of System Components
1. Intake Air Temperature Pressure Sensor
1.1 Function of the sensor:

Detect air intake pressure and temperature in air intake manifold, which will be provided to
ECU as main load signal of engine; ECU will calculate injection pulse-width based on this signal.
1.2 Principle of the sensor:
Intake air temperature pressure sensor is a sensor that integrates an intake air pressure sensor
and an intake air temperature sensor. Absolute pressure sensor element of intake manifold is
composed of a silicon chip. A pressure diaphragm is etched on the silicon chip. On the pressure
diaphragm, there are 4 piezo-resistances, which serve as strain sensors and constitute a Wheatstone
bridge. In addition to this pressure diaphragm, a signal processing circuit is also integrated on the
silicon chip. The silicon chip and a metal housing constitute a closed reference, where the absolute
pressure of the gas inside approaches to zero. Thus, a micro-electronic mechanical system is
formed. The active face of the silicon chip stands a pressure close to zero, while its back face stands
the pending measuring intake manifold absolute pressure introduced by a connecting pipe. The
thickness of the silicon chip is merely several mm, so the absolute pressure change in intake manifold
will bring mechanical deformation to the silicon chip. The 4 piezo-resistances will accordingly
deform and their resistances also change. The voltage signal in linear relation to the pressure is
formed after process by the signal processing circuit on the silicon chip. The intake temperature
sensor element is a negative temperature coefficient (NTC) resistance, which will change with the
intake temperature. This sensor sends out a voltage indicating the intake temperature change to the
controller.
进气压力温度传感
Intake air temperature
器
pressure sensor
Cross-section view for sensor of air absolute pressure and temperature in intake manifold
1 Gasket 2 Stainless Steel Sleeve 3 PCB Board 4 Sensing Element 5 Housing 6 Pressure Bracket 7 Soldering 8
Bonded With Bonding Agent

1.3 Parameters of technical features
This sensor is designed to be mounted on the plane of auto engine intake manifold. The
pressure connecting pipe together with the temperature sensor protrudes inside the intake manifold
and an O gasket is used to enable atmosphere-proof.
If it is mounted on an auto through an appropriate method (picks up pressure from the intake
manifold and the pressure connecting pipe tilts down etc.), it can be ensured that no condensed water
will be formed on the pressure-sensitive element.
Drilling and fixing on the intake manifold must be carried out according to the supply drawing
so as to ensure a long seal and a good tolerance to fretting by agent.
The reliable contact of electric connection of a joint will mainly be affected by the joints of
components and parts, and it is also in relation to the material quality and dimensional precision of
the joint fitted with it on the harness.
1.4 Failure effects and judgment method
l Failure effects: spark extinction and poor idling etc.
l General Failure Reason:
1. Abnormal high voltage or inverse strong current occur during working;
2. The vacuum element is damaged during maintenance.
l Maintenance precautions: during maintenance, impinge using high pressure gas toward the
vacuum element is prohibited; when replacing the sensor after a failure is found, remember to
check if output voltage and current of the generator is normal.
l Simple measurement method:
1.4.1 Temperature sensor:
With the joint removed, turn the digital multimeter to Ohm shift, and then connect the two
meter pens respectively to 1# and 2# pins of the sensor; At 20℃, the rated resistance should be 2.5
kΩ±5%, and the other corresponding resistances can be measured out from the characteristic curve
in above chart. Analogue method can also be used when measuring, i.e., use an electric drier to blow
the sensor (be careful not to be too close to the sensor), and then observe the change of the sensor
resistance. At this point, the sensor resistance should fall.
1.4.2 Pressure sensor:
With the joint connected, turn the digital multimeter to DC Voltage shift, and then connect the
black pen to ground while the red pen respectively to 3# and 4# pins. Under idle speed state, 3# pin
should have a 5V reference voltage while the voltage on 4# pin should be around 1.3V (the actual
value depends on the model); Under no load state, when opening the throttle slowly, the voltage on
4# pin may change little; when opening the throttle rapidly, the voltage on 4# pin may reach around
4V instantly (the actual value depends on the model) and then fall to around 1.5V (the actual value
depends on the model).

2. Tachogenerator of Engine

As one of the uppermost sensors of engine, the tachogenerator of engine provides ECU with rev
signal, acceleration signal and crank angle signal etc. of engine. ECU will calculate injection
pulse-width, injection time and ignition timing through these signals and provide the instruments
with rev signal of engine.
The inductive tachogenerator work together with pulse disc, it is used in ignition system
without distributor providing engine speed and crank shaft top dead center information.
Inductive tachogenerator is made up of a permanent magnet and coil outside of magnet.
Pulse disc is a tooth disc with 60 teeth originally but there are two teeth opening. Pulse disc is
assembled on crank shaft and rotate with crankshaft. When the tooth tip passes through closely the
end of the inductive engine tachogenerator, the pulse disc made of the ferromagnetic material will
cut the line of magnetic force of the permanent magnet in the inductive engine tachogenerator to
generate inductive voltage in the coil as engine speed signal output.
Tachogenerator
1. Shielded wire 2. Permanent magnet

3. Housing of sensor 4. Installation bracket
5. Soft magnet core 6. Coil
7. Air gap 8. 60-2 gear ring

Item Value Unit
Min. Typical Max.
Resistance under a room temperature of 774 860 946 W
20°C
Inductance 310 370 430 mH
Output voltage at a crankshaft >1650 mV
revolution of 416rpm
2.4 Installation attentions:

l For the inductive tachogenerator, it is permitted to take out from its pack before it is assembled
to the auto or testing device right away.
l Inductive tachogenerator is assembled by press in method but not hammer tapping.
l Partly micro-encapsulated bolt M6´12 for fixing of the inductive engine tachogenerator is
recommended.
l The tightening torque is 8±2Nm.
l Gas clearance between inductive tachogenerator and pulse disc tip is 0.8-1.2mm.
Dimension d (see the figure below): 4.7mm.
tachogenerator
Installation of the
2.5 Failure effects and judgment method:

l Failure effects: start failure etc.
l General cause of the failure: man induced failure.
l Maintenance precautions: during maintenance, the tachogenerator should be installed by using
press-in method instead of hammering method.
1. With the joint removed, turn the digital multimeter to Ohm shift, and then connect the two
meter pens respectively to 2# and 3# pins; At 20℃ , the rated resistance should be 860Ω±10%.
2. With the joint connected, turn the digital multimeter to AC Voltage shift, and then connect the
two meter pens respectively to 2# and 3# pins of the sensor; start the engine and voltage output
should be present at this point. (Inspection with vehicle oscilloscope is recommended).
Oscillogram in Test

3. Phase Sensor

Provide ECU with phase signal, i.e. help crankshaft position sensor of engine to judge it is then
at compressing top dead center or air exhaust top dead center.
The phase sensor is consisted of the Hall generator installed on the valve cover and the signal
wheel machined on the intake camshaft. When the camshaft rotates, the signal wheel will make the
magnetic flux passing the Hall generator change, thus generating a variable Hall signal.
Ground site
Phase sensor
87# pin of main relay

3.3 Effects and judgment method:
l Failure effects: over proof emission and fuel consumption rise etc.
(connect the joint) switch on ignition switch but do not start the engine; put digital multimeter on DC
volt shift, connect two meter pen to No. 1 and No. 3 sensor connectors and make sure there is 12V
reference voltage. Start the engine, check if it is in good conditions of No.2 pin by oscillograph on
vehicle.
4. Water Temperature Sensor

The water temperature sensor simultaneously provides ECU and instruments with water
temperature signal. ECU will calculate and regulate injection pulse-width and ignition advance angle
through water temperature signal. In addition, through water temperature signal, ECU also can
control turn-on and turn-off of cooling fan to prevent engine from damage caused by overheat.
The water temperature sensor is a minus temperature coefficient type electric resistance model
sensor; the higher the temperature is, the less the resistance will be. But, temperature rise and
resistance fall are not in linear relation.

Coolant temperature
sensor

(1) Data limit
Item Value Unit
Rated voltage Can only be run by ECU
Rated resistance at 20℃ 2.5±5% kW
Range of running temperature -30 to +130 ℃
Max. measuring current passing the 1 mA
sensor
Permissible vibration acceleration 600 m/s2
4.4 Installation attentions

Coolant temperature sensor is installed on the cylinder body and the copper heat conducted
socket is inserted into coolant. There are thread on the socket, and screw in coolant temperature
sensor onto the threaded hole on cylinder block by the hexagon head of the socket. The maximum
permissible tightening torque is 15Nm.

l Failure effects: starting difficulties etc.
meter pens respectively to 1# and 2# pins of the sensor; At 20℃, the rated resistance should be
2.5kΩ±5% and the others can be measured out from the characteristic curve in above chart.
Analogue method can also be used when measuring, i.e., dip the working area of the sensor in boiled
water (dip for adequate time), observe the resistance change of the sensor, at this point, the resistance
should fall to 300Ω-400Ω(the actual value depends on the temperature of the boiled water).

5. Knock Sensor

The knock sensor provides ECU with knock signal. When the engine generates knock, ECU
will control to gradually reduce ignition advance angle to eliminate the knock; when no knock
occurs during certain strokes, ECU will gradually increase ignition advance angle to enable the
engine to obtain max. torque.

Knock sensor is a kind of vibrating acceleration sensor and is assembled on cylinder block.
Either single or multiple can be installed. The sense organ of the sensor is a piezoelectric element.
The vibration of cylinder block is transferred to piezoelectric crystal by mass block inside of sensor.
The piezoelectricity crystalloid gets pressure from mass block vibration, producing voltage on two
polar and transferring vibration signals to voltage signal and output it. See the following frequency
response characteristic curve. Because the frequency of knock vibration signal is much higher than
the normal engine vibration signal, the ECU can separate the signal into knock signal and non-knock
signal.
5.3 Attentions
Knock sensor has a hole in the middle, through which it is fastened on the cylinder by a M8 bolt.
For the aluminum alloy block, using long bolt with 30 mm; for the casting iron, using 25mm bolt.
The tightening torque is 20±5Nm. The installation position should ensure that the sensor is liable to
receive vibration signals from all cylinders. Decide the optimal installation position of knock sensor
through modal analysis to the engine body. Generally, for a 4-cylinder engine, the knock sensor is
installed between 2# cylinder and 3# cylinder; for a 3-cylinder engine, it is installed at the center of
2# cylinder. Do not let liquid such as engine oil, coolant, brake fluid and water etc. contact the sensor
long. Use of gasket of any type is not allowed in installation. The sensor must cling to the cylinder
tightly through its metal surface. During wiring of sensor signal cables, do not make the signal
cables resonate; otherwise, they may break. Be sure to prevent turning on of high voltage between 1#
and 2# pins of the sensor; otherwise, damage to the piezoelectric element may occur.
5.4 Effects and judgment method

Failure effects: poor acceleration etc.
l Reasons for general failures: long time contact of liquid such as engine oil, coolant, brake fluid
and water etc. with the sensor, which may corrode the sensor.
l Maintenance precautions: (see installation attentions)
l Simple measurement method: (remove the joint) put digital multimeter at ohm shift, and contact
the No. 1, No. 2 and No. 3 pin with its two meter pens. The resistance value should be more
than 1MΩ¸ under normal temperature. Leave the digital multimeter at millivolt shift, and tap
around the sensor using little hammer, there should be voltage signal output.
6. Electric Throttle Body
6.1 Function:

The electronic throttle body can automatically open or close the throttle according to the
driver’s will to apply the accelerator pedal to let the engine work under the corresponding operating
mode. The electronic throttle has cancelled the conventional throttle guy and the opening of throttle
is controlled by ECU based on the signal from accelerator pedal and other signals (such as A/C,
power assisted steering, back and gearshift etc.) through an electronic step motor inside the
electronic throttle body. In addition to cancel of conventional idle speed by-pass and idle speed step
motor, there are also throttle position sensors on the electronic throttle body to feed back the opening
of the throttle. This suite of throttle position sensor is different from the common one; totally two
suites of throttle position sensors are installed inside the electronic throttle body to monitor
rationality of the signals from the latter; when any problem occurs in a certain signal, ECU can still
use the other suite of signals to work on.
6.2 Working principle:
The throttle driving motor is a micro motor, which is composed of multi steel stators in a circle
and a rotor, with one coil on each steel stator. The rotor is a permanent magnet with a nut at its center.
All stators coils are constantly power on. As long as the direction of current of one coil is changed,
the rotor will turn a certain angle. When the directions of current of all stator coils is changed in a
proper order, a rotating magnetic field is formed, which will drive the rotor made from permanent
magnet rotate along a certain direction. Its principle is just that of a micro direct current motor.
This motor drives a suite of special gear reducing mechanism and a bidirectional spring; when
the system is under power off condition, this mechanism can ensure that the opening of throttle valve
plate maintains at a safe position where is bigger than that for idle speed but not too high, so that the
vehicle can continue to run; if engine ECU has entered this failure mode, when applying the
accelerator pedal, the valve plate of the electronic throttle body will no longer act.
电子节气门
Electronic throttle
6.3 Failure diagnosis:
ECU can monitor short-circuit and break of coil of the throttle driving motor, and light the engine
failure light in case of such failure to let the engine enter failure mode, when the engine fails to
accelerate, has very poor driving performance and needs maintenance immediately.
7. Oxygen Sensor

Oxygen sensor is one of the principal sensors on modern autos; it can feed back the mixture
strength by detecting oxygen content in exhaust gas. ECU will correct the mixed gas based on the

signals fed back by the oxygen sensor, i.e. control injection pulse-width to let the mixed gas always
maintain an approximately ideal air-fuel ratio (14.7:1).
Sensing element of oxygen sensor is a kind of ceramic tube with holes, and outside of tube
walls are surrounded by engine exhaust gas and inside is air. Ceramic sensor element is a kind of
solid state electrolyte with electrical heating tube inside (as shown in the figure).
Cross-section view of oxygen sensor
1. Cable 2. Dish washer 3. Insulation bush 4. Protective bush

5. Clamp fitting of heating element 6. Heating rod 7. Contact pad
8. Sensor seat 9. Ceramic probe 10. Protection sleeve
Output voltage V
Excessive air-fuel ratio λ
Characteristic Curve of oxygen sensor at 600°

C
The operation of the oxygen sensor is achieved by converting the concentration difference of
oxygen ion between inside and outside of the ceramic sensor element to the voltage signal output. It
bears the characteristic of solid electrolyte once the temperature of the ceramic sensor element
reaches 350℃. Because of the particularity of its materials, the oxygen ion can pass the ceramic
sensor element freely. Taking advantage of this characteristic, the concentration difference will be
converted to electric potential difference to form electric signal output. If the mixed gas is
comparatively thick, the oxygen ion thickness difference between inside and outside of the ceramic
tube will be higher and the potential difference will also be higher, then a mass of oxygen ion will
move from inside to outside, so, the output voltage is comparatively high (close to 800mV-1000mV);
If the mixed gas is comparatively thin, the oxygen ion thickness difference between inside and
outside of the ceramic tube will be smaller and the potential difference will also be smaller, then just
a few of oxygen ion will move from inside to outside, so, the output voltage is comparatively low

(close to 100mV). The signal voltage will mutate near theoretical equivalent air-fuel ratio (λ=1), see
the figure above.
Main relay 者 87#
Oxygen sensor
Every oxygen sensor bears a cable and the other end of the cable is the wire connector. The wire
connector of oxygen sensor produced by our company has four pins:
No.1 connects to the positive pole of heater power supply (white);
No.2 connects to the negative pole of heater power supply (white);
No.3 connects to signal negative pole (gray);
No.4 connects to signal positive (black).

l The requirement to exhaust pipe: the segment of exhaust pipe in the area before the oxygen
sensor must be heated up rapidly. If possible, the exhaust pipe should be designed to be tilting
down to avoid accumulation of condensed water in front of the oxygen sensor.
l Do not inappropriately heat up the metal snap ring of the cable at oxygen sensor side, especially
after the engine is shut down.
l Do not apply purge fluid, oiliness fluid or volatile solid on connector of the oxygen sensor.
l The screw thread of the oxygen sensor is M18´1.5.
l The size of the hexagonal head wrench for the oxygen sensor is 22-0.33.
The tightening torque for the oxygen sensor is 40-60Nm.

l Failure effects: poor idling, poor acceleration, over proof tail gas and excessive fuel
consumption etc.
l General causes of the failure:
1. Moisture entering inside of sensor, and when the temperature is changed, the pin will be
broken;
2. The oxygen sensor “intoxicates”. (Pb, S, Br, Si)
Maintenance precautions: application of cleaning fluid, oiliness fluid or volatile solid on the
oxygen sensor during maintenance is prohibited.
1. Remove joint, put digital multimeter to ohm shift, connect meter pen to No.1 (white) and
No.2 (white) pins of the sensor. The resistance value is 1~6W at constant temperature.
2. With the joint connected, under idle speed state, when the working temperature of the oxygen
sensor reaches 350℃ , turn the digital multimeter to DC Voltage shift and connect the two meter pens
respectively to 3# (gray) and 4# (black) pins; at this point, the voltage should fluctuate rapidly
between 0.1-0.9V.

8. Fuel Pump Assembly
8.1 Function of fuel pump:

Fuel pump is used to deliver the fuel in the fuel tank to inside the engine at a certain pressure
for combustion. It also needs to regulate the fuel pressure duly as required by system pressure (non
fuel return type). Generally, the system fuel pressure provided by fuel pump is around 3.5-4bar.
8.2 Operating principle of fuel pump:
The electrical fuel pump is comprised of the DC motor, vane pump and end cover (integrates
check valve, relief valve and anti-electromagnetic interference element) as shown in following
figure.
The pump and the motor are installed on the same shaft within same closed housing. The pump
and electromotor are full of gasoline for coolant and greasing inside of the casing. The accumulator
provide power to electric fuel pump via fuel pump relay, and the relay switches on electric fuel pump
only when engine starting and running. When the engine stops for some reason, the pump will stop
to run by itself.
The max pressure at the outlet of the electrical fuel pump shall be between 450 and 650 kPa,
depending on the relief valve. Because the system is a non fuel return system, the pressure of the
whole fuel system will be controlled by the fuel pressure regulator. The value is 400KPa in general.
The electric fuel pump has different flow to the engine’s request. In order to facilitate the
production, the electromotor revolutions of EKP13 series electric fuel pumps of the same structure
are adjusted by changing the coil’s number of turns, and thus the flow is adjusted. Therefore, do not
apply an electric fuel pump for one model to another at will.
1. End cover of oil pump

2. Electromotor
3. Oil passage
4. Paddle pump
Cross-section view of electric fuel pump

Under certain fuel supply pressure, the flow of the electric fuel pump is in direct proportion to
voltage. The fuel pumps used by complete vehicle manufacturers are different.
EKP13 series electric fuel pump can only be used inside fuel tank. When installing the fuel
pump, the filter net at fuel inlet with mesh size not bigger than 60mor arranged with the customer
must be installed. Be careful not to let the fuel jet from air vent spray on the filter net at fuel inlet,
fuel pump bracket or fuel tank wall. Be careful when carrying the fuel pump. First, be sure to protect
the filter net at fuel inlet from load and impact. The fuel pump should be taken out of the plastic

wrapping material with care only when installing. The viser can be taken off only when the fuel
pump is to be installed. Takeoff of the filter net at fuel inlet is absolutely not allowed. The foreign
material that enters the fuel inlet of the fuel pump or the filter net may lead to damage of the fuel
pump.
l Failure effect: strong running noise, poor acceleration, failure to start (starting difficulties) etc.
l Reasons for general failures: use of inferior fuel leads to:
1. Accumulated colloid became insulation layer;
2. Fuel pump bushing and armature blocked;
3. Components of fuel level sensor eroded.
l Maintenance precautions:
1. The electric fuel pump has different flow according to the requirement of engine. The pump
with same shape and possible to assemble perhaps is not available. For service, the part number of
replaced fuel pump must be in conformity with the original ones;
2. Do not run the pump at dry status to prevent the pump from accident;
3. Please pay attention to take cleaning measures for fuel tank and pipeline and replace fuel
filter in case replace fuel pump.
Simple measurement method:
1. With the joint removed, swift the digital multimeter on ohm shift, connect the two meter pens
to two pins of pump respectively to measure the inner resistance, it is indicated that is not at zero or
infinite (that is non short circuit, open circuit status).
2. With the joint connected, connect the fuel pressure gauge onto the sucker, start the engine
and then observe if the fuel pump works; if the fuel pump does not run, check if mains voltage is
present at “+” pin; if the fuel pump works, under idling mode, check if the fuel pressure is about
400kPa.
9. Injector
9.1 Function of injector:

ECU controls the coil of the injector through pulse to make the injector open or close, so that,
appropriate fuel will be injected into air intake pipe in due time to mix with air.
ECU sends electrical impulse to injector coil to form magnetic field force. When magnetic field
force increase to resultant force that enough to conquer return spring pressure, needle valve gravity
and friction force, the needle valve begin to rise up and start the injection process. The pressure of
return spring makes needle valve close again when the injection impulse is stopped.

1. O-ring
2. Filter net
3. Injector body with electric connector
4. Coil
5. Spring
6. Valve needle with coil armature
7. Valve seat with nozzle plate
Cross-section view of electromagnetic injector
Connects to 87# pin of the

main relay
1# cylinder 1# cylinder 1# cylinder 1# cylinder

Injector
Circuit diagram of electromagnetic injector

Item Value Unit
Min. Typical Max.
Operating pressure (pressure 350 KPa
difference)
Injector electric resistance at 20℃ 11 16 W
Allowable fuel:
The injector can only use the fuel in compliance with the provisions in GB 17930-1999 (for
vehicle unleaded gasoline) and GWKB 1-1999 (harmful substance control standard for vehicle
gasoline), and detergent is required to be added into gasoline. It should be specially pointed out that
too long storage of gasoline may make it deteriorate. Especially, the taxi with a (LPG and gasoline)
dual-fuel engine uses LPG as fuel long and gasoline is only used for startup, so, daily consumption
of gasoline is little. However, because the fuel pump runs long, so the temperature of fuel tank is
quite high. If gasoline is stored in the fuel tank of such auto, it may quite liable to oxidation and
deterioration, which may lead to choke even damage of injector.
l Use specific connector for certain injector and no mixed use will be allowable.
l For installation convenience, it is recommended to daub silica-free clean engine oil on the

surface of the O-ring at the upside of the injector where it connects with the fuel distributing
pipe. Be careful not to let engine oil contaminate inside of the injector and the nozzle.
l Place the injector in its bracket vertically along injector bracket, then fix it to the bracket with
retaining clips. Note:
① By location mode, the remaining clips for injector fall into axial location remaining clip and
axial and radial location remaining clip; misuse should be avoided.
② For installation of an axially located injector, make sure that the bayonet at middle of the
remaining clip is completely locked into the groove of the injector and the grooves at both sides
of the remaining clip are completely locked into the outskirt flanging of the injector seat.
③ When instal ling an injector that both axial and radial locations are required, use an axial and
radial location remaining clip and place the locating piece of the injector and the locating pin of
the injector seat respectively into the corresponding grooves on the location remaining clip.
④ If the injector has two grooves, be careful not to place by mistake, refer to the installation site
of the original.
l Installation of injector should be done by hand and knocking the injector with such tools as
hammer etc. is prohibited.
l When disassemble/reassemble the fuel injector, the O ring must be replaced. And pay attention
to not damage the sealing surface of the injector.
l Do not pull the support gasket of O-ring out of the injector. When installing, avoid damage to
fuel inlet end, support ring, nozzle plate and electric connector of the injector. If damaged, use
is prohibited.
l After installation of injector, perform leakproofness detection for fuel distributing pipe
assembly. It is acceptable only when no leakage exists.
l The failure part must be disassembled by hand. Remove remaining clip of the injector first, and
then pull out the injector from the injector seat. After disassembly, ensure cleanliness of the
injector seat and avoid contamination.
l Failure effects: Poor idling, poor acceleration, failure to start (starting difficulties) etc.
l Reasons for general failures: failure caused by colloid accumulation inside the injector due to
lack of maintenance.
l Maintenance precautions: (see installation attentions)
l Simple measure method:
(remove the joint) swift the digital multimeter on ohm shift, connect the meter pens to the two pins
of injector. The rated resistance should be 11 - 16Ω¸ when it is 20℃.
Suggestion: regularly wash and analyze the injector using a special washer analyzer for injector.
10. Ignition Coil
10.1 Function of ignition coil:

Primary and secondary circuits are integrated inside the ignition coil; when ECU controls
on-off of current in the primary coil, a high voltage as high as thousands volts will be generated in
the secondary coil, which will then generate spark through ignition cable and spark plug to ignite the
mixed air in the cylinder.
10.2 Working principle
Ignition coil ZS - K2´2 consists of two primary windings, two secondary windings, mandrel, and

casing. When one of the primary windings grounding channel is connected, the primary winding is
in charging. Once the primary winding circuit is cut off by ECU, the charging will be stopped. At the
same time, the high voltage is sensed in the secondary winding and making the spark plug
discharging. There is a different with the distributor ignition coil: for the ignition coil ZS - K2´2,
there is one spark plug on both side of the secondary winding, so the both spark plugs can ignite at
the same time. These two primary windings power on/off alternatively, correspondently, these two
secondary windings discharge alternatively.
Double spark ignition coil
10.3 Technical characteristic

Item Value Unit
Min. Typical Max.
Nominal voltage 14 V
Resistance Primary winding 0.42 0.5 0.58 W
(20 to 25℃) Secondary 11.2 13.0 14.8 kW
winding
Inductance Primary winding 3.4 4.1 4.8 mH
(20 to 25℃) Secondary 26.5 32.0 37.5 H
winding
Voltage produced 50pF load 30 kV
50pF//1MW load 23 kV
l Failure effects: start failure etc.
l Reasons for the failures: burn out due to too strong current, damage by external force etc.
l Maintenance precautions: use of “test ignition by short circuit” to test the ignition function is
prohibited during maintenance to avoid damage to the electronic controller.
With the joint removed, turn the digital multimeter to Ohm shift, and then connect the two meter
pens respectively to the two pins of primary winding. At 20℃, the resistance should be 0.42-0.58Ω,
while this value of secondary winding should be 11.2-14.8kΩ.

11. Spark Plug
The operating conditions of spark plug is extremely inclement, it is exposed to high pressure,
high temperature and impact as well as strong corrosion from combustion product; therefore, it is a
wearing part.
11.1 Outline drawing
Covered with rivet Covered with rivet
Mono-pole Triple-pole
11.2 Thermal performance

The spark plug must maintain a proper temperature to keep good working order. Practically,
when insulator skirt of the spark plug maintains a temperature of 500-700℃, the oil drop that falls
on the insulator can be burnt away immediately without carbon deposit formed. This temperature
is called “self cleaning temperature of spark plug”. With a temperature below this scope, the spark
plug is liable to carbon deposit and electric leakage, thus causing ignition failure; with a temperature
above this scope, when the mixed air is contacting with the red-hot insulator, pre-ignition may occur
to produce knock, even it may burn in intake stroke and cause backfire.
11.3 Potential failures due to fall of ignition performance of spark plug

Starting difficulties, unsteady speed, chatter of engine, black smoke out of exhaust pipe, high
fuel consumption and poor power.
11.4 Judge if the vehicle status matches with the spark plug type through color of spark plug
Yellow, brown yellow normal indicates that the combustion status of mixed air is normal
Black with carbon deposit carbon deposit check if the spark plug type matches and then
replace with the spark plug with lower heat value (slow heat radiation).
Black with blot soot clean if the injector nozzle is dirty
Dilute if the mixture ratio of oil gas is too big.
Check ignition coil etc. if the high voltage is poor.
Black with oil stain combustion of engine oil check sealing status of the seal ring and if

scratch is present on the cylinder wall.
Pearl overheating check if the spark plug type matches, and then replace with the spark plug
with lower heat value (rapid heat radiation).
11.6 Regular replacement and use overdue
The spark plug is the low-value consumption goods. Though cheaper compared with other
matching parts, its ignition performance directly affects the performance of the engine. Therefore, it
needs regular replacement. For the spark plug used in our vehicles, we suggest that you should
replace the spark plug at the following mileages: 10,000-15,000 km (single electrode);
15,000-25,000 km (multi electrode).
Ignition performance fall of spark plug will make fuel consumption rise and power drop off.
The economic loss caused by excessive fuel consumption unconsciously will even afford to
hundreds of new spark plugs. Use overdue makes the working condition of the engine poor in long
term and brings some damage to the engine.
11.7 Inspection and maintenance of the spark plug
The inspection items for spark plug mainly include carbon deposit, electrode burn through, gap,
and sealing and spark jump performances of the spark plug etc.
The electrode gap of the spark plug should be 0.7-0.9mm. Too small electrode gap will reduce
the breakdown voltage and weaken the spark intensity; while too big electrode gap will increase the
voltage required by the spark plug and cause spark out, especially when the ignition coil is aging and
the ignition system is in poor maintenance, spark out is more liable to occur.
Common failures of spark plug: fall in sealing performance, air leak and soot at the air leakage
position. The above failures can be inspected and judged through sealing performance test and spark
jump test. Both sealing performance test and spark jump test can be conducted on a spark plug
cleaning tester.
It is unscientific that some drivers and maintenance professionals remove the spark plug from
the engine, place it on the cylinder head and inspect if it is in sound conditions using high voltage of
the vehicle. In this test, the spark plug electrode is under an atmosphere other than a gas pressure of
over 800KPa, its working pressure. Therefore, spark jump of a spark plug under an atmosphere
does not indicate that it will also reliably produce spark jump under a high pressure conditions in the
cylinder.
It is required that carbon deposit disposal and proper adjustment of spark plug gap should be
done after a mileage of 10,000-15,000 km in its lifetime. When the temperature in cylinder rises, the
electrode gap should be increased properly. That is, increase the electrode gap in summer while
reduce it in winter. If the mixed air is strong, the electrode gap should be increased; otherwise,
decreased. In plain region, the electrode gap should be decreased while in plateau region, increased.
12. Carbon Canister Solenoid Valve Control
12.1 Function:
Carbon canister solenoid valve is a device used to enable the fuel steam in fuel tank to enter
cylinder to combust through control of ECU. Through controlling duty cycle of a solenoid valve,
ECU can accomplish open and close of the solenoid valve.
The canister control valve is composed of solenoid, armature iron and valve etc. There is a filter
net at the inlet. The airflow through the canister control valve at one hand depends on the duty cycle
of the electric pulse output of canister control valve by ECU, and at another hand depends on the

pressure difference between the inlet and the outlet of the canister control valve. The canister control
valve will be closed when there is not any electric pulse.
Canister control valve
1 From fuel tank

2 Canister
3 Atmosphere
4 Canister control valve
5 To intake manifold
ΔP is the difference between environmental pressure
6 Throttle
Pu and intake manifold pressure Ps
Cross-section view of Installation drawing of canister control valve

canister control valve

See above installation drawing for connection among canister control valve, carbon canister and
intake manifold.
l In order to avoid transfer of solid borne noise, floating installation of the canister control valve
on the hose is recommended.
l During installation, make sure that the airflow direction meets the specification.
l Appropriate measures such as filtering and purge etc. must be taken to prevent such foreign
material as particles from entry into the canister control valve from carbon canister or hose.
It is recommended that a corresponding protective strainer (size of grid<50mm) should be
installed on outlet of carbon canister.
12.5. Failure effects and judgment method
l Failure effects: Failure of functions etc.
Reasons for general failure: corrosion or poor sealing performance etc. due to entry of foreign
material into inside of the valve.
l Maintenance precautions:
1. During installation, make sure that the airflow direction meets the specification;
2. In case of control valve failure due to black particle inside the valve body, when replacement
of the control valve is required, check the status of the canister;
3. During maintenance, try to avoid entry of such liquid as water and oil etc. into the valve;
4. In order to avoid transfer of solid borne noise, floating installation of the canister control
valve on the hose is recommended.

meter pens respectively to both pins of the canister control valve. The rated resistance at 20℃ should
read 26±4Ω.
13. Electronic Accelerator Pedal
13.1 Function:
The electronic accelerator pedal has cancelled the conventional throttle guy and the position of
accelerator pedal is fed back to ECU by means of electronic signal, through which ECU can
calculate and control the action of the electronic accelerator pedal. Two sets of Hall sensors are
integrated in the pedal; ECU can compare and analyze the two signals, if one signal is improper,
ECU will duly access the other signal and light the failure indicator.
The pedal is a Hall sensor. The fixed Hall generator and signal processing circuit are installed
on fixed mounting of the pedal. The two permanent magnets with different magnetic sheet thickness
act together with the pedal. When the pedal acts, the magnetic flux passing the Hall generator will
also change accordingly, the signal processing circuit will process these signals and then send them
to ECU.
13.3 Detection:
The relationship between the two signals of the accelerator pedal is that signal 1 is equal to
signal voltage.
At idle speed position, the voltage of signal 1 is 4.59 and that of signal 2 is 4.30. When the
pedal is at middle position, the voltage will be the minimum; when the pedal is at either end position,
the voltage will be the maximum.
14. Three-way Catalytic Converter
14.1 Function:
Three-way catalytic converter is used to convert the noxious gas in tail gas into such innocuous

gases as carbon dioxide and water etc. At 300-800℃, the conversion efficiency of three-way
catalytic converter is maximum; with a temperature below this scope, the conversion efficiency will
be very poor, while, with a temperature above this scope, the three-way catalytic converter may be
burnt out. Three-way catalytic converter can exert better conversion efficiency only when the
oxygen sensor works. In control strategies of ECU, there are several protective modes for three-way
catalytic converter, and ECU can protect the three-way catalytic converter by regulating air-fuel ratio
and ignition advance angle.
15. Fan Control
15.1 Function:
In order to abstract heat from engine system and from condenser with A/C turned on, fan
control is affected by the signal to ECU sent by water temperature sensor; When water temperature
is high (above the threshold value set by ECU), the fan will run, and when water temperature is low
(below the threshold value set by ECU), the fan will also run; with A/C turned on, the fan will run at
low speed.
15.2 Composition:
DC electric motor double fan (high and low speed change).
15.3 Installation requirements:
The fan is installed between the rear of radiator and the engine, be careful when installing: not
to damage fin of fan blade, otherwise, running noise of the fan will increase, if serious, it may lead to
sharp fall of heat radiation effect of the engine.
15.4 Failure diagnosis:
Fan control circuit is a short or open circuit to ground;
The fan has failure itself;
Too loud fan noise;
Failure in power supply circuit of fan.
15.5 Troubleshooting:
First, validate whether it is a high speed fan system problem or a low speed fan system problem.
Provided that this is a fan control system problem, use a diagnostic tester to locate the failure point,
and then validate whether it is a short-circuit or a break in control circuit.
Failure symptom: the fan failure may result in rise of engine coolant temperature and poor
refrigeration of A/C system.
15.6. Fan Control:

Main relay
Turn-on of low gear of fan:
1. Temperature of engine coolant: 96℃-102℃;
2. On request for A/C, the fan will start up; High speed Low speed
relay of fan relay of fan
3. When driving speed is too high, the fan will start up;
High speed startup of fan:
1. Engine coolant temperature sensor failure;
2. Air flow meter failure;
3. Engine coolant temperature exceeds 102℃.
Pins:
Fan motor
Brief sketch map of fan control

1. High speed fan control (corresponds to ECU50#);
2. Low speed fan control (corresponds to ECU68#);
The operating mode of fan after engine stops:

1. Failure of intake air temperature sensor of engine, delay 60s;
2. Failure of intake air temperature sensor of engine, delay 60s;
3. Engine coolant temperature exceeds 100.5℃, delay 60s;
4. Engine coolant temperature exceeds 70.5℃, delay 60s.
16. Position Sensor of Double Brake Pedal
16.1 Function:
制动开关传感器是将刹车信号送给 ECU，ECU 根据（原文不全）
Inside the brake switch, there are two mutually independent switches with one normal close and
the other normal open. After applying the accelerator pedal, the former normal close switch turns to
be normal open, while the normal open one turns to be normal close. Both signals will be sent to
ECU to be used to control other systems. Whenever the two signals disaccord, ECU will enter failure
mode, the electronic throttle will not respond when applying the accelerator pedal and the engine
will maintain idle speed working state.
Composition: the double brake switch is installed on the bracket of the brake pedal and contains two
independent switches inside.
Installation requirement: the assembly is installed on the pedal and there is a thread adjusting
mechanism on the switch for stroke adjustment of the switch and effective stroke adjustment of the
brake switch.
Long flame (30) Main power supply (15)
Double brake switch
17. Clutch Position Sensor
17.1 Function:

Clutch position switch provides ECU with the signal of clutch position, but this signal can only
be used to distinguish between disengaging and engaging positions of the clutch.
ECU provides clutch position switch with a 12V power supply; when the clutch is under
disengaging state, the power supply will ground and ECU will lose 12V high potential signal, by
which the position of the clutch can be judged.
Clutch position switch

合
器
位
置
开
关
18. A/C Control
By receiving the A/C signal from A/C switch, ECU can control working of A/C compressor.
ECU also can receive the signals from high and low pressure switches of A/C to ensure safety of A/C
system. When A/C signal is sent to ECU through high and low pressure switches, if the low pressure
switch breaks, ECU will not receive the A/C signal; the compressor is thus unable to work. If A/C
system has a too high pressure, the high pressure switch will break and A/C signal can not be
provided to ECU; so, ECU will immediately cut off the compressor. When system pressure is normal
or a little higher (medium pressure), the medium pressure switch will cut in; thus, ECU can control
the fan to run immediately at high speed to ensure a system pressure within the normal range.
Cut off pressure of the low pressure switch: 0.12Mpa
Cut-in pressure of the medium voltage switch: 1.6Mpa
Cut off pressure of the high pressure switch: 3.2Mpa
Through evaporator temperature sensor of the A/C system, ECU
can also protect the A/C system and prevent evaporator case from
freezing. When the temperature provided by the evaporator 高中
Medium voltage switch
temperature sensor is blow 3.75℃, ECU will cut off the 低压

High and low voltage switch
压开
compressor; when the temperature is above this degree, ECU will 开关
automatically engage the compressor to let it work. 关
A/C开关
switch

Chapter Two Fundamental Principle for Failure Diagnosis of
Electronic Fuel Injection System
1. Failure Information Records
The ECU monitors sensor, actuator, related circuit, malfunction indicator and
battery voltage etc., and even EUC itself continuously. At the same time, the ECU
inspect the reliability test on sensor signal output, actuator driving signal and internal
signal (e.g.: closed loop control, knock control, idle speed control and accumulator
voltage control etc.). ECU will set the malfunction record on RAM malfunction
memory immediately once the malfunction or the unlikelihood signal is detected. The
failure information records are stored in the form of diagnostic trouble code (DTC) and
are displayed in the precedence order of occurrence of the failures.
Failures can be divided into “stable state failures” and “random failures” (for example,
caused by transient open circuit of wires or poor contact of inserted parts) by failure
frequency.
2. Failure State
Once duration of occurrence of an identified failure exceeds the given stabilization time
for the first time, ECU will account it as a stable failure and then store it as a “stable
state failure”. If this failure disappears, it will be stored as a “random failure” and
“non-existent”. If this failure is identified again, it will still be a “random failure”, but a
“existent” early failure that will not affect average service of the engine.
3. Failure Types
Short circuit to positive pole of power supply

Short circuit to ground
Open circuit (for the case where there are pull-up resistors or pull-down resistors during
input stage, ECU will recognize failure of open circuit at input port as that of short
circuit to positive pole of power supply or that of short circuit to ground)
Signals can not be used
4. Failure Frequency Counter
For every identified failure, a separate frequency counter numerical value (Hz) will be
set.
This numerical value (Hz) for frequency counter determines the time this failure

information record will be stored in memory after the identified failure disappears (after
troubleshooting).
When a failure is identified for the first time, Hz will be set as its initial value 40. If
failure status does not change, then this numerical value will maintain all along.
Once it is identified that this failure has disappeared and the state has held for a certain
time, whenever the engine starts with success (its engine speed has exceeded the value
at end of starting) once, Hz will decrease by 1. At this point, ECU will believe that this
failure has disappeared, but the failure information record still exists.
If a failure (for example, as a result of poor contact) frequently appears and disappears,
then Hz will increase by 1, but will not exceed its given upper limit value 100.
If value of Hz has been decreased to zero, the failure information records in this failure
memory will be completely cleared.
5. Limp Home
For some identified significant failures, when duration exceeds the given
stabilization time, ECU will take appropriate software countermeasures, for example,
closing some control functions such as closed loop control of oxygen sensor etc. and
setting substituted values for some data that are considered to be suspect and so forth.
At this point, though the working condition of the engine is comparatively poor, the
auto can still run. The purpose to do this is to enable the auto limply run home or to a
service station for overhaul, so as to avoid the embarrassment that the auto breaks down
on highway or afield. Once it is identified that the failure has disappeared and Hz has
fell to below 40, use of normal data will be resumed again.
6. Failure Alert
In the electric control system, when failure take places in any of such important
parts as ECU, absolute pressure sensor in intake manifold, throttle position sensor,
coolant temperature sensor, knock sensor, oxygen sensor, phase sensor, injector, two
driver stages of step motor of idle speed actuator, canister control valve, or fan relay at
corresponding failure location, ECU will give an alarm through lightening of failure
indicator lamp until this failure location restores.
7. Readout of Failure
The failure information records can be called out of ECU through a trouble diagnosis
tester. If the failure relates to the function of mixed air (fuel and air) proportional
regulator, then the engine must at least run for 4 minutes before reading out failure
information records; especially for failure in oxygen sensor, be sure not to detect data
until the engine runs and warms up.
- -

Figure 3-1 ISO 9141-2 Standard Diagnostic Connector
8. Clearing Failure Information Records
After the failure is removed, the failure information records in memory should be
cleared. The diagnostic trouble code can be cleared through the following approaches:
When the numerical value of frequency counter in ECU reaches zero, the failure
information records in failure memory will be automatically cleared.
Employing fault diagnostic tester to clear records of failure with the instruction of “reset
memory for records of failure”.
Pulling out connectors of ECU or disconnecting wires of battery to clear records of
failure in external ram.
9. Failure Locating
After obtaining failure information records through above means, only rough
location where the failure takes place is aware, but this does not mean that the failure
has been located; because the cause that triggers a piece of failure information may be
damage of electric element (such as sensor, actuator or ECU etc.), lead break, lead
short-circuit to ground or anode of battery, even may be mechanical failure.
The failure is intrinsic and the result of its extrinsic representations is a variety of
symptoms. After a symptom is found, first, check for failure information records with a
trouble diagnosis tester or based on the flash code, after that, remove the correlated
failure in accordance with the failure information, and then locate the failure based on
symptom of the engine.
10. Failure Code Table
Failure
No. DTC Explanation class
1 P0016 Improper relative installation position between camshaft and crankshaft class5
2 P0030 Failure in heating control circuit of upstream oxygen sensor class31
3 P0031 Too low voltage in heating control circuit of upstream oxygen sensor class31

4 P0032 Too high voltage in heating control circuit of upstream oxygen sensor class31
5 P0105 Signal failure of intake air pressure sensor class31
6 P0106 Improper signal from intake air pressure sensor class31
7 P0107 Too low voltage in signal circuit of intake air pressure sensor class31
8 P0108 Too high voltage in signal circuit of intake air pressure sensor class31
9 P0112 Too low voltage in signal circuit of intake air temperature sensor class5
10 P0113 Too high voltage in signal circuit of intake air temperature sensor class5
11 P0117 Too low voltage in signal circuit of engine coolant temperature sensor class31
12 P0118 Too high voltage in signal circuit of engine coolant temperature sensor class31
13 P0121 Improper signal from electronic throttle position sensor 1 class34
14 P0122 Too low voltage in signal circuit of electronic throttle position sensor 1 class34
15 P0123 Too high voltage in signal circuit of electronic throttle position sensor 1 class34
16 P0130 Improper signal from upstream oxygen sensor class31
17 P0131 Too low voltage in signal circuit of upstream oxygen sensor class31
18 P0132 Too high voltage in signal circuit of upstream oxygen sensor class31
19 P0134 Failure in signal circuit of upstream oxygen sensor class31
20 P0201 Failure in 1# cylinder injector control circuit class5
24 P0219 Engine revolution exceeds the maximum revolution limit class5
25 P0221 Improper signal from electronic throttle position sensor 2 class34
26 P0222 Too low voltage in signal circuit of electronic throttle position sensor 2 class34
27 P0223 Too high voltage in signal circuit of electronic throttle position sensor 2 class34
28 P0261 Too low voltage in 1# cylinder injector control circuit class5
29 P0262 Too high voltage in 1# cylinder injector control circuit class5
36 P0321 Improper signal of crankshaft top dead center class33
37 P0322 Engine speed signal failure class33
38 P0324 Failure in knock signal processing chip and its circuit class5
39 P0327 Too low voltage in signal circuit of knock sensor class31
40 P0328 Too high voltage in signal circuit of knock sensor class31

41 P0340 Failure in signal circuit of phase sensor class5
42 P0341 Improper signal from phase sensor class5
43 P0342 Too low voltage in signal circuit of phase sensor class5
44 P0343 Too high voltage in signal circuit of phase sensor class5
45 P0444 Failure in control circuit of canister control valve class31
46 P0458 Too low voltage in control circuit of canister control valve class31
47 P0459 Too high voltage in control circuit of canister control valve class31
48 P0480 Failure in relay control circuit of electronic cooling fan (low speed) class5
49 P0481 Failure in relay control circuit of electronic cooling fan (high speed) class5
50 P0501 Improper speed signal class5
51 P0504 Improper signal of brake pedal A/B class5
52 P0506 Engine speed under idle speed control is below the target idle speed class5
53 P0507 Engine speed under idle speed control is above the target idle speed class5
54 P0537 Too low voltage in signal circuit of evaporator temperature sensor class5
55 P0538 Too high voltage in signal circuit of evaporator temperature sensor class5
56 P0560 Improper system voltage signal class33
57 P0562 Too low system voltage signal class33
58 P0563 Too high system voltage signal class33
59 P0571 Failure in signal circuit of brake pedal class5
60 P0601 Failure in EEPROM of ECU class33
61 P0602 Unprogrammed failure in ECU class33
62 P0604 Failure in RAM of ECU class34
63 P0605 Failure in ROM of ECU class34
64 P0606 Safety monitoring function failure of electronic throttle class34
65 P0627 Failure in control circuit of fuel pump relay class33
66 P0628 Too low voltage in control circuit of fuel pump relay class33
67 P0629 Too high voltage in control circuit of fuel pump relay class33
68 P0645 Failure in control circuit of A/C compressor relay class5
69 P0646 Too low voltage in control circuit of A/C compressor relay class5
70 P0647 Too high voltage in control circuit of A/C compressor relay class5
71 P0688 Improper output voltage of main relay class33
72 P0689 Too low output voltage of main relay class33
73 P0690 Too high output voltage of main relay class33
74 P0691 Too low voltage in relay control circuit of electronic cooling fan (low speed) class5
Too high voltage in relay control circuit of electronic cooling fan (low
75 P0692 speed) class5
Too low voltage in relay control circuit of electronic cooling fan (high

Too high voltage in relay control circuit of electronic cooling fan (high
78 P0704 Improper clutch pedal signal class5
79 P1336 Restrictive effect of safety monitoring torque of electronic throttle class34
The deviation between physical location and target location of electronic
80 P1545 throttle overruns class34
81 P1558 Too large opening resistance of electronic throttle class34
82 P1559 Failure in self-study process of electronic throttle class34
System voltage fails to meet the conditions for self-study of electronic
83 P1564 throttle class34
Failure in self-study of initialization of lower limit position of electronic
84 P1565 throttle class34
85 P1568 Too large restoration resistance of electronic throttle class34
86 P1579 Fails to meet the conditions for self-study of electronic throttle class34
87 P1604 Failure in self-study of gain adjustment of electronic throttle class34
88 P1610 Unprogrammed error in Secret Key and Security Code class39
89 P1611 Security Code acceptance error class39
90 P1612 Challenge request failed class36
91 P1613 Immo Code request failed class36
92 P1614 Transponder check error class36
93 P1677 Too high voltage in control circuit of detector lamp (SVS) class5
94 P1678 Too low voltage in control circuit of detector lamp (SVS) class5
95 P1679 Failure in control circuit of detector lamp (SVS) class5
96 P2106 Failure in driver stage of electronic throttle class34
Too low voltage in signal circuit of electronic accelerator pedal position
97 P2122 sensor 1 class34
Too high voltage in signal circuit of electronic accelerator pedal position
Too low voltage in signal circuit of electronic accelerator pedal position
Too high voltage in signal circuit of electronic accelerator pedal position
101 P2138 Improper signal from electronic accelerator pedal position sensor class34
Self-study value of closed loop air fuel ratio control is above the upper limit
102 P2177 (normal load zone) class5
Self-study value of closed loop air fuel ratio control is below the lower limit
103 P2178 (normal load zone) class5
104 P2187 (idle speed zone) class5
105 P2188 (idle speed zone) class5

106 P2191 (heavy load zone) class5
107 P2192 (heavy load zone) class5
Main power cord
Engine
theft-proof
module 1
Electrical Schematic Diagram of Diagnostic Interface

11. The Steps for Implementation of Failure Diagnosis According to
Failure Information Records
11.1 Electronic Throttle Failure
Failure codes: P012, P0122, P0123, P022, P0222, P0223, P1336, P154, P1558, P1559, P1564,
P1565, P1568, P1579, P1604
No. Operating steps Result Follow up steps
1 Put the ignition switch to “ON”. Next step
2 Pull out the joint of throttle position sensor on Yes Next step
harness; use a multimeter to check if the
No 5
magnitude of voltage between its 3# and 5# pins
is around 12V and if a 5V voltage is present
between 6# and 2# pins.
3 Use a multimeter to check if the resistance Yes Next step
values between 1#, 4# and 6# pins of the sensor No Replace the sensor
are between 0.5kΩ and 1.6kΩ.
4 Meanwhile, use a multimeter to check if it is Yes Replace the sensor
break or short circuit between 1#, 4# and 6#
pins of throttle position sensor and ECU38#, No Replace ECU
54#, 36#; or, turn blade of the throttle to observe
if its resistance value jumps and if the resistance
values between 1#, 4# and 6# change
accordingly with rotation of throttle.
5 Connect an adaptor between ECU and harness, Yes Repair or replace
use a multimeter respectively check if it is break wire harness
or short circuit between 1#, 2#, 6# and 4# pins
No Replace ECU
of the sensor and 10#, 32#, 36# and 54# pins of
ECU joint.
Note: This auto adopts the electronic throttle body and has cancelled former step motor,
and the functions that were accomplished by the stop motor on a common throttle body
are now completely accomplished by the throttle driving motor. The electronic throttle
can not be repaired and failure rate of the throttle body is very low, if damaged,
replacing the assembly is the only choice to deal with the problem.
Special attention: The electronic throttle body can not be disassembled and repaired at
service station; in addition, after replacing electronic throttle body, be sure to let it carry
out self-study; otherwise, unsteady working at idle speed of engine may occur. See also
the section about electronic throttle for detailed study scheme. Maintenance of the
throttle body is analogous to that of the common valve body.

11.2 Knock Sensor failure
Failure codes: P0324, P0327, P0328

1 Close the ignition switch, and the engine stops. Next step
2 Pull out the joint of knock sensor on harness, use a Yes Next step
multimeter to check if both resistance values
between 1# and 2# pins and between 1# pin and No Replace with a new
shielded wire (sensor shield) pin of knock sensor sensor
are more than 1MΩ.
3 Knock on the edge of knock sensor with a small Yes Next step
hammer and check with multimeter if there is
No Replace the sensor
communicating signal output between sensor pin
1# and 2#.
4 Turn on the ignition switch but do not start the Next step
engine.
5 Connect an adaptor between ECU and harness, use Yes Repair or replace
a multimeter respectively check if it is break or wires
short circuit between 19#, 20# pins of ECU and No Replace ECU
1#, 2# pins of sensor joint.
Note: Generally, knock sensor is not liable to damage. When disassembling and installing the knock
sensor, be careful not to leave dirt on the contact surface of the sensor and the engine body and do
not add any gasket. If the sensor is damaged, it will have an comparatively great effect on
economical efficiency and emission of the engine. After the knock sensor is damaged, the electric
control system of the engine will lock ignition advance angle of the engine at a fixed ignition angle,
so, the acceleration performance of the engine will fall and economical efficiency and emission of
the engine will also be greatly affected.

11.3 Air Pressure Sensor Failure
Failure codes: P0102, P0103, P0112, P0113

2 Pull out joint of intake air pressure sensor on Yes 4
harness; use a multimeter to check if a 5V
No Next step
voltage is present between 2# and 3# pins of the
joint.
3 Between ECU and harness, use a multimeter to Yes Repair or replace
respectively check if it is break or short circuit harness
between 42# and 33# pins of ECU and 1#, 2#, No Next step
3#, 4# pins of sensor joint.
4 Replace the intake air temperature pressure Next step
sensor.
Note: In case the sensor shorts to 5V or 12V power supply or ground, the engine may not start up or
stop running.

11.4 Front Oxygen Sensor Failure
Failure codes: P0130, P0131, P0132, P0134, P0135

2 Pull off the connector of harness of oxygen sensor. Yes Next step
Check the voltage between pin 1# (+) and 2# (-)
No 4
with multimeter and detect if it is around 12V.
3 Use a multimeter to check if the resistance value Yes Replace ECU
between 1# and 2# pins of the oxygen sensor is No Replace the sensor
between 2Ω and 5Ω at 23℃.
4 Check if heating circuit of the oxygen sensor is Yes Next step
normal. No Check the circuit
5 Check if it is short circuit or break circuit between Yes Repair or replace

the pin 2# of oxygen sensor and main relay 87# harness
pin and between the sensor connector 1# pin and No Next step
ECU 1# pin with multimeter.
6 Connect the oxygen sensor connector of harness Next step
and use neutral. Start the engine and leave it at
idle speed until its coolant temperature reaches to
the normal value.
7 Pull off the oxygen sensor connector of harness. Yes Next step
Check the battery output voltage between pin 3#
(+) and pin 4# (-) of the sensor with multimeter
and detect if it is from 0.1 to 0.9V (after the
engine warms up).
8 Connect the adaptor between ECU and harness. Yes Repair or replace
Check if it is short circuit or break circuit between harness
the pin 36# and pin 13# of ECU and the sensor No Replace ECU
connector pin 3# and pin 4# respectively with
multimeter.
9 Plug in the oxygen sensor connector of harness Next step
the normal value.
10 Connect special diagnostic tester for Chery to read Yes Next step
part of data stream of the engine, and then observe
if part of data stream of the sensor fluctuates
between 100mv and 900mv.
11 Start the engine and let it run at idle speed until Next step
coolant temperature reaches normal value.

12 Connect special diagnostic tester for Chery to read Yes Check other part
part of data stream of the engine, and then
carefully observe part of data stream of the sensor; No Replace the sensor
apply the accelerator pedal to bottom and then
rapidly release it, observe if the output voltage of
the oxygen sensor can reach below 100mv.
Note: when checking data flow of the oxygen sensor, be sure to note working position
of the engine and let the working temperature of the engine reach the normal value,
because the oxygen sensor only can start to work normally when the temperature is over
300 ℃.

11.5 Rear Oxygen Sensor Failure
Failure codes: P0136, 0137, 0138, 0036, 0037, 0038, 0054

2 Pull off the oxygen sensor connector of harness. Yes Next step
Check the voltage between pin 1# (+) and 2# (-)
No 4
with multimeter and detect if it is around 12V.
between 1# and 2# pins of the oxygen sensor is No Replace the sensor
between 2Ω and 5Ω at 23℃.
4 Check if heating circuit of the oxygen sensor is Yes Next step
normal. No Check the circuit

pin 2# of oxygen sensor and main relay 87# pin harness
and between the sensor connector 1# pin and ECU No Next step
1# pin with multimeter.
the normal value.
7 Validate if the three-way catalytic converter works Yes Next step
normally. No Replace the
three-way catalytic
converter
8 Pull out the oxygen sensor joint on harness. Yes Next step
Rapidly apply the accelerator pedal for several
times, and then use a multimeter to check if a
output voltage between 0.1V and 0.9V is present
between 3# (+) and 4# (-) pins of the sensor (after
the engine warms up).
9 Connect the adaptor between ECU and harness. Yes Repair or replace
Check if it is short circuit or break circuit between harness
the pin 36# and pin 55# of ECU and the sensor No Replace ECU
connector 3# and 4# pins respectively with
multimeter.
the normal value.
11 Connect special diagnostic tester for Chery to read Yes Next step
part of data stream of the engine, and then observe

part of data stream of the engine, and then observe No Replace the sensor
if part of data stream of the oxygen sensor is or the three-way
around 100 under standard idling operation. catalytic converter
coolant temperature reaches normal value.
13 Connect special diagnostic tester for Chery to read Yes Check other part
part of data stream of the engine, and then
carefully observe part of data stream of the sensor; No Replace the sensor
rapidly apply the accelerator pedal for several
times and observe if the output voltage of the
oxygen sensor fluctuates within a comparatively
large scope.
Note: The characteristics and operating principle of rear oxygen sensor is basically the
same as those of front oxygen sensor, in special conditions, they can be interchanged to
use. The only difference between them is their different installation sites (working
atmospheres), therefore, during maintenance and diagnostic processes of the vehicle,
please pay attention to some inspection techniques for front and rear oxygen sensors.

11.6. Coolant Temperature Sensor Failure
Failure codes: P0112, P0113

2 Pull out joint of coolant temperature sensor on Yes Next step
harness; use a multimeter to check if the
No 4
magnitude of voltage between 1# (+) and 2# (-)
pins of this joint is around 5V.
between 1# and 2# pins of the sensor is in
proportion to its temperature (refer to relevant part
in this service manual).
4 Use a multimeter to check if it is break or short Yes Repair or replace
circuit between 17# and 29# pins of ECU and 2# harness
and 1# pins of sensor joint. No Replace ECU
5 Start the engine, while engine coolant temperature Yes Next step
rises, check if the voltages on two wires of the No Replace the sensor
sensor falls as water temperature of the engine
rises.
6 Start the engine, disconnect the connector of water Yes Check other part
temperature sensor, and then observe if cooling No Replace the ECU or
fan of the engine starts up and runs at high speed. the circuit

11.7 Failure in Driver Stage of Injector
Failure codes: P0201, P0202, P0203, P0204, P0261, P0262, P0264, P0265, P0267, P0268, P0270,
P0271
1 Close the ignition switch, and the engine stops. Next step
2 Pull out each electromagnetic injector joint on Next step
harness in turn, and then lap the two pins of
multimeter between 2# pin of the joint and the
engine.
3 Put the ignition switch to “ON”. Observe if, at the Yes Repeat 2
instant when the ignition switch cuts in, the
All yes 6
multimeter displays an around 12V voltage value
of battery (mainly check if the injector has power No Next step
supply, which is provided by main relay).
4 Use a multimeter to check in turn if it is break or Yes Repair or replace
short circuit between 87# pin of output terminal of harness
main relay of the engine and 1# pin of each No Next step
electromagnetic injector joint.
5 Repair or replace fuel pump relay and main relay Yes Repair or replace
and their circuits. harness
6 Connect the adaptor between ECU and harness; No Next step
use a multimeter to check in turn if it is break or
short circuit between 27#, 7#, 47# or 6# pins of
ECU and 2# pin of each corresponding
electromagnetic injector joint on harness.
7 Use a multimeter to check in turn if a resistance Yes Repeat 7
between 12Ω and 16Ω is present at 20℃ between All yes Next step
1# and 2# pins (and resistance value of injector) of No Replace the
the electromagnetic injectors. electromagnetic
injector
8 Re-plug all electromagnetic injector joints, engage Yes Repeat 8
the gear to neutral position, start the engine, and
No Replace ECU
then let it run at idle speed. Pull out all
electromagnetic injector joints on harness in turn.
Whenever a joint is pulled out, observe if engine
vibration is aggravated accordingly (equivalent to
spark out experiment).
Note: The damage probability of injector is very low; its main failure is carbon deposit
in injection nozzle, which may result in atomization of fuel injection, poor spray and
unsteady idle speed of engine; therefore, when inspecting, above failure should be
inspected as an emphasis.

11.8 Failure in Driver Stage of Canister Control Valve
Failure codes: P0443, 0444, 0445

engine coolant temperature reaches normal value.
2 Pull out canister control valve joint on harness; Yes Next step
use a multimeter to check if an around 8.6V
No 5 (check positive
battery voltage is present between two pins of this
wire)
joint.
3 Re-plug the canister control valve joint on harness, Yes Next step
increase engine revolution to 2000rpm, and then
No 7 (check ground
touch the valve body by hand to check if the
wire)
canister control valve has slight vibration and
impact (frequency control).
between A# and B# pins of the canister control No Replace the canister
valve is around 25Ω (20℃). control valve
the pin of main relay 87# and the pin of canister the harness
control valve 1# with multimeter. No Next step
6 Repair or replace the main relay and the circuit.
7 Cut off the engine; connect the adaptor between Yes Repair or replace
ECU and harness, and use a multimeter to check if harness
it is break or short circuit between 46# pin of ECU No Replace ECU
and A# pin of the canister control valve.
8 With ignition switch ON, disconnect canister Next step
control valve joint, and then use a multimeter to
check the A# and B# pins at harness end of
solenoid valve.
9 Use a multimeter to check if an around 12V Yes Next step
battery voltage is present between B# pin and No Check feed circuit
ground wire.
10 Use a multimeter to check if an around 3.6V Yes Check other part
battery voltage is present between A# pin and Check ECU circuit
ground wire. No or replace the ECU
Note: The carbon canister solenoid valve is used for the emission control system, a
system set up for environmental protection and air pollution prevention. When engine
runs at idle speed or under heavy load operating mode, the solenoid valve will not
participate in the work. A malfunction of this solenoid valve will result in unsteady
operating mode of the engine. These details should be noted during maintenance
process.

11.9 Failure in Driver Stage of Malfunction Indicator Lamp (MIL)

1 Put the ignition switch to “ON” Next step
2 Disassemble the dashboard, and then use a Yes Check the circuit
multimeter to check if it is break or short circuit No Next step
between 29#, 30# pins at instrument end and 62#,
81# pins of ECU.
3 Replace the instrument and then check if it is Yes Next step
normal No Replace the
instrument
4 Replace ECU, and then re-check if it works Yes Replace ECU
normally. No Check other part
5 Check CAN circuit for the place where is Yes Replace the harness
grounding or short. No Check other part
Note: The malfunction indicator lamp is controlled by ECU. When a failure occurs in
the system, ECU will control the malfunction indicator lamp to light. There are two
kinds of malfunction indicator lamps on this auto (engine failure indicator lamp and
EPC), but the engine failure indicator lamp on the instrument may be shielded in the
system, that is, when a failure occurs, EPC lamp will light, which should be noted
during maintenance process.

11.10 Failure in Driver Stage of 1#, 2# Coils of Step Motor
Failure codes: P1682, 1683

1 Turn on the ignition switch but do not start the Next step
engine.
2 Pull out connector of the electronic throttle, and Yes Next step
then check if the resistance value between 5# and No Replace the
3# pins of the connector is around 6.1Ω. electronic throttle
body
3 Pull out the connector, and then use a multimeter Yes Next step
to check if a 12V alternate voltage is present
between 5# and 3# connectors of the electronic No Check the circuit
throttle.
4 Use a multimeter to check if a 12V voltage is Yes Replace the idle
present between the connector of the harness and speed actuator
ground when the key is ON. No Next step
5 Between ECU and harness, use a multimeter Yes Repair or replace
respectively to check if it is break or short circuit the harness
between 67#, 65# pins of ECU and 5# pin of the No Replace ECU
connector and between 66#, 64# pins of ECU and
3# pin of the connector.
Note: Much about failure diagnosis for other parts has been involved above.

11.11 Crankshaft Position Sensor Failure
Failure code: P0016

2 Pull out camshaft position sensor joint on harness, Yes Next step
and then use a multimeter to check if the voltage
No Check circuit and
between 1# pin of this joint and ground wire is
main power supply
around 12V (battery voltage).
and then use a multimeter to check if the voltage
between 2# pin of this joint and ground wire is
around 11.5V (power supply from ECU and the ECU
voltage is below the battery voltage).
circuit between 79# pin of ECU and 2# pin of the harness
sensor joint. No Next step
and then use a multimeter to check if it is No Replace the sensor
conducting between 3# pin of this joint and
ground wire.
6 Connect the sensor connector and start the engine. Next step
7 Use a oscillometer to check if an around 6V Yes Check other part
square wave signal output is present in 2# signal No Replace the sensor
cable.
Note: The camshaft position sensor is an auxiliary sensor and has great effect on emission of the system.
When failure occurs in this sensor, the vehicle will be difficult to start; though the vehicle will be
basically normal after startup, driving restrictive practice will be found on the engine and the maximum
revolution of engine can not exceed 4000rpm.

11.12 Craftshaft Position Sensor Failure

2 Pull out crankshaft position sensor joint on Yes Check the circuit
harness, use a multimeter to check if it is short or
No Next step
break circuit between 1# pin of this joint and 34#
pin of ECU.
3 Pull out crankshaft position sensor joint on Yes Next step
harness, use a multimeter to check if it is short or
break circuit between 3# pin of this joint and 15#
pin of ECU. ECU

circuit between 79# pin of ECU and 2# pin of the harness
sensor joint. No Next step
5 Pull out crankshaft position sensor joint on Yes Next step
harness, and then use a multimeter to check if the No Replace the sensor
two signal cables on the sensor has a resistance
value of around 1000Ω.
6 Connect the sensor connector and start the engine. Next step
6 Use an oscillometer to check if signal waveform Yes Check other part
output is present in signal cable. No Replace the sensor
Note: Crankshaft position sensor is the main sensor of electronic control unit of engine. If crankshaft
position sensor failure occurs, the engine will be difficult to start; acceleration performance of the engine
will be greatly restricted after startup; the maximum revolution of the engine can not exceed 3800rpm;
meanwhile, emission of the engine will deteriorate.

11.12 Ignition Coil Failure

2 Pull out ignition coil joint on harness, and then use Yes Next step
a multimeter to check if the voltage between 3#
No Check the circuit
pin of this joint and ground wire is an around 12V
battery voltage.
3 Pull out ignition coil joint on harness, and then use Yes Check circuit and
a multimeter to check if it is short or break circuit ECU
between 1# pin of this joint and 5# pin of ECU. No Next step
4 Pull out ignition coil joint on harness, and then use Yes Check circuit and
a multimeter to check if it is short or break circuit ECU
between 2# pin of this joint and 2# pin of ECU. No Next step
5 Check if the resistance of primary coil of the Yes Next step
sensor is around 0.9Ω. No Replace the ignition
coil
6 Check if the resistance of secondary coil of the Yes Next step
sensor is around 14.5kΩ. No Replace the ignition
coil
7 Use an oscillometer to check if secondary ignition Yes Check other part
waveform of ignition cable of ignition system is No Replace the ignition
normal. coil
Note: The ignition coil is mainly used to provide ignition system of engine with ignition energy. The
failure rate of the coil itself is very low, but its failure probability can not be completely excluded. When
failure occurs in ignition coil, the ignition energy of engine will be deficient, which may further lead to
such failures as unsteady idle speed of engine and emission deterioration.

11.13 Accelerator Pedal Position Sensor Failure
Failure codes: P2106, P2122, P2123, P2127, P2128, P2138

2 Pull out accelerator pedal position sensor joint on Yes Next step
harness, and then use a multimeter to check if an
around 5V voltage signal is present between 3#,
6# pins of this joint and ground wire.
3 Pull out accelerator pedal position sensor joint on Yes Check the circuit
harness, and then use a multimeter to check if it is
No Next step
short or break circuit between 3#, 6# pins of this
joint and 32#, 33# pins of ECU.
harness, and then use a multimeter to check if it is No Next step
harness, and then use a multimeter to check if it is No Next step
6 Use a diagnostic tester to read signal output of Yes Next step
accelerator pedal position sensor, and then check No Replace the sensor
if signal 1 increases as opening of accelerator assembly
pedal increases.
7 Use a diagnostic tester to read signal output of Yes Check other part
accelerator pedal position sensor, and then check No Replace the sensor
if signal 2 increases as opening of accelerator assembly
pedal increases.
Note: This pedal is an integrated circuit device, which can not be processed through repair; therefore,
during maintenance process, the service station can maintain it by means of part replacement and can not
disassemble the sensor.

11.14 Double Brake Switch
Failure codes: P0571, P0504

2 Pull out brake switch joint on harness, and then Yes Next step
use a multimeter to check if it is short or break
circuit between 1#, 2# pins of this joint and 21#,
58# pins of ECU.
3 Close the ignition switch, and then check if an Yes Next step
around 12V battery voltage is present on 3# pin of No Check the circuit
the switch joint.
4 Open the ignition switch, and then check if an Yes Next step
around 12V battery voltage is present on 4# pin of No Check the circuit
the switch joint.
5 Release brake pedal, disconnect sensor connector, Yes Next step
and then check if 1# and 3# pins cut off. No Replace the brake
switch
6 Release brake pedal, disconnect sensor connector, Yes Next step
and then check if 2# and 3# pins conducts. No Replace the brake
switch
7 Apply brake pedal, disconnect sensor connector, Yes Next step
and then check if 1# and 3# pins conducts. No Replace the brake
switch
8 Apply brake pedal, disconnect sensor connector, Yes Check other part
and then check if 2# and 4# pins cut off. No Replace the brake
switch

11.15 Theft-proof Control System Failure

1 Insert the ignition key into the ignition lock. Next step
2 Put the ignition switch to ON position, and then Yes Check other part
observe if engine failure indicator lamp or EPC
No Next step
lamp works normally (quick flash of failure
indicator lamp or EPC lamp indicates a abnormal
condition).
3 Connect a diagnostic tester to the system, and then Yes Remove the failure
enter corresponding diagnostic program unit to and clear the DTC
check if DTC exists in the system. No Next step
4 Pull out theft-proof module joint on harness, and Yes Next step
then use a multimeter to check if an around 12V
operating voltage is present on A1#, A4# pins of
the joint when ignition switch is under ON state.
5 Pull out theft-proof module joint on harness, and Yes Check the circuit
then use a multimeter to check if such electric and No Next step
circuit failures as short circuit and break circuit
exist in the circuit between A5#, A8# pins of this
joint and 31# and 71# pins of ECU.
then use a multimeter to check if poor contact No Next step
exists between A2# pin of this joint and ground
wire of the vehicle.
then use Ohm Shift of the multimeter to check if No Replace the
the circuit between B1#, B2#, B3# pins of this theft-proof module
joint and the coil exists.

12. Steps for Implementation of Failure Diagnosis by Engine
Symptom
12.1 Perform Preliminary Inspection First before Following the Steps for
Implementation of Failure Diagnosis by Engine Symptom.
(1) Make sure that ECU and failure indicator lamp (or EPC lamp) have no off-normal
phenomenon (excluding the models that have no failure indicator lamp).
(2) Use a failure diagnostic tester to check and make sure no failure information record
exists.
(3) Employ failure diagnostic tester to check that hot idle data from electronic control
system fall within normal scope.
Hot idle speed parameter table:

Name Parameter
Air intake temperature 20-70℃
Battery voltage 12-14V (affected by engine revolution)
Temperature of engine coolant 80-90 ℃ (normal operating temperature)
Position of accelerator pedal 0%~99.00%
Air-fuel ratio control integrator 5%-5%
Ignition advance angle 5-10°( may change with fluctuation of
engine revolution)
Outer corner of throttle 0%~99.61%
Fuel injection time 2-7ms (has a strong relation with engine
revolution)
Engine revolution n Expected idle speed ± 50rpm
Duty cycle of canister control valve 0%~99.9%
Self-adapting value of air-fuel ratio 0.95-1.05
control
Self-adapting value of air-fuel ratio 120-140
control
Intake manifold absolute pressure 350-650hPa
Voltage of oxygen sensor Quickly fluctuates at 0.1-0.9V
Air intake pressure
(4) Validate that the failure effect the owner complained exists and then locate the exact
position of the symptom. Please note that the information provided by the customer is
very important, especially the failure symptoms, occurrence time, position and if any
other failure symptoms occurred before; these information can help technical personnel
rapidly and effectively judge the failure, thus increasing maintenance speed and
improving maintenance quality.
Then check the appearance:

Check that grounding of wire harness is clean and firm.
Check that vacuum pipeline is unbroken, twisted and in right connection.
Check that there is no obstruction in pipe.
Check that air intake pipe is not squashed or damaged.
Check that the seal between throttle body and intake manifold is perfect.
Check that ignition cable of ignition system is unbroken, no ageing and in right wiring.
Check that wires are in right connection, no loosing or poor connection for connectors.

12.2 The Engine Does not Rotate or Rotates Slowly when Starting

1 Use a multimeter to check if a voltage around Yes Next step
10-12.5V is present between two battery No Repair or
terminals. replace the
battery
2 Put the ignition switch to “ON”. Use a Yes Next step
multimeter to check if a battery voltage around
No Repair wiring
10-12.5V is present on the terminal on the
terminal or
ignition switch that connects with anode of
replace cable
battery.
3 Maintain ignition switch at START position, Yes Next step
and then use a multimeter to check if a voltage
above 8V is present on the terminal on the No Replace the
ignition switch that connects with pull in ignition switch
winding of starting motor.
4 Put the ignition switch at start position, check Yes Next step
the anode terminal of starting motor by No Repair wiring
multimeter and observe the voltage if it is above terminal
8V. Or replace
cable
5 Check if it is short circuit or break circuit in the Yes Repair or
starting motor. replace the
starting motor
No Next step
6 Check if there is jammed by poor lubricating. Yes Troubleshootin
g
No Next step
7 If the failure is happened in winter time, check if Yes Replace with
it is because of the wrong engine lubricant and appropriate oil
gearbox oil causes the big resistance of the No Check if other
starting motor. systems are
normal
Note: When this problem occurs, mainly inspect voltage, starter and ground system. In
modern sedan, lubricant has little effect on startup of the vehicle, so, basically, it needs
not to allow for lubricant problem, but the problem if the engine has too large self
resistance should be taken into consideration.

12.3 When Starting, Engine Can be Dragged to Rotate but Can not Start
with Success.

1 Put the ignition switch to “ON”. Use a failure Yes Remove the
diagnostic tester to check if any failure failure displayed
information record exists. No Next step
2 Pull out cylinder distribution wire, connect Yes 8
spark plug with the distance between electrode
No Next step
of spark plug and engine body as 8-10mm, use
the starting motor to drag the engine to rotate,
and then check if blue-white high-voltage spark
occurs (disconnect all injection nozzles on the
engine).
3 Check if resistance value of ignition cable is Yes Next step
normal (can not exceed 16kΩ). No Repair, replace the
ignition cable.
4 Check ignition coil and ignition cable for burn Yes Replace
through, damage and crack. No Next step
5 Check if ignition cable is normal. Yes Replace

No Next step
6 Check if the ignition coil is working normally. Yes Next step
No Replace
7 Check if connectors of ignition coil and Yes Next step
ignition cable are connected properly. No Connect the
connectors
properly
8 Put the ignition switch to “ON”. Check if fuel Yes Next step
pump relay and fuel pump can keep working for No Overhaul the fuel
a period of time. pump circuit
9 Connect fuel manometer valve. Short 30# and Yes Next step
87# pins of fuel pump relay to make the fuel
No 13
pump run, and then check if fuel pressure is
around 400kPa.
10 Pull off the fuel distributing pipe and the fuel Yes 12
injector; pull off the joints of fuel injector on the
No Next step
harness one by one. And supply the voltage of
12 V from battery to fuel injector directly and
look if the fuel injector can inject normally.
11 Yes Next step

Clean out the fuel injector and observe if it can No Replace the fuel
work correctly. injector
12 Check if fuel is bad or moisture. Yes Replace fuel

No 18
13 Check if the fuel pressure value is below 400 Yes Next step
kPa. No 17
14 Close the fuel manometer valve. Re-engage the Yes Next step
ignition switch to let the fuel pump run for a No 16
period of time, and then check if fuel pressure
can be built up.
15 Open the valve of fuel gauge and clamp the oil Yes Check other part
return pipe by oil return baffle so that the oil can No Repair or replace
not return. Check if the oil pressure occurs the fuel pump
immediately.
16 Check if there is leakage or jam in oil intake Yes Repair or replace
pipe. oil intake pipe
No Replace oil pump
17 Check if the oil return pipe is bended or Yes Repair or replace
jammed. oil return pipe
No Replace fuel
pressure regulator
18 Check if it is break or short circuit between 1#, Yes Repair or replace
2# pins of crankshaft position sensor and 34#, the harness
15# pins of ECU. No Next step
19 Check if the part of air intake system is leaking. Yes Repair

No Next step
20 Check if air flow meter works normally. Yes Repair or replace
No Next step
21 Check if the coolant temperature sensor is Yes Next step
working correctly. No Repair or replace
22 Check if the reason for the failure on starting is Yes Remove the
about mechanism, such as much cylinder mechanical failure
clearance, cylinder leaking, and so on. No Replace ECU
Note: When checking this problem, if all parts in electronic fuel injection system are
normal, consider if mechanical part of the engine works normally, or if cylinder
pressure is normal and if air leakage exists and so forth.

12.4 Warm Starting Difficulty

1 Put the ignition switch to “ON”. Use a special Yes Remove the failure
diagnostic tester to check if any failure displayed
2 Connect fuel manometer valve. Short 30# and 87# Yes Next step
pins of fuel pump relay to make the fuel pump
No 9
run, and then check if fuel pressure is around
400kPa.
3 Disconnect the connecting oil pipe and turn off the Yes Next step
ignition switch. Observe the voltage of fuel system No Repair the fuel
and look if it is around 300 kPa after an hour. system to avoid
leakage
4 Put the connecting oil pipe through, use fuel tube Yes Replace fuel
clamp to intercept the oil return pipe, meanwhile, pressure regulator
close the fuel manometer valve. Turn off the No Next step
ignition switch, after one hour, observe if pressure
of fuel system still can maintain at around 400kPa.
5 Check if there is fuel leakage of fuel injector and Yes Replace the injector
oil pipe. and fuel pipe
No Next step
6 Pull out water temperature sensor joint and start Yes Check coolant
the engine. Observe if the engine can start with temperature and
success. circuit
No Next step
7 Connect an adaptor between ECU and harness, Yes Next step
check if a voltage around 5V is present on 39#, No Repair or replace
17# pins, meanwhile, check if the resistance value the harness
of water temperature sensor is within normal
scope.
8 Replace ECU and perform warm start again; Yes End
observe if the engine can be started successfully. No Replace ECU
9 Check if there is jam or bending of fuel pipe and if Yes Next step
the pressure regulator valve of oil pump is No Repair or replace
working correctly.
10 Check if there is battery voltage between the plugs Yes Next step
of oil pump with multimeter.
No Repair or replace
fuel pump relay and
wires
11 Try to replace the fuel pump and see if the system Yes Next step
can return to normal. No Replace fuel pump

12 Check if the fuel pump is stopped up. Yes Replace fuel pump
No Replace ECU
Note: Warm starting difficulty is in connection with many systems, such as battery,
throttle body and water temperature sensor etc. as well as mechanical part of the engine,
such as valve sealing. Thermal expansion of engine under warm state may lead to rise of
engine resistance.

12.5 Engine Speed is Normal, but it is Difficult to Start at any Time

1 Put the ignition switch to “ON”. Use a special Yes Remove the failure
2 Check the air cleaner and look if it is open. Yes Next step
No Replace
3 After starting successfully, check if air intake Yes Next step
consumption of the engine at idle speed is No Eliminate the
around 300Kg/h (remember to check if cylinder failure of air intake
pressure is normal). system leaking
4 Step on the throttle slightly and observe if it is Yes Replace the
easy to be started easily. electronic throttle
body
5 Connect fuel manometer valve. Short 30#, 87# Yes Next step
pins of fuel pump relay to make the fuel pump No 9
run, and then check if fuel pressure is around
400kPa.
6 Use a special joint to directly supply a 12V Yes 8
voltage and intermittent ground wire from No Next step
battery to injector and check if the injector
works normally (work intermittently).
7 Clean out the fuel injector and look if it can Yes Next step
work correctly. No Replace fuel
injector
8 Replace fuel 8, and check if the fuel is Yes Replace fuel
deteriorated or moisture. No 14
kPa. No 13
ignition switch to let the fuel pump run for 3s, No 12
and then check if fuel pressure can be built up.
11 Open the valve of fuel gauge and clamp the oil Yes Replace fuel
return pipe by oil return baffle so that the oil can pressure regulator
not return. Check if the oil pressure occurs No Repair and replace
immediately. fuel injector and oil
pipe
12 Check if there is leaking or jam in oil intake Yes Repair or replace
No Replace oil pump

No Replace fuel
pressure regulator
14 When engine coolant is at low temperature, pull Yes Next step
out electronic throttle body on harness and No Check electronic
observe if engine revolution will rise. throttle body for
damage
15 Put the ignition switch to “ON”. Check if Yes Next step
voltage on the following pins of ECU is normal: No Check wires and
if it is a battery voltage around 12V on 12#, 14#, plugs
15# pins; if the voltage between 51#, 53#, 3#,
61#, 80# pins and the wire is zero.
16 Check if ignition advance angle is normal. Yes Next step
No Check other
systems
17 Check if cylinder compression pressure of Yes Next step
engine is normal, if low, add a little engine oil No Troubleshooting
into each cylinder and re-measure if the cylinder
pressure is normal.
18 If air cleaner or airflow sensor is choked. Yes Repair or replace
No Next step
19 Check if the coolant temperature sensor is Yes Replace ECU
working correctly. No Repair or replace
Note: Note if theft-proof system has started up. After theft-proof system has started up,
when starting the engine, the staring motor can run normally, but the engine can not
start; therefore, please note if this system can work normally.

12.6 Cold Starting Difficulty

1 Put the ignition switch to “ON”. Use a failure Yes Remove the failure
2 Use a multimeter to check if the coolant Yes Next step
temperature sensor is normal. (A 2.8KΩ electric
resistance can also be connected in series between
39# and 17# pins of ECU to start the engine in
stead of the coolant temperature sensor. If the
engine can start, it indicates off normal of coolant
temperature sensor.)
3 Put the ignition switch to “ON”. Check if voltage Yes Next step
on the following pins of ECU is normal: if it is a No Check wires and
battery voltage around 12V on 12#, 14#, 15# pins; plugs
if the voltage between 51#, 53#, 3#, 61#, 80# pins
and the wire is zero.
No Replace
consumption of the engine at idle speed is around No Eliminate the
300Kg/h (remember to check if cylinder pressure leakage failure of
is normal). air intake system
6 Step on the throttle slightly and observe if it is Yes Check the
easy to be started easily. electronic throttle
No Next step
7 When engine coolant is at low temperature, pull Yes Next step
out electronic throttle body joint on harness and No Check the electric
observe if engine revolution will rise. throttle body
8 Connect fuel manometer valve. Let 86# pin of fuel Yes Next step
pump relay directly ground. Turn on ignition
No 12
switch to make fuel pump relay and fuel pump
work, and then check if fuel pressure is at around
400kPa.
9 Use a special joint to directly provide a 12V Yes 11
electricity and ground wire from battery to injector No Next step
and check if the injector works normally.
10 Clean out the fuel injector and look if it can work Yes Next step
correctly. No Replace fuel
injector
11 Check if fuel is deteroprated or moisture. Yes Replace fuel

No 17
12 Check if the fuel pressure value is below 300 kPa. Yes Next step
No 16
period of time, and then check if fuel pressure can
be built up.
14 Open the valve of fuel gauge and clamp the oil Yes Check fuel pressure
return pipe by oil return baffle so that the oil can regulator and fuel
not return. Check if the oil pressure occurs pump
immediately. No Repair and replace
fuel injector and oil
pipe
15 Check if the oil intake pipe is leaky or jammed. Yes Repair or replace
oil intake pipe
No Replace oil pump
16 Check if the oil return pipe is bended or jammed. Yes Repair or replace
oil return pipe
No Replace fuel
pressure regulator
or fuel pump
17 Check if the pressure of cylinder is normal. Yes Next step
No Troubleshooting
18 Check if the engine air intake system is leaky. Yes Repair
No Next step
19 If air cleaner or airflow sensor is choked. Yes Repair or replace
No Replace ECU
Note: The cold starting problem relates to more failure points, among which water
temperature sensor is comparatively important, because it is the major parameter for
determination of injection pulse-width when starting the engine. In case of a water
temperature sensor failure or it generates a false signal, the system can not judge the
temperature and starting difficulty may occur.

12.7 Unsteady Idle Speed at Any Time
2 Check if electronic throttle system of engine Yes Repair or replace
works normally. the electronic
throttle
No Next step
3 Turn on ignition switch, connect an adaptor Yes Check wires and
between ECU and harness, and then check if the plugs
voltage between 17# and 42# pins of ECU,
between 39# and 17# pins of ECU (signal output No Next step
terminal of intake air temperature sensor and
coolant temperature sensor) as well as 64#, 65#,
66#, 67# pins of ECU (for control of DC motor) is
normal.
4 Let engine run at idle speed, spark out cylinder in Yes 8
turn, and observe if engine revolution will fall and No Next step
fluctuate (cut fuel to injector).
5 Check the fuel injectors of each cylinder and look Yes Next step
if they are in right conditions. No Check fuel injector
and wires
6 Check if resistance value of ignition cable of each Yes Next step
cylinder is normal (can not exceed 16kΩ). No Replace
7 Check if ignition system works normally. Yes Maintain
No Next step
8 Check if the spark plug is in right conditions. Yes Next step
No Replace spark plug
9 Connect fuel manometer valve. Short 30# and 87# Yes Next step
pins of fuel pump relay to make the fuel pump
run, and then check if fuel pressure is around No 13
400kPa.
power supply and intermittent ground wire signal No Next step
from battery to injector and check if the injector
can work intermittently.
11 Clean out the fuel injector and look if it can work Yes Next step
correctly. No Replace fuel
injector
No 18

13 Check if the fuel pressure value is below 300kPa. Yes Next step
No 17
period of time, and then check if fuel pressure can
be built up.
pipe
16 Check if there is leaking or jam in oil intake pipe. Yes Repair or replace
oil return pipe
No Replace oil pump
17 Check if the oil return pipe is bended or jammed. Yes Repair or replace
oil return pipe
No Replace fuel
pressure regulator
18 Check the pressure of air intake pipe and if the Yes Use detergent to
sense port of air intake temperature sensor is wash
jammed. No Next step
19 Let engine run at idle speed, after coolant Yes Next step
temperature reaches the active temperature of No Check the oxygen
closed loop control, observe if the oxygen sensor sensor and harness
works normally (rapidly fluctuate between 0.1V
and 0.9V).
Check if the engine air intake system is leaky. Yes Remove leakage
20 No Next step
21 Check if the pressure of cylinder is normal. Yes Next step
No Troubleshooting
22 Let engine run at idle speed, after coolant Yes Replace ECU
temperature reaches normal value, then use a
No Check other part
special diagnostic tester to check if ignition
advance angle is within the standard scope.
Note: Unsteady idle speed relates to many systems, such as air leak, carbon deposit and
throttle body etc.; before replacing a part, make sure that air cleaner, spark plug and
ignition system of engine are normal.

12.8 Unsteady Idle Speed during Warming up Process
No Replace
consumption of the engine at idle speed is around No Eliminate the
300Kg/h (remember to check if cylinder pressure leakage failure of
is normal). air intake system
4 Turn on ignition switch, connect an adaptor Yes Next step
between ECU and harness, and then check if the
voltage between 17# and 42# pins of ECU, No Overhaul
between 39# and 17# pins of ECU (signal output
normal.
5 Before finish of warming up of engine, pull out Yes Next step
the joint on electronic throttle body and observe if No Check the electric
engine revolution will change. throttle body
6 Check if the coolant temperature sensor is Yes Next step
working correctly. No Replace
7 Let engine run at idle speed, after coolant Yes Replace ECU
temperature reaches normal value, then use a
No Check the ignition
special short diagnostic tester to check if ignition
timing mechanism
advance angle is normal.
Note: Unsteady idle speed occurs seldom during warming up process, its
troubleshooting is similar to that for previous case, but validate if water temperature
sensor works normally in advance.

12.9. Unsteady Idle Speed after Warming up
No Repair or replace the
harness
66#, 67# pins of ECU (for control of DC motor)
is normal.
3 Turn off the engine. Check the air cleaner and Yes Next step
look if it is open. No Replace
consumption of the engine at idle speed is No Eliminate the leakage
around 300Kg/h (remember to check if cylinder failure of air intake
pressure is normal). system
87# pins of fuel pump relay to make the fuel No 9
around 400kPa.
power supply and intermittent ground wire from No Next step
battery to injector and check if the injector can
work intermittently.
7 Clean out the fuel injector and look if it can Yes Replace
work correctly. No Replace fuel injector
No 14
9 Check if the fuel pressure value is below Yes Next step
300kPa. No 13
can be built up.
11 Open the valve of fuel gauge and clamp the oil Yes Replace fuel pressure
return pipe by oil return baffle so that the oil can regulator
pipe

12 Check if there is leaking or jam in oil intake Yes Repair or replace oil
pipe. intake pipe
No Replace oil pump
13 Check if the oil return pipe is bended or Yes Repair or replace oil
jammed. return pipe
No Replace fuel pressure
regulator
temperature reaches normal value, then use a No Check other systems
diagnostic tester to check if ignition advance
angle is normal.
15 Pull off the coolant temperature sensor and Yes Replace the coolant
observe if the engine is in right conditions. temperature sensor
No Next step
16 Check if the compression pressure of cylinder is Yes Next step
normal. No Troubleshooting
17 Check if resistance value of ignition cable of Yes Next step
each cylinder is normal (can not exceed 16kÙ). No Replace
18 Check if ignition coil and ignition cable system Yes Replace
works normally and if crack exists on ignition No Next step
coil.
19 Check if the spark plug is in right conditions. Yes Replace ECU
Note: After finish of warming up, engine will enter normal idle speed state, under
which, unsteady revolution is in connection to many factors, such as spark plug, ignition
cable, ignition coil, if air leak exists in the system, if carbon deposit exists in the system
and if cylinder pressure is normal an so forth.

12.10 Unsteady Idle Speed or Extinguish with Load (A/C etc.)
2 Turn on A/C switch, connect an adaptor Yes Next step
between ECU and harness, and then measure
No Check and repair air
75# pin of ECU to see if input signal is present
conditioning circuit
(high potential signal loaded by A/C switch
through high and low voltage switches).
3 Check if the pressure of air conditioning system, Yes Next step
the electromagnetic clutch of compressor and No Repair or replace
the air conditioning pump are in right
conditions.
4 Check the voltage on 64#, 65#, 66# and 67# Yes Next step
pins of ECU (for control of DC motor) as well No Check controlling
as corresponding pins on valve body is normal. circuit
5 Remove electronic throttle body and check if Yes Check the electric
throttle is locked or is dumb to run. throttle body
No Next step
6 Start engine, turn on A/C, use a failure diagnosis Yes Replace ECU
tester to read such signals as air intake flow and No Replace the
engine revolution and check if engine electronic throttle
acceleration occurs. body
Note: 75# pin is the up level request signal. When turning on A/C switch, an up level
signal will be sent to ECU through this pin, and then ECU will further check other
systems of A/C. If all systems are normal, ECU will control A/C relay to ground and
A/C system will start to work. 60# pin of ECU is medium voltage signal input; when
high potential signal is loaded on this pin, cooling fan will start and run at high speed.

12.11 Periodic Unsteadiness (Have to Perform Self-study again after ECU
is Power off)
No Replace
consumption of the engine at idle speed is around No Check and repair
300Kg/h (remember to check if cylinder pressure air intake and leak
is normal).
4 Let engine run at idle speed, spark out cylinder in Yes 7
turn, and observe if engine revolution will fall and No Next step
fluctuate (it is prohibited to carry out spark out
experiment by disconnecting ignition cable).
No Repair or replace
cable
normal.
temperature reaches normal value, then use a No Check other part
diagnostic tester to check if ignition advance angle
of the system is normal.
7 Check air intake system for such failures that may Yes Sweep
affect working of engine as blocking and air leak No Next step
etc.
No Next step
9 Use a special joint to directly provide a 12V Yes Next step
power supply and intermittent ground wire from No Check and repair
battery to injector and check if the injector can oil injector and
work intermittently. related wires
10 Check if the resistance values of cylinders’ Yes Next step
ignition cable are normal. No Replace
11 Check if the ignition coil is damaged or cracked. Yes Replace

No Next step

12 Check if the spark plug is in right conditions. Yes Replace ECU
Note: For periodic unsteadiness, mainly check air intake system for air leak or
electronic throttle body for failure. Following are the steps for inspection of electronic
throttle body: while turning on ignition key, throttle may jiggle; during self-checking
procedure, throttle should act with actions of accelerator pedal.

12.12 Too High Idle Speed (Have to Perform Self-study again after ECU is
Power off)
2 Check if throttle valve plate is locked and if Yes Adjust or replace
failure exists in electronic throttle body. No Next step
3 Check if the canister control valve, the fuel Yes Repair or replace
pressure regulator, the positive crankcase No Next step
ventilation vacuum pipe and the vacuum pipe of
brake system are mounted steadily or they are
damaged.
4 Run the engine at idle speed and use neutral. Step Yes Next step
on the accelerator and observe if the idle speed is No 6
too high.
5 Clamp the vacuum pipe and observe if the idle Yes Repair or replace
speed becomes normal. the vacuum booster
No Next step
6 Replace PVC valve and clamp the positive Yes Replace PVC valve
crankcase ventilation vacuum pipe. Observe if the No Next step
idle speed becomes normal.
7 Clamp the canister control valve pipe and observe Yes Replace the canister
if the idle speed becomes normal. control valve
No Next step
8 Check if electronic throttle body is dumb or Yes Repair or replace
locked. No Next step
9 Check other parts of air intake pipe for leakage. Yes Repair or replace
No Next step
10 Check if the gasket of fuel injector is in good Yes Next step
condition. No Replace the gasket
11 Check air intake system for air leak and air flow Yes Replace ECU
meter for normal working. No Replace the sensor
Note: Check if the system goes through self-study, if not, the system will be under
failure mode or an uncertain state all the time, which may result in too high idle speed
of engine. The other cause is air leak in the system, if air leakage in the system is too
large and exceeds regulation and control range of ECU, idle speed fluctuation may
occur.

12.13. Engine Revolution Speed is too Low or Flameout
No Replace
3 Run the engine at idle speed and check if the Yes Next step
engine revolution speed is normal at idle speed. No Next step,
overhaul with
reference to idle
speed failure
entries
consumption of the engine at idle speed is No Overhaul
around 300Kg/h (remember to check if cylinder
pressure is normal).
temperature reaches normal value, then use a No Check other
diagnostic tester to check if ignition advance systems
angle of the system is normal.
around 400kPa.
work correctly. No Replace fuel
injector
No 15
kPa. No 14
can be built up.

return pipe by oil return baffle so that the oil can No Repair and replace
not return. Check if the oil pressure occurs fuel injector and
immediately. oil pipe
13 Check if there is leaking or jam in oil intake Yes Repair or replace

No Replace oil pump
No Replace fuel
pressure regulator
15 Put the ignition switch to “ON”. Check if Yes Next step
voltage on the following pins of ECU is normal:
if it is a battery voltage around 12V on 12#, 14#, No Repair or replace
15# pins; if the voltage between 51#, 53#, 3#, cable
61#, 80# pins and the wire is zero.
16 Check if ignition coil, ignition cable and spark Yes Replace ECU
plug are normal.
No Adjust or replace
the parts involved
Note: This phenomenon indicates a comparatively obvious failure and some minute
details, such as if strainer of the system or exhaust pipe is blocked and so forth, should
also be checked. For other causes, check spark plug and ignition cable etc.

12.14 Slow Response when Accelerating
2 Turn off the engine. Check the air cleaner and Yes Next step
look if it is open. No Replace
engine revolution speed is normal at idle speed. No Repair in accordance
with idle speed
failure item
4 Run the engine at idle speed and check if the air Yes Next step
intake pressure is from 35 to 65 kPa. No Overhaul
5 Put the ignition switch to “ON”. Check if it is Yes Next step
break or short circuit between 38#, 32#, 54#, No Repair or replace
36# pins on ECU connector and 1#, 2#, 4#, 6# Harness
pins of throttle position sensor of electronic
throttle valve body.
angle is normal.
around 4000kPa.
8 Use a special joint to directly provide 12V Yes 10
power supply and intermittent 12V power No Next step
supply from battery to injector and check if the
injector can work intermittently.

No 16
kPa. No 15
can be built up.

13 Open the valve of fuel gauge and clamp the oil Yes Replace the pressure
pipe
pipe. intake pipe
No Replace oil pump
jammed. return pipe
No Replace the pressure
regulator
16 Check if the exhaust system and three-way Yes Replace or clean
catalytic converter are jammed. No Replace ECU
Note: For slow response when accelerating, mainly check air intake pressure and injection pulse-width
etc.; choked exhaust pipe and smudgy air cleaner may be causes for this problem. In addition, spark plug
and ignition cable problems may also be causes.

12.15 Poor Performance and Disability when Accelerating.
1 Check if failure occurs, such as clutch slipping, Yes Repair

low tire pressure, brake delay, wrong tire size No Next step
and incorrect four-wheel alignment.
2 Check if the electronic throttle can be full Yes Next step
opening. No Repair or replace the
throttle
temperature reaches normal value, then use a No Check the parts
diagnostic tester to check the ignition advance involved
angle.
break or short circuit between 38#, 32#, 54#,
36# pins on ECU connector and 1#, 2#, 4#, 6#
throttle valve body. check if the voltage between No Repair or replace
17# and 42# pins of ECU, between 39# and 17# Harness
pins of ECU (signal output terminal of intake air
temperature sensor and coolant temperature
sensor) as well as 64#, 65#, 66#, 67# pins of
ECU (for control of DC motor) is normal.
6 Run the engine at idle speed and check if the air Yes Next step
intake pressure is from 35 to 65kPa. No Overhaul
around 400kPa.

No 16
kPa. No 15

can be built up.
13 Open the valve of fuel gauge and clamp the oil Yes Replace the pressure
pipe
pipe. intake pipe
No Replace oil pump
jammed. return pipe
No Replace the pressure
regulator
16 Check if leak and blocking exist in air intake Yes Next step
system and if air flow meter works normally. No Replace the sensor
17 Check if spark plug, ignition cable and ignition Yes Next step
coil are normal.
No Replace or adjust
18 Check if it results from air conditioning system. Yes Check A/C system
No Replace ECU
Note: Poor acceleration of system relates to many factors, such as problem in mechanical part of the
engine itself, cylinder pressure and carbon deposit on valve etc. In addition, it is also in connection with
other systems, such as power steering system and A/C system.

12.16 Unable to Reach the Maximum Revolution when Accelerating
2 With engine off, check if air cleaner is smooth Yes Next step
(can not simply rely on visualization, remove No Replace
the air cleaner and then perform test drive again)
and if air intake system is chocked.
with idle speed
failure item
angle is normal.
around 400kPa.
8 Check if working positions of camshaft position Yes Next step
sensor and crankshaft position sensor are No Replace the parts
normal. involved

No 16
kPa. No 15
12 Yes Replace or clean

Check if the exhaust system and three-way No Replace ECU
catalytic converter are jammed.
Note: In case the engine is unable to reach its maximum revolution when accelerating, mainly check if
exhaust pipe is chocked and air cleaner is smudgy. In addition, for electric control system of A21, in case
of a failure in crankshaft or camshaft position sensor, ECU will take restrictive driving measures to
restrict engine revolution to exceed certain value, which should be noted during maintenance process.

12.17 When Releasing Accelerator Pedal after Acceleration, Unsteady Idle
Speed Occurs at Instant, even Extinguishes.
2 With engine off, check if air cleaner is smooth Yes Next step
(can not simply rely on visualization, remove No Replace
the air cleaner and then perform test drive again)
and if air intake system is chocked.
with idle speed
failure item
angle is normal.
around 400kPa.
8 Remove air intake hose, check if carbon deposit Yes Clear carbon deposit
or other soil (this may result in air intake system No Next step
of engine being chocked when the valve plate
closes) exists.

No 16
11 Yes Next step

Check if the fuel pressure value is below 400 No 15
kPa.
12 Check if the exhaust system and three-way Yes Replace or clean

catalytic converter are jammed. No Replace ECU
Note: For an electric control motor with the electronic throttle body, the main actuators of its air intake
system are air flow meter and electronic throttle body. Air flow meter has very high operational reliability
and very low failure rate, while, due to particularity of road status in China and affected by operating
environment, choke is liable to occur between valve plate and valve body of the electronic throttle body,
which may obstruct air from entering the engine and result in extinguish of engine.

12.18 A/C System Failure
1 Check if there is enough coolant, if the A/C belt, Yes Next step
the A/C clutch and the pressure switch are in No Troubleshooting
good condition.
2 Let engine run at idle speed and turn on A/C Yes Remove the failure
switch. Enter A/C self diagnosis mode to check displayed
the A/C system for failure. No Next step
3 Turn on the A/C switch and connect an adaptor Yes Next step
between ECU and harness. Measure 75# pin No Check the harness
(A/C switch) of ECU and see if there are input
signals on it.
4 If this vehicle adopts low level control, check if Yes Replace or repair the
the air condition is working still even though it harness
is turned off. No Next step
5 Check if there is low level output at ECU pin Yes Repair the A/C
No.69 (connect to the ground of pull in winding replay and harness
of A/C relay). No Replace ECU
Note: Different from the controlling means of other models, the A/C control system of A21 adopts the
automatic A/C and uses double-pressure switch to control incorporation of the A/C system and the fan
after A/C starts up.

13. Safety Precautions for System Maintenance
13.1 Safety Precautions for Diagnosis and Maintenance of Gasoline
Injection Electronic Control System
(1) Disassembly and assembly requirements for electronic control unit (ECU):
Controllers shall be removed before welding or paint-baking;

When disassembling and installing the controller, be sure to set ignition switch to
CLOSE position and disconnect the battery with the system for fear to damage the
engine control unit during disassembly and installation.
Power supply wires shall not be removed from battery when engine is in operation or
electric system is in use;
Do not use such heavy current equipment as charger etc. to start the engine by direct
bridging;
Note that the ambient temperature for the controller should not exceed 80℃.
(2) Requirements for cleanness: the following rules should be observed for any
operation on oil-supply system and oil-injection system:
The parts removed should be place at a clean site and covered properly; do not use the
cloth (cotton cloth and gauze) with falling off fibre;
(3) Connect and disconnect the connectors of all sorts of harnesses and the connectors
of failure diagnosis testers only after the ignition switch is turned off.
When measuring mains voltage or ground wire grounding of the electronic control
system, be sure to check if the connection order and mode are correct;
Disconnect power cord or ground wire of battery from the system and disconnect
harness connector of ECU; both operation modes above may cause loss of information
about diagnosis and self-study stored in ECU (the retention time of information after the
ECU installed is power off depends on the model).
(4) Attentions during maintenance of fuel feed system (fuel feed line, fuel pump
and fuel injection system):
Disassembly or installation of oil pump on the tank full of oil or partly full of oil,
please note:
Before operation, get material ready near the fuel tank opening for absorption of heavy
discharging fuel, so that, the fuel discharged can be duly absorbed;
Avoid skin from direct contact with gasoline as best as you can;
Before loosening a connection part, thoroughly clean this part and the area around the
connecting pieces;
Dishcloth shall be placed around the connecting part for avoide oil-spraying;

If disassembled parts can not be repaired or for other processing immediately, store
them properly.
The spare parts can be taken out of their package only when they are to be installed; do
not use the spare parts without package or with package heavily damaged;
When installing an injector, be careful not to damage the O-gaskets at both ends of the
injector; for installation convenience, apply a little lubricant on the O-gaskets.
After fuel and fuel feed systems are disassembled, avoid use of compressed air and
move of the vehicle as best as you can.
(5) Safety precaution

In order to avoid maintenance technical personnel from being injured and fuel injection
and ignition devices from being damaged, please note:
In case the engine is running or under starting speed, disconnection of ignition
harness is forbidden. Checking the engine for poor working of single cylinder by means
of spark test with ignition cable disconnected is not allowed;
if it is required to drag the engine by the starter without starting the engine itself,
for example, in the case of inspection of cylinder pressure of engine etc., disconnect the
harness connectors on engine revolution sensor and camshaft (phase) sensor and
connect each sensor properly after the corresponding job has finished, and then use a
special diagnostic tester for Chery to clear the failure codes in the system;
When the engine is running at high speed, touching wheel train of engine and
revolving parts are forbidden;
When the engine reaches normal operating temperature, both water temperature
and pressure of cooling system are very high; therefore, in case maintenance for the
cooling system of engine is required, perform corresponding operations only after the
engine has stopped and the cooling system has been fully cooled.
When maintaining fuel system of engine, if maintenance for engine compartment
is involved, perform the operations only after temperature inside engine compartment of
the vehicle has adequately fell;
Under a state that power on of the system is normal, do not touch cooling fan of
the engine by hand at any time, because the cooling fan may start up abruptly.

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Service Manual for Chery

(QR513 Transmission Case)

After Sales Service Department of Chery

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1. This service manual applies to use and maintenance of QR513 transmission

manufactured by Chery Automobile Co., Ltd.

2. Service Manual for QR513 Transmission describes relations among various

parts and assemblies of this transmission, which provide the maintenance

personnel with a reference when maintaining and repairing QR513 transmission.

please inform us of any problem in and improvement idea on QR513

service manual, for which we express our thanks herein.

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I. Assembly Drawing of QR513 Transmission

1. Input shaft 2. Clutch 3. Output shaft 4. Differential

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III. SN of QR513 Transmission

1. Print position of SN of QR513 transmission

The print position of SN of QR513 series transmission is as shown in the figure:

2. Composition and connotation of SN of QR513 transmission

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Character code of the year

Table 1 Character Codes Indicating the Years

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IV. Specification of QR513 Transmission

QR513 Series Transmission

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I. Decomposition Process for QR513 Transmission

1. Bleeding lubricant in transmission

2. Disassembly of external parts of transmission

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Bolts-for gearshift housing and Backup lamp switch assembly

3. Separation of gear shift mechanism and transmission

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4. Disassembly of the connecting bolts for clutch and transmission housings

Connecting bolts for transmission and clutch housings

5. Separation of transmission and clutch housings

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Bolts for reverse gear rocker arm bracket (2 in total)

Reverse gear idler assembly

Reverse gear rocker arm

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8. Disassembly of gearshift fork mechanism

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9. Disassembly of gearshift mechanism

Gearshift arm bracket bolts (2 in total)

Reverse gear lockup mechanism bolts (2 in total)

10. Disassembly of input shaft

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12. Disassembly of differential

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13. Disassembly of release mechanism of clutch

Bush Release return spring

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Outer ring of bearing Oil duct Figure 16

14. Disassembly of transmission housing

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