Engine—Electric Injection—System Components

Engine Control System (1.3L Delphi MT20U2)

System Components
Engine management system hardware works under the control of engine control module(ECM) and
consists of such subsystems as the control & signal acquisition, fuel supply, ignition, air intake control,
exhaust control, trouble diagnosis and communication.

Engine Management
发动机管理系统
System

(EMS)

Fuel Supply Ignition Air Intake Control Exhaust Control Fault Diagnosis and
控制信号采集系统
Control
System
Signal Acquisition 供油系统
System 点火系统
System
进气控制系统
System
排放控制系统
System
故障诊断及通讯系统
Communication System

Control & Signal Acquisition

控制及信号采集系统
System

Engine Control Unit

发动机控制单元(ECM)
（ECM）

EMS Control Harness

发动机管理系统
控制线束

Crankshaft
曲轴转速及位置 Speed & Air Intake Manifold
进气歧管压力 冷却液温度
Coolant 排气氧含量
Exhaust Oxygen Throttle
节气门位置 Position Air
进气温度 Intake Vehicle
Position Sensor Pressure Sensor Temperature sensor Sensor Temperature
车速
Speed
传感器 传感器 传感器
Sensor 传感器 传感器 传感器
Sensor 传感器
Sensor

Fuel Supply System

供油系统

油泵总成
Fuel Pump 管路
Pipeline 油轨总成
Fuel Rail
Assy Assy

Fuel
油泵 Oil inlet Filter Oil rail
Pump
油位传感器
Oil level Sensor 进油管
Pipe
滤清器 Oil进油管
Pipe
inlet 油轨 Oil
油压调节器 进油管
pressure Inlet
Regulator
Pipe

进气控制系统
Air Intake Control System
(Throttle Valve Body)
点火系统
Ignition System
（节流阀体）

Valve Throttle Sensor

Ignition Coil
点火线圈 Spark Plug Lead
火花塞引线 Spark Plug
火花塞 阀体
Body 节气门传感器 怠速控制阀
Idle Control Valve

排放控制系统
Exhaust Control System
故障诊断/通讯及防盗系统
Fault Diagnosis/Communication and
Anti-theft System

尾气排放控制
Exhaust Gas Control Evaporative
蒸发排放控制 exhaust
Control 故障诊断及通讯
Fault 防盗器控制
Anti-theft Alarm
Diagnosis/Communicatio Control

Oxygen sensor 3-way Catalyst Canister Solenoid

氧传感器 三元催化器
Convertor
碳罐电磁阀 System Communication
系统通讯接口
Interface 发动机故障指示灯
Engine Fault Indicator 防盗控制器
Anti-theft 密码发射器
Password Emitter
Controller
 Engine—Electric Injection—System Components
List of Basic Function Parts and Components of Delphi MT20U2 EMS

No. Part name Qty. No. Part name Qty.

Engine control
1 1 Fuel rail assy 1
module(ECM)
12
2 Crankshaft position sensor 1 Fuel injector 4

3 Air intake manifold pressure 1 Fuel pressure regulator 1

Air intake manifold

4 1 13 Gasoline pump assy 1
temperature

Air intake manifold

5 1 14 Ignition coil assy. 1
pressure/temperature

Throttle valve body

6 Coolant temperature sensor 1 1
assembly
15
7 Oxygen sensor 2 Idle speed control valve 1

8 Camshaft position sensor 1 Throttle position sensor 1

Canister control solenoid

9 Knock sensor 1 16 1
valve

Vehicle speed
10 sensor(provided by vehicle 1 17 3-way catalyst convertor 1
manufacturer)

A/C evaporator temperature G sensor or ABS wheel

11 1 18 1
sensor speed sensor(option)

1. Engine control module(ECM)

(1) CPU parameters: 16-bit core chip

32M clock frequency

256K FLASH memory

12K RAM memory

4K EEPROM memory

(2) Working parameters

(a) Range of working voltage

Range of normal working voltage: 9.0V～16V

Overvoltage and reverse polarity protection: +24V/-12V＜60 sec.

(b) Installation

MT20U2 ECM is designed to be installed within the engine compartment (but not on the engine body),
however should be placed for easy service.
 Engine—Electric Injection—System Components
ECM housing and fixing bolts must be electrically insulated from the chassis.

(C) Temperature

Storage temperature: -40～125℃

Working temperature: -40～105℃

Function MT20U2发动机控制模块功能图
chart of MT20U2 Engine Control Module
12V battery power 12V电瓶电源
supply Ignition coil A/B(Cylinder 1/4)
点火线圈A/B(1/4缸)

supply

点火系统
12V ignition power 12V点火电源
supply Ignition coil A/B(Cylinder 2/3)
点火线圈C/D(2/3缸)

控制
系统电源控制

Ignition
system
control
12V power supply earth wire
12V电源地线 Ignition coil点火线圈
power
5V sensor reference supply
5V传感器参考电源 Ignition coil点火线圈
5V sensor reference supply earth
5V传感器参考电源接地
Injector A (Cylinder 1)
System
control

Ignition module点火模块驱动器接地
driver earth 喷油器A(1缸)

Fuel injection
喷油嘴控制 control
主电源继电器控制
Main power supply relay control Injector B (Cylinder 3)
喷油器B(3缸)
Injector (Cylinder
喷油器(4缸) 4)

nozzle
进气歧管压力传感器（MAP）
Intake manifold pressure (MAP) sensor Injector (Cylinder
喷油器(2缸) 2)
Throttle position sensor (TPS)
节气门位置传感器（TPS）
Idle speed valve control coil A(HI)
进气温度传感器（IAT）
Air intake temperature (IAT) sensor 怠速阀控制线圈A(HI)
valve
怠速阀控制
MT20U2
模拟信号输入

Idle speed valve control coil A(LO)

Coolant temperature sensor (CTS)
冷却液温度传感器（CTS） 怠速阀控制线圈A(LO)
Analog signal input

Engine Idle speed valve control coil B(HI)

前氧传感器（F-02） 怠速阀控制线圈B(HI)
发
control

Front oxygen sensor (F-02) Control

Idle

后氧传感器（R-02）
Rear oxygen sensor(R-02) Module 怠速阀控制线圈B(LO)
Idle speed valve control coil B(LO)
(ECM)
油箱油位传感器
Tank fuel level sensor 动
加速度传感器（G）
Acceleration sensor (G) Fuel pump relay
燃油泵继电器
机
System components
supply control

废气再循环反馈信号（LEGR）
Linear exhaust gas recirculation (LEGR) signal Front oxygen sensor heating
前氧传感器加热
系统部件
电源控制

控 Rear oxygen sensor heating

后氧传感器加热
58X engine58X发动机转速及曲轴位置传感器
revolution speed and crankshaft Canister solenoid valve
碳罐电磁阀
频率信号输入

制
power

position sensor
signal input

凸轮轴位置传感器 LEGR废气再循环阀(LEGR)
Frequency

valve
Camshaft position sensor
Knock sensor
爆震传感器 模
车速传感器 A/C clutch relay
空调离合器继电器
supply

Vehicle speed sensor

块
附件电源控制

A/C rear evaporator shutoff valve

空调后蒸发器切断阀
Front-mounted A/C evaporator temperature
Accessories

sensor 前置空调蒸发器温度传感器
(ECM) A/C 空调冷凝器风扇继电器
condenser fan relay
Accessories control signal

control

Rear-mounted A/C evaporator temperature

附件控制信号输入

后置空调蒸发器温度传感器 散热器低速风扇继电器
power

Radiator low-speed fan relay

sensor 空调请求开关 散热器高速风扇继电器
Radiator high-speed fan relay
A/C request switch
鼓风机开关
Blower switch
大灯开关 Engine revolution
发动机转速 speed
Headlight switch
Coolant temperature
仪表信号

P/N position switch P/N档位开关 冷却液温度

input

Instrument

助力转向开关
Power-assisted steering switch 油量信号
Oil level signal
signal

System系统故障指示灯
fault indicator lamp
Other其他系统故障指示灯
system fault indicator lamp
Electronic电子防盗器
anti-theft alarm
Anti-theft

commun
通讯

Electronic anti-theft signal

防盗

ication

KW2000通讯
and及

KW2000 communication 电子防盗器信号

Anti-theft

diagnosi

信号
诊断
, 防盗

s signal

Fault diagnosis request signal

CAN bus CAN总线通讯
communication 故障诊断请求信号

基本功能
Basic function Optional选装功能
function

2. Crankshaft position sensor

(1) Performance
 Engine—Electric Injection—System Components

No need of power supply;

Temperature range: -40～150℃

Output voltage: increasing with revolution speed

(400mV@60RPM)

Clearance with 58×ring gear: 0.3～1.5mm;

Coil resistance: 560Ω±10%@25±5℃;

Coil inductance: 240mH±15%@1KHz

(2) Mounting position

The sensor is mounted in a place vertical to the crankshaft and

works with 58× ring gear installed on the crankshaft.

(3) Connectors

Terminals:

Tailed terminals: A - signal +, B - signal -, C- shielded layer;

Tailless terminals: A – signal +, B – signal -.

3. Air intake temperature sensor

(1) Performance

Working voltage: 5V DC

Working temperature: -40～135℃

Dissipation constant: 9Mw/℃

Thermal response time: ＜15sec.;

Air Intake Temperature Sensor Unloaded Resistance -

Temperature Characteristic Table:

Temp. Resistance Reference Temp. Resistance Reference Temp. Resistance Reference Temp. Resistance Reference
Accuracy Accuracy Accuracy Accuracy

(2)Mechanical properties

Hexagon nut: 18.90mm

Thread size: M12×1.5

Effective seal pressure: 145KPa

 Engine—Electric Injection—System Components
Mounting torque: 60Nm

(3) Mounting position:

Generally, the air intake temperature sensor is mounted on the intake pipe before throttle body or the
engine air cleaner.

(4) Connectors:

Terminals: A – signal ground, B – temperature signal.

4. Air intake manifold absolute pressure sensor

(1) Performance

Pressure range: 15～102kpa

Working temperature: -40～105℃

Working voltage: 5.0±0.1V

Working current: 12mA(max.)

Output impedance: ＜10Ω

DC load: 30kΩ(min.)

51kΩ(recommendation)

Output function: Eo=Er(0.01059P-0.10941)(P unit is kpa).

(2) Mounting position:

Generally, it is mounted on the stabilized pressure chamber of intake manifold;

While the use of manifold pressure for cylinder detection requires it be mounted on Cylinder 1 or 4 air
passage of intake manifold

(3) Connectors: Terminals: A – signal ground, B – pressure signal, C - +5V.

5. Air intake manifold pressure/temperature sensor

(1) Working parameters

(a) Manifold pressure sensor:

Pressure range: 10～110kpa

Working temperature: -40～125℃

Working voltage: 5.0±0.1V

Working current: 12mA(max.)

Output voltage: -100～100mV

Output impedance: ＜10Ω;

DC load: 30kΩ(min.), 51kΩ(recommended);

Pressure sensor output function: Eo=Er(0.01059P-0.10941)

P unit is kpa; the reference values are listed below(only for reference):
 Engine—Electric Injection—System Components
Pressure(kpa) 15 40 94 102

Output voltage(V) 0.12～0.38 1.52～1.68 4.44～4.60 4.86～5.04

(b) Air intake temperature sensor:

Air Intake Temperature Sensor Unloaded Resistance - Temperature Characteristic Table:

Temp. Resistance Reference Temp. Resistance Reference Temp. Resistance Reference Temp. Resistance Reference
Accuracy Accuracy Accuracy Accuracy

Typical working voltage: 5V DC;

Working temperature: -40～135℃;

Dissipation constant: 9mW/℃;

Thermal response time: ＜15 sec.;

(2) Mounting position:

For the model using the manifold pressure for cylinder identification,
this sensor is mounted on the pipe of engine’s cylinder 4 intake
manifold.

For the model using the camshaft position sensor for cylinder
identification, this sensor is mounted on the stabilized pressure
chamber of the engine.

(3) Connector:

Terminals: A- pressure signal, B - +5V, C – temperature signal, D – signal ground.

(4) Instructions for operation and maintenance:

This sensor should be mounted at an angle less than 30°with vertical direction to avoid the condensate
on terminals retaining in the sensor. Any installation against these instructions will directly affect the
sensor reliability and durability.

When necessary, the sensor may be cleaned with isopropyl alcohol and air dried. Immersion time with
isopropyl alcohol shall not be longer than 1min and during the cleaning, prevent the washing solution
from entering the sensor

6. Coolant temperature sensor

(1) Performance

Typical working voltage: 5V DC;

Working temperature: -40～135℃;

Dissipation constant: 25mW/℃;

 Engine—Electric Injection—System Components
Thermal response time: 17～27 sec.

(2)Mechanical properties

Hexagon nut: 18.90mm

Thread size: M12×1.5;

Effective seal pressure: 145KPa;

Mounting torque: 20Nm.

(3) Mounting position:

The coolant temperature sensor is usually mounted on main water passage of the engine.

(4) Connectors: terminals: A – signal ground, B – temperature signal

7. Camshaft position sensor

(1) Performance

Working temperature: -40～150℃

Working voltage: 4.5～13V;

Working clearance:0.3～2mm

(2) Mounting position:

It is mounted near the camshaft.

(3) Connectors: terminals: A – signal, B – signal ground, C - +5V

8. Knock sensor

(1) Performance

Output signal: Frequency Output signal

5kHz 17～37mV/g

8 kHz +15% at 5kHz

13 kHz +30% at 5kHz

18 kHz Double at 13kHz

In any case ＞17 mV/g

Frequency response range: 3～18 kHz

Capacitance:1480～2220pf@25℃@1000Hz

Resistance:＞1M@25℃

Working temperature: -40～150℃

(2) Mounting position:

This sensor is mounted at the location sensitive to engine knock.

Due to relatively weaker sensor signal, the sensor's lead is the shielded wire.
 Engine—Electric Injection—System Components
(3) Connectors: terminals: A – signal, B – earthing through the shield.

9. Oxygen sensor

(1) Features: waterproof;

No need of air penetration and filtration device;

Resistance to high temperature, backpressure and thermal

impact;

Ultra-low temperature property;

Ultra-strong antipoisoning ability;

Low energy consumption heater;

This sensor uses teflon insulated wire and stainless steel elements.

(2) Performance

Performance parameters

Temperature 260℃ 450℃ 595℃

Rich output voltage(mV) ＞800 ＞800 ＞750

Thin output voltage(mV) ＜200 ＜200 ＜150

Thin to rich response time(ms) ＜75 ＜75 ＜50

Rich to thin response time(ms) ＜150 ＜125 ＜90

Internal resistance (Ω) ＜100K

Max. working temperature(continuous): exhaust temperature:＜930℃

Temperature at the mounting support:＜600℃

Temperature at 6 corners of outer housing: ＜500℃

Temperature at wire and sleeve: ＜275℃

Temperature at wire gasket: ＜250℃

Temperature at connector: ＜125℃

Storage temperature: -40～100℃

Recommended working condition: exhaust temperature: 200～850℃

Allowed content of fuel impurities: lead – below 0.005g/L

phosphor – below 0.0002g/L

sulfur – below 0.04%(weight ratio)

silicon – below 4ppm

MMT – below 0.0085g/L

Engine oil consumption is not above 0.02L/hr.

 Engine—Electric Injection—System Components
Mounting position: this sensor is mounted between the exhaust valve and 3-way catalyst.

Connectors: A –low signal, B –high signal; C -heating power -, D – heater power +.

10. Fuel rail

(1) Working parameters

Working temperature: -30～115℃;

It is mounted on the air intake manifold.

11.Fuel injector

(1) Features:

Working temperature: -40～130℃

Min. working voltage: 4.5V

Coil resistance:12±0.4Ω

(2) Mounting position:

It is fixed to the air intake manifold through the fuel rail.

(3) Connectors: A - +12V, B – ECM

12. Fuel pressure regulator

(1) Working parameters

Pressure invariableness: oil return type: 300kpa±2%(static);

Non-fuel-return type: 350kpa±2%

Flow limit of pressure regulation: 3～60g/s

Working temperature: -40～120℃

Min. explosion pressure: 2000MPa.

(2) Mounting position:

For model of fuel-return design, the regulator is mounted at the end of fuel rail.

For model of non-fuel-return design, the regulator is mounted on the fuel pump assy.

13. Fuel pump assembly

(1) Features:

Fuel pump: Output pressure: ＞350kpa;

Output flow: ＞10g/s;

Safety pressure relleased: ＜900kpa;

Pressure holding: 24 kpa;

Working voltage: 8～16V;

Overpressure protection: -13.5～26V(＜60 sec.);

 Engine—Electric Injection—System Components
Operation without fuel: ＜60sec.

Fuel level sensor: resistance ＜130Ω;

Max. working current: ＜150mA.

(2) Mounting position:

The assembly is integrally built in the fuel tank.

(3) Connectors:

1×4 type: A- relay, B – instrument, C- instrument, D – ground;

2×2 type: A- instrument, B – relay, C- ground, D –instrument;

3-wire connector: A – system ground, B – fuel pump +, C –

fuel level sensor +.

14.Ignition coil

(1) Features:

Primary resistance: 0.5±0.05Ω;

Secondary resistance: 9840±980Ω;

Primary inductance: 2.75±0.25mH

Secondary inductance: 17.5±1.2H;

Voltage range：6～16V；

Interruption current peak: 9.5A;

Secondary output voltage: 34KV;

Shortest duration of ignition: 0.8ms.

(2) Mounting position:

Ignition coil may be in the engine compartment or on the engine

(3) Connectors: terminals: A – Cylinder1-4 drive, B - +12V, C – Cylinder 2-3 drive.

15. Throttle body

(1) Features:

Diameter of valve hole: depending on the engine displacement;

(2) Mounting position:

It is mounted before the air intake manifold.

16. Throttle position sensor

(1) Features:

Range: 7%～93% opening;

Working voltage: 5.0±0.1V;

 Engine—Electric Injection—System Components
Close throttle: 12% of reference voltage;

Fully opened throttle: 83%～93% of reference voltage;

AB impedance: 3k～12kΩ;

Working temperature: -40～150℃

(2) Mounting position:

This throttle position sensor is mounted on the throttle body

assembly and shares the shaft with accelerator rod and throttle
valve plate.

(3) Connectors:

Terminals: A - +5V, B – signal ground, C – throttle position signal.

17. Idle speed control valve

(1) Features:

Coil resistance: 53Ω±10%;

Coil inductance:33mH±20%;

Working voltage: 7.5～12V;

Air
Limiting voltage: 3.5～14V.
ISC valve
(2) Mounting position:

In this model, this valve is mounted on the throttle body

(3) Connectors:
Throttle valve
Terminals: A – coil B-, B – coil B+, C – coil A-, D – coil A+. body

18. Canister control solenoid valve

(1) Features:

Rated overvoltage: +12V

Range of working voltage: 8～16V;

Limiting voltage: 25V(＜60s)

Working temperature: -40～120℃;

Coil resistance:19~20Ω

Coil inductance: 12～15mH.

(2) Mounting position:

This valve is mounted between fuel vapor canister and air intake
manifold and the engine compartment

(3) Connectors:

Terminals: A – ECM, B - +12V.

Engine—Electric Injection—System Components
 Engine—Electric Injection—On-Board Diagnostic (EOBD)
On-Board Diagnostic (EOBD)
1. Description of EOBD

After the system begains to work and the engine runs, ECM controls the operation of all system
components and detects those connected with it. When one or several components work abnormally, the
system will automatically alarm, every malfunction state is assigned with an exclusive code, and so long
as malfunction occurs, the system will send this code (i.e. trouble code) via the diagnostic interface and
simultaneously activate the "engine malfunction indicator” to inform the driver for timely service. A trouble
code indicates the possible location of malfunction

In the event of malfunction, the system may also use the temporary emergency plan to control the
engine operation to ensure that the user may drive to the service station instead of breaking down on the
way.

2. Description of malfunction indicator (MI)

MI is an indicator connected with on-board diagnostic (OBD) system to inform the driver
when any emission related component or OBD system develops a trouble, as shown by
the right schematic

3. Criteria of MI action

MI must be activated at the required moment when the malfunction of a component or system causes
the vehicle emission to exceed regulatory requirements. Based on the effects of trouble affecting the
emission, MI is activated as per the followings:

Code of trouble affecting emission:

Class A: MI lights up and trouble code is recorded for a single occurrence;

Class B: MI lights up and trouble code is recorded for occurrence once in two continuous strokes

Class E: MI lights up and trouble code is recorded for an occurrence in three continuous strokes each;

Code of trouble not affecting emission:

Class C: trouble code is recorded with MI off, the manufacturer may turn on SVS lamp based on needs.

Class D: trouble code is recorded with no MI on.

Turnoff of MI: In three continuous strokes, if detection system for MI activation fails to detect a trouble or
does not detect other malfunction which may separately activate MI, then MI turns off.

Elimination of trouble code: if one malfunction does not occur in over 40 engine warm-up cycles again,
OBD system will clear this trouble code and the mileage at the time of its occurrence and freeze the data
information.

Note: A stroke refers to a drive cycle where all OBD tests could be completed and it may take the testing
procedure (Part I and Part II) of National III Emission Standard as standard.
 Engine—Electric Injection—On-Board Diagnostic (EOBD)
4. Detailed explanation of diagnostic trouble code (DTC)

DTC List of DELPHI MT20U2 Engine Management System

Trouble Trouble
Description Class Description Class
code code

P0106 MAP/TPS signal rationality E P1392 Sensor G voltage too low C

P0107 Manifold pressure sensor circuit voltage too low A P1393 Sensor G voltage too high C

P0108 Manifold pressure sensor circuit voltage too high A P0325 Knock control system fault C

P0112 Intake air temperature sensor circuit voltage too low E P0327 Knock sensor circuit fault C

P0113 Air intake temperature sensor circuit voltage too high E P0336 Crankshaft position sensor circuit performance problem E

P0117 Coolant temperature sensor circuit voltage too low A P0337 Crankshaft position sensor circuit fault A

P0118 Coolant temperature sensor circuit voltage too high A P1336 Crankshaft position gear information unlearned A

P0122 Throttle position sensor circuit voltage too low A P0342 Camshaft position sensor circuit no signal A

P0123 Throttle position sensor circuit voltage too high A P0351 Ignition circuit 1 fault A

P0131 Front oxygen sensor circuit voltage too low E P0352 Ignition circuit 2 fault A

P0132 Front oxygen sensor circuit voltage too high E P0420 Catalyst efficiency below threshold A

P0133 Front oxygen sensor response slow E P0443 Canister purge circuit failure E

Front oxygen sensor activity inadequate or open

P0134 A P0462 Fuel level sensor circuit input too low C
circuit

P0135 Front oxygen sensor heater circuit can’t work A P0463 Fuel level sensor circuit input too high C

P1167 Front oxygen sensor AFR high in DFCO mode E P0480 Fan 1 fault C

P1171 Front oxygen sensor AFR low in PE mode E P0481 Fan 2 fault C

P0137 Rear oxygen sensor circuit voltage too low E P0482 Fan 3 fault C

P0138 Rear oxygen sensor circuit voltage too high E P0483 PWM fan fault C

P0140 Rear oxygen sensor activity inadequate or open circuit E P0502 No vehicle speed signal E

P0141 Rear oxygen sensor heater circuit can’t work A P0506 Idle speed control system fault – revolution speed too low E

Idle speed control system fault – revolution speed too

P0171 Fuel correction too thin E P0507 E
high

P0172 Fuel correction too rich E P0562 System voltage high C

P0201 Cylinder 1 injector circuit failure A P0563 System voltage low C

P0202 Cylinder 3 injector circuit fault A P0532 A/C pressure circuit voltage too high C

P0203 Cylinder 4 injector circuit fault A P0533 A/C pressure circuit voltage too low or open C

P0204 Cylinder 2 injector circuit fault A P1545 A/C clutch output circuit fault C

P0230 Fuel pump relay fault C P2001 Rear A/C evaporator sensor fault C

P0300 Misfire B/A P0615 TCM fault A

 Engine—Electric Injection—On-Board Diagnostic (EOBD)

DTC P0106: unreasonable correspondence between manifold absolytely pressure sensor signal and
throttle position sensor signal.

Test condition: no DTC relevant to manifold absolute pressure sensor, throttle position sensor and
coolant temperature sensor.

Malfunction judgement: altitude compensating intake pressure value exceeds the limits set by the control
system based on the engine RPM and throttle opening

Emergency control plan: disable the fuel correction pulse width

Do not update self-learning value anymore

Prohibit adjusting the target idle speed

Do not update atmospheric pressure anymore

Possible causes: MAP sensor trouble

Sensor pick-up hole blocked

The circuit between MAP sensor and ECM damaged

Poor connection

DTC P0107: MAP sensor circuit voltage too low

Test condition: no malfunction of throttle position sensor

Battery voltage higher than 11.45V

Engine speed lower than/equal to 1000RPM and throttle opening above 0%, or the engine speed higher
than 1000RPM and throttle opening above 5%.

Malfunction judgement: ECM detects that manifold pressure is 12kpa

Emergency control plan: disable the fuel trim pulse width

Do not update self-learning value anymore

Prohibit adjusting the target idle speed

Do not update atmospheric pressure anymore

Take MAP value as the default

Possible causes: between MAP sensor and ECM develops a short circuit to ground or open circuit

MAP sensor trouble

Poor connection

Engine air intake system abnormal

DTC P0108: MAP sensor circuit voltage too high

Test condition: no malfunction of the throttle position sensor

Engine running time longer than 2 sec

The engine speed lower than/equal to 2400RPM and throttle opening below 2.7%, or the engine speed
 Engine—Electric Injection—On-Board Diagnostic (EOBD)
higher than 2400RPM and throttle opening above 10%

Malfunction judgement: ECM detects that manifold pressure value is greater than 103kpa

Emergency control plan: disable the fuel trim pulse width

Do not update self-learning value anymore

Prohibit adjusting the target idle speed

Do not update atmospheric pressure anymore

Take MAP value as the default

Possible causes: between MAP sensor and ECM develops a short circuit to ground or open circuit

MAP sensor trouble

Poor connection

Engine air intake system abnormal

DTC P0112: IAT sensor circuit voltage too low

Test condition: no malfunction of the vehicle speed sensor

Vehicle speed greater than 50km/h

Engine running time longer than 60 sec.

Malfunction judgement: ECM detects that IAT sensor signal voltage is less than 0.1V

Emergency control plan: use the system default air intake temperature value.

Possible causes: between IAT sensor and ECM develops a short circuit to ground.

Sensor trouble

Poor connection

DTC P0113: IAT sensor circuit voltage too high

Test condition: no malfunction of vehicle speed sensor and coolant temperature sensor

Vehicle speed lower than 25km/h

Coolant temperature greater than 70℃

Engine running time longer than 60 sec

Malfunction judgement: ECM detects that IAT sensor signal voltage is higher than 4.9V

Emergency control plan: use the system default air intake temperature value

Possible causes: between IAT sensor and ECM develops a short circuit to power supply or open circuit

Poor connection

Ground wire open circuit

DTC P0117: coolant temperature sensor (CTS) circuit voltage too low

Test condition: the engine running time longer than 60 sec

Malfunction judgement: ECM detects that CTS signal voltage is too low and indicated temperature is
 Engine—Electric Injection—On-Board Diagnostic (EOBD)
higher than 149℃

Emergency control plan: Control system estimates the maximum temperature not exceeding 90.75℃ as
per the default formula based on the engine running time and air intake temperature

After trouble code setup, high-speed fan starts working after 0.5sec.

Possible causes: between CTS and ECM develops a short circuit to ground.

Poor connection

CTS trouble

DTC P0118: coolant temperature sensor (CTS) circuit voltage too high

Test condition: the engine running time longer than 60 sec.

Malfunction judgement: ECM detects that CTS signal voltage is too high and indicated temperature is
below -38℃.

Emergency control plan: Control system estimates the maximum temperature not exceeding 90.75℃ as
per the default formula based on the engine running time and air intake temperature.

After trouble code setup, high-speed fan starts working after 0.5sec.

Possible causes: between CTS and ECM develops a short circuit to power supply or open circuit

Ground wire open circuit

Poor connection

CTS sensor trouble

DTC P0122: throttle position sensor (TPS) circuit voltage too low

Test condition: the engine in operation

Malfunction judgement: ECM detects that TPS signal value is less than 2.8%

Emergency control plan: estimate the throttle opening based on engine RPM

Possible causes: between TPS and ECM develops a short circuit to power supply or open circuit

Poor connection

TPS trouble

DTC P0123: throttle position sensor (TPS) circuit voltage too high

Test condition: the engine in operation

Malfunction judgement: ECM detects that TPS signal value is greater than 98%

Emergency control plan: estimate the throttle opening based on engine RPM

Possible causes: between TPS and ECM develops a short circuit to power supply or open circuit

Poor connection

TPS trouble

DTC P0131: front oxygen sensor (O2A) circuit voltage too low

Test condition: no trouble code like P0106, P0171 and P0172, no trouble code relating to MAP sensor,
 Engine—Electric Injection—On-Board Diagnostic (EOBD)
CTS, TPS, fuel injector, misfire, crankshaft position sensor, ignition system, idle speed control system
and canister cleaning circuit.

Coolant temperature higher than 70℃

System voltage higher than 10V

Malfunction judgement: ECM detects that oxygen sensor signal value is less than 0.03 V

Emergency control plan: stop the closed loop fuel control

Possible causes: between oxygen sensor and ECM develops a short circuit to ground

Insufficient fuel injection due to blockage of fuel pump, fuel supply pipeline or fuel injector

Fuel pressure regulator damaged

Poor grounding from ECM to the engine block

Air intake vacuum leak

Exhaust pipeline leaking

Fuel contamination

DTC P0132: front oxygen sensor (O2A) circuit voltage too high

Test condition: no trouble code like P0106, P0171 and P0172, no trouble code relating to MAP sensor,
CTS, TPS, fuel injector, misfire, crankshaft position sensor, ignition system, idle speed control system
and canister cleaning circuit.

Coolant temperature higher than 70℃

System voltage higher than 10V

Malfunction judgement: ECM detects that oxygen sensor signal voltage is higher than 3.8V

Emergency control plan: stop the closed loop fuel control

Possible causes: between oxygen sensor and ECM develops a short circuit to ground.

Fuel pressure too high

Fuel injection leaking

Fuel pressure regulator damaged

DTC P0133: front oxygen sensor (O2A) response slowly

Test condition: no trouble code like P0106, P0171 and P0172, no trouble code relating to MAP sensor,
CTS, TPS, fuel injector, misfire, crankshaft position sensor, ignition system, idle speed control system
and canister cleaning circuit.

Coolant temperature higher than 70℃

System voltage higher than 10V

1600RPM＜engine revolution speed＜3000RPM

Malfunction judgement: the time of oxygen sensor response to the change of oxygen concentration in
exhaust gas exceeds the limit set by the system

Emergency control plan: stop the closed loop fuel control

 Engine—Electric Injection—On-Board Diagnostic (EOBD)
Possible causes: heavy metal poisoning or phosphorus/sulfur poisoning of oxygen sensor due to fuel
contamination

Carbon poisoning of oxygen sensor due to large engine oil consumption

DTC P0134: insufficient activity or open circuit of front oxygen sensor

Test condition: no trouble code like P0106, P0171 and P0172, no trouble code relating to MAP sensor,
CTS, TPS, fuel injector, misfire, crankshaft position sensor, ignition system, idle speed control system
and canister cleaning circuit.

Coolant temperature higher than 70℃

System voltage higher than 10V

Malfunction judgement: ECM detects that oxygen sensor signal voltage is higher than 1.3V but lower
than 3.8V

Emergency control plan: stop the closed loop fuel control

Possible causes: poor circuit contact or damaged circuit between oxygen sensor and ECM

Trouble of oxygen sensor heater circuit or the heater

Exhaust gas leaking

Fuel contamination

Excessive engine oil consumption

DTC P0135: front oxygen sensor (O2A) heater does not work

Test condition: the engine running time longer than the setting

Malfunction judgement: ECM detects that voltage of heater circuit is continuously too high or low

Emergency control plan: stop the closed loop fuel control

Possible causes: between the heater and ECM develops a short circuit to power supply, a short circuit to
ground or open circuit

Poor connection

Heater damaged

DTC P1167: In DFCO mode, front oxygen sensor (O2A) indicates a rich air fuel ratio.

Test condition: no trouble code like P0106, P0171 and P0172, no trouble code relating to MAP sensor,
CTS, TPS, fuel injector, misfire, crankshaft position sensor, ignition system, idle speed control system
and canister cleaning circuit.

Engine gets into the deceleration fuel cutoff (DFCO) mode

Malfunction judgement: ECM detects that oxygen sensor signal voltage is higher than 0.55V

Emergency control plan: stop the closed loop fuel control

Possible causes: between oxygen sensor and ECM develops a short circuit to power supply

Fuel pressure too high

Fuel injector leaking

 Engine—Electric Injection—On-Board Diagnostic (EOBD)
Fuel pressure regulator damaged

DTC P1171: In PE mode, front oxygen sensor (O2A) indicates a lean air fuel ratio.

Test condition: no trouble code like P0106, P0171 and P0172, no trouble code relating to MAP sensor,
CTS, TPS, fuel injector, misfire, crankshaft position sensor, ignition system, idle speed control system
and canister cleaning circuit.

Engine gets into the power enrichment (PE) mode

Malfunction judgement: oxygen sensor signal voltage is lower than 0.35V

Emergency control plan: stop the closed loop fuel control

Possible cause: between oxygen sensor and ECM develops a short circuit to ground

Insufficient fuel injection due to blockage of fuel pump, fuel supply pipeline or fuel injector

Fuel pressure regulator damaged

Poor grounding from ECM to the engine block

Intake vacuum leaking

Exhaust pipeline leaking

Fuel contamination

DTC P0137: rear oxygen sensor (O2B) circuit voltage too low

Test condition: no trouble code like P0106, P0171 and P0172, no trouble code relating to MAP sensor,
CTS, TPS, fuel injector, misfire, crankshaft position sensor, ignition system, idle speed control system
and canister cleaning circuit.

Coolant temperature higher than 70℃

Malfunction judgement: ECM detects that rear oxygen sensor signal voltage is lower than 0.03V

Emergency control plan: disable the rear oxygen sensor signal

Possible causes: between oxygen sensor and ECM develops a short circuit to ground.

Poor connection

DTC P0138: rear oxygen sensor (O2B) circuit voltage too high

Test condition: no trouble code like P0106, P0171 and P0172, no trouble code relating to MAP sensor,
CTS, TPS, fuel injector, misfire, crankshaft position sensor, ignition system, idle speed control system
and canister cleaning circuit.

Coolant temperature higher than 70℃

Malfunction judgement: ECM detects that rear oxygen sensor signal voltage is higher than 3.8V

Emergency control plan: disable the rear oxygen sensor signal

Possible causes: between oxygen sensor and ECM develops a short circuit to ground.

Poor connection

Sensor trouble

DTC P0140: rear oxygen sensor activity inadequate or open circuit

 Engine—Electric Injection—On-Board Diagnostic (EOBD)
Test condition: no trouble code like P0106, P0171 and P0172, no trouble code relating to MAP sensor,
CTS, TPS, fuel injector, misfire, crankshaft position sensor, ignition system, idle speed control system
and canister cleaning circuit.

Coolant temperature higher than 70℃

System voltage higher than 10V

Malfunction judgement: ECM detects that oxygen sensor signal voltage is higher than 1.3V but lower
than 3.8V

Emergency control plan: disable the rear oxygen sensor signal

Possible causes: poor connection

Short circuit to ground between oxygen sensor and ECM

Oxygen sensor trouble

DTC P0141: the circuit of rear oxygen sensor heater does not work

Test condition: the engine in operation

System voltage higher than 10V

Malfunction judgement: the voltage of rear oxygen sensor heater is too high or low

Emergency control plan: disable the rear oxygen sensor signal

Possible causes: between the heater of rear oxygen sensor and ECM develops a short circuit to power
supply, a short circuit to ground or open circuit.

DTC P0171: fuel correction system too lean

Test condition: no trouble code like P0106, no trouble code relating to MAP sensor, ITA sensor, CTS,
TPS, oxygen sensor, fuel injector, crankshaft position sensor, camshaft position sensor, idle speed
control system, misfire and canister cleaning circuit.

Enter the closed loop fuel control mode

Engine RPM, coolant temperature, throttle opening and air intake pressure meeting the system default
requirements.

Malfunction judgement: the fuel self-learning value bigger than the limit set by the system

Emergency control plan: None

Possible causes: air leaking

Fuel pressure inadequate

Positive crankcase ventilation valve jammed

Fuel injector blocked

DTC P0172: fuel correction system too rich

Test condition: no trouble code like P0106, no trouble code relating to MAP sensor, ITA sensor, CTS,
TPS, oxygen sensor, fuel injector, crankshaft position sensor, camshaft position sensor, idle speed
control system, misfire and canister cleaning circuit.

Enter the closed loop fuel control mode

 Engine—Electric Injection—On-Board Diagnostic (EOBD)
Engine RPM, coolant temperature, throttle opening and air intake pressure meeting the system default
requirements.

Malfunction judgement: the fuel self-learning value bigger than the limit set by the system

Emergency control plan: None

Possible causes: air intake system blocked

Fuel injection leaking

Fuel pressure too high

DTC P0201: Cylinder 1 electric circuit trouble

Test condition: system voltage higher than 9.0V

Engine speed greater than 700RPM

Malfunction judgement: the voltage of fuel injector control circuit too high or too low

Emergency control plan: get the fuel into the open-loop control

Possible causes: between fuel injector and ECM develops a short circuit to power supply, a short circuit
to ground or open circuit

DTC P0202: Cylinder 3 injector electric circuit trouble

Test condition: system voltage higher than 9.0V

Engine speed greater than 700RPM

Malfunction judgement: the voltage of fuel injector control circuit too high or too low

Emergency control plan: get the fuel into the open-loop control

Possible causes: between fuel injector and ECM develops a short circuit to power supply, a short circuit
to ground or open circuit

DTC P0203: Cylinder 4 injector electric circuit trouble

Test condition: system voltage higher than 9.0V

Engine speed greater than 700RPM

Malfunction judgement: the voltage of fuel injector control circuit too high or too low

Emergency control plan: get the fuel into the open-loop control

Possible causes: between fuel injector and ECM develops a short circuit to power supply, a short circuit
to ground or open circuit

DTC P0230: fuel pump relay trouble

Test condition: the ignition switch is at the energized position and the power-on time is greater than the
limit set by the system.

Malfunction judgement: the voltage of fuel pump relay too high or too low

Emergency control plan: None

Possible causes: between fuel pump relay and ECM develops a short circuit to power supply, a short
circuit to ground or open circuit
 Engine—Electric Injection—On-Board Diagnostic (EOBD)
Relay trouble

DTC P0300: misfire

Test condition: no trouble code relevant to MAS sensor, CTS, TPS, crankshaft position sensor, camshaft
position sensor and vehicle speed sensor.

Malfunction judgement: Under normal condition, ECM detects that the fluctuation of crankshaft rotational
speed exceeds the limit set by the system.

Emergency control plan: if the misfire is not serious, only affecting the emission, there is no such plan,
only with DTC recorded, data flow froze and MI turned on.

If the misfire is serious, causing the catalystic convertor overheating:

Positively enter the open-loop fuel control mode

Disable the rear oxygen sensor correction learning

When engine speed exceeds 2000RPM or MAP exceeds 50KPA, MI flashes at 1Hz, reminding the driver
to reduce the engine RPM and load immediately, and go to the service station for repair as soon as
possible.

Possible causes: ignition system trouble

Air leaking

Clearance of crankshaft position sensor incorrect

Ignition timing incorrect

Fuel injection trouble

Fuel pressure incorrect

Engine compression ratio incorrect

ECU trouble

DTC P1392: G sensor signal voltage too low

Test condition: run the engine for a while

Malfunction judgement: ECM detects that G sensor output signal value is too small

Emergency control plan: determine whether to disable the misfire diagnosis without reference to the
signal of G sensor

Possible causes: between G sensor and ECM develops a short circuit to ground.

Poor connection

G sensor trouble

DTC P1393: G sensor signal voltage too high

Test condition: run the engine for a while

Malfunction judgement: ECM detects that G sensor output signal value is too big

Emergency control plan: determine whether to disable the misfire diagnosis without reference to the
signal of G sensor
 Engine—Electric Injection—On-Board Diagnostic (EOBD)
Possible causes: between G sensor and ECM develops a short circuit to ground.

Poor connection

G sensor trouble

DTC P0325: the knock control system trouble

Test condition: the engine revolution speed higher than 1600RPM

Coolant temperature higher than 50℃

Malfunction judgement: ECM detects that the mean value of cylinders’ maximum signals of knock sensor
is smaller than the threshold limit value set by the system, or the mean value of cylinders’ minimum
signals greater than the threshold limit value set by the system.

Emergency control plan: take the system default value as the spark advance angle

Possible causes: poor connection

Open circuit of the line between knock sensor and ECM

Knock sensor trouble

DTC P0327: trouble of knock sensor circuit

Test condition: engine speed above 1600RPM

Coolant temperature higher than 50℃

Malfunction judgment: ECM detects that difference among knock signals from various cylinders is lower
than the limit value set by the system

Emergency control plan: ignition advance angle applies the default value set by the system

Possible cause: poor connection

Signal interference

Knock sensor trouble

DTC P0336: Problem of circuit performance of crank position sensor

Test condition: engine running

Malfunction judgement: ECM detects that pulse signals of crank position sensor lose too much

Emergency control plan: none

Possible cause: poor electric connection

Noise interference

Circuit trouble between crank position sensor and ECM

Target wheel trouble

ECM trouble

DTC P0337: circuit trouble of crank position sensor

Test condition: during starting

No camshaft indicates main sensor trouble

 Engine—Electric Injection—On-Board Diagnostic (EOBD)
System voltage decreases about by 1V

Malfunction judgement: ECM can not receive signals from crank position sensor

Emergency control plan: none

Possible cause: Circuit trouble between crankshaft position sensor and ECM

Air clearance between crankshaft position sensor and ring gear does not conform to the specification

Trouble of crankshaft position sensor

DTC P1336: gear information of crankshaft position not learnt

Test condition: no trouble codes related to coolant temperature sensor, throttle position sensor, crank
position sensor, camshaft position sensor, speed sensor, fuel injector, ignition system etc.

Malfunction judgement: gear information learning mark is not positioned

Emergency control plan: none

Possible cause: the vehicle hasn’t executed gear information learning program (refer to Appendix 2 for
gear information learning program)

DTC P0342: no signal from the circuit of crank position sensor

Test condition: engine running

Malfunction judgement: ECM does not receive any signal from crank position sensor

Emergency control plan: none

Possible cause: poor connection

Open circuit between crank position sensor and ECM

Crank position sensor is damaged

DTC P0351: trouble of ignition circuit 1

Test condition: the engine in operation

Power voltage is above 10V

Malfunction judgement: ignition circuit of cylinder 1, 4 is open or shorted to power supply or ground

Emergency control plan: stop fuel injection of cylinder 1, 4

Disable closed-loop fuel control

Possible cause: ignition circuit between ignition coil and ECM is shorted or open

Poor contact of ignition coil connector

Ignition coil is damaged

DTC P0352: trouble of ignition circuit 2

Test condition: the engine in operation

Power voltage is above 10V

Malfunction judgement: ignition line of cylinder 2, 3 is open or shorted to power supply or ground
 Engine—Electric Injection—On-Board Diagnostic (EOBD)
Emergency control plan: stop fuel injection of cylinder 2, 3

Disable closed-loop fuel control

Possible cause: ignition circuit between ignition coil and ECM is shorted or open

Poor contact of ignition coil connector

Ignition coil is damaged

DTC P0420: catalyst efficiency is below the limit

Test condition: no trouble codes related to MAP sensor, coolant temperature sensor, TPS sensor,
cooling system, oxygen sensor, fuel correction, speed sensor, fuel injector, fire, crankshaft position
sensor, camshaft position sensor, ignition system, idle speed control, system voltage

Coolant temperature higher than 70℃

With fuel system loop-closed, stop the vehicle and run at idle speed after driving for a certain distance at
even speed.

Malfunction judgement: the system calculates oxygen storage time of catalytic converter by comparing
signals from front and rear oxygen sensor, when weighted oxygen storage time is less then the set limit,
the system will report this trouble

Emergency control plan: none

Possible cause: catalystic convertor performance deterioration

DTC P0443: trouble of canister cleaning circuit

Test condition: ignition switch is at power-on position

System voltage is above 11V

Malfunction judgement: control circuit voltage of canister solenoid valve too high or too low.

Emergency control plan: stop canister cleaning function

Possible cause: control circuit between canister solenoid valve and ECM is open or shorted to power
supply or ground.

Canister solenoid valve is damaged

DTC P0462: fuel level sensor circuit input is too low

Test condition: the engine in operation

Power voltage is above 10V

Malfunction judgement: sensor signal voltage is higher than 4.3V

Emergency control plan: system should apply default fuel level value

Disable fire diagnosis

Circuit between the sensor and ECM is shorted to the power supply

Poor connection

DTC P0480: trouble of Fan 1

Test condition: engine in operation

 Engine—Electric Injection—On-Board Diagnostic (EOBD)
Malfunction judgement: ECM detects that the control line is shorted or open to power supply or ground

Emergency control plan: when coolant temperature is too high, start high-speed fan

Possible cause: control circuit between the fan and ECM is open or shorted to power supply or ground

DTC P0481: trouble of Fan 2

Test condition: engine in operation

Malfunction judgement: ECM detects that the control line is shorted or open to power supply or ground

Emergency control plan: none

Possible cause: control circuit between the fan and ECM is open or shorted to power supply or ground

DTC P0482: trouble of Fan 3

Test condition: engine in operation

Malfunction judgement: ECM detects that the control line is shorted or open to power supply or ground

Emergency control plan: none

Possible cause: control circuit between the fan and ECM is open or shorted to power supply or ground

DTC P0483: trouble of Fan PWM

Test condition: engine in operation

Malfunction judgement: ECM detects that the control line is shorted or open to power supply or ground

Emergency control plan: none

Possible cause: control circuit between the fan and ECM is open or shorted to power supply or ground

DTC P0502: no vehicle speed signal

Test condition: engine in operation

Coolant temperature is higher than 60℃

No trouble codes related to MAP sensor, TPS sensor etc.

Malfunction judgement: under acceleration condition, vehicle speed is lower than 10kph; and under
deceleration condition, vehicle speed is lower than 5kph

Emergency control plan: disable closed-loop control at idle speed

Under heavy-load condition, disable air conditioning no more

Possible cause: poor connection

Circuit between speed sensor and ECM is shorted or open

Speed sensor is damaged

DTC P0506: trouble of idle-speed control system – rotating speed is too low

Test condition: no trouble codes related to MAP sensor, coolant temperature sensor, TPS sensor,
cooling system, oxygen sensor, fuel correction, speed sensor, fuel injector, misfire, crankshaft position
sensor, camshaft position sensor, ignition system, idle speed control, system voltage

Engine in operation
 Engine—Electric Injection—On-Board Diagnostic (EOBD)
Coolant temperature is higher than 60℃

Malfunction judgement: the duration that idle speed is lower than target idle speed 100RPM set by the
system is longer than 10s

Emergency control plan: disable idle-speed adjustment

Possible cause: trouble of idle-speed control circuit

Trouble of idle-speed step motor

Ignition system trouble

DTC P0507: trouble of idle-speed control system – rotating speed is too high

Test condition: no trouble codes related to MAP sensor, coolant temperature sensor, TPS sensor,
cooling system, oxygen sensor, fuel correction, speed sensor, fuel injector, misfire, crankshaft position
sensor, camshaft position sensor, ignition system, idle speed control, system voltage

Engine in operation

Coolant temperature is higher than 60℃

Malfunction judgement: the duration that idle speed is lower than target idle speed 200RPM set by the
system is longer than 10s

Emergency control plan: disable idle-speed adjustment

Possible cause: circuit trouble between idle-speed control valve and ECM

Trouble of idle-speed control valve

Ignition system trouble

Vacuum leaking

DTC P0562: system voltage is too high

Test condition: ignition switch is at power-on position

Malfunction judgement: system voltage is higher than 16V

Emergency control plan: none

Possible cause: charging system trouble

Poor connection

Internal damage of ECM

DTC P0563: system voltage is too low

Test condition: ignition switch is at power-on position

Malfunction judgement: system voltage is higher than 11V

Emergency control plan: none

Possible cause: charge system trouble

Poor connection

Harness is shorted or open to the ground

 Engine—Electric Injection—On-Board Diagnostic (EOBD)
Internal damage of ECM

DTC P0532: voltage of air conditioning pressure circuit is too high

Test condition: engine in operation

Malfunction judgement: ECM detects that air conditioning pressure signal is lower than 0.05V

Emergency control plan: cut off air conditioning clutch immediately

Ai conditioning pressure signal applies system default value

Possible cause: the circuit between air conditioning pressure sensor and ECM is shorted to the power
supply

Poor connection

Trouble of air conditioning pressure sensor

DTC P0533: voltage of air conditioning pressure circuit is too low or open

Test condition: engine in operation

Malfunction judgement: ECM detects that air conditioning pressure signal is lower than 4.95V

Emergency control plan: cut off air conditioning clutch immediately

Ai conditioning pressure signal applies system default value

Possible cause: the circuit between air conditioning pressure sensor and ECM is shorted or open to the
power supply

Poor connection

Trouble of air conditioning pressure sensor

DTC P1545: trouble of output circuit of air conditioning clutch

Test condition: ignition switch is at power-on position

Malfunction judgement: ECM detects circuit trouble of air conditioning clutch relay

Emergency control plan: none

Possible cause: the harness between air conditioning clutch relay and ECM is shorted or open to the
power supply or to the ground

DTC P2001: trouble of rear air conditioning evaporator sensor

Test condition: engine in operation

Malfunction judgement: ECM detects that the signal from rear evaporator sensor is too high or too low

Emergency control plan: none

Possible cause: poor connection

Harness between evaporator sensor and ECM is shorted or open to the power supply or to the ground

Trouble of rear evaporator sensor

DTC P0615: TCM trouble

Test condition: engine in operation

 Engine—Electric Injection—On-Board Diagnostic (EOBD)
Malfunction judgement: ECM received trouble information transmitted from TCM

Emergency control plan: none

Possible cause: trouble of transmission control system

 Engine – Electronic fuel injection part – Typical troubles and troubleshooting
Typical trouble and troubleshooting
1. Repair notice

(1) Preparation before repair:

(a) Do not repair vehicle at petrol station

(b) Do not repair fuel system at the place where fire source exists

(c) No smoking is allowed during repair operation

(2) When removing parts of fuel system (e.g. replacing filter, removing oil pump or oil inlet/outlet pipe of
fuel rail)

(a) Disconnect battery cathode first to prevent fuel vapor being ignited by discharge spark produced from
accidental short circuit.

(b) Cover oil pipe connector with cloth, then loose the connector carefully to release oil pressure from the
pipe

(c) Prevent fuel from splashing onto the engine and high-temperature exhaust pipe;

(d) Keep gasoline away from rubber or leather parts

(e) Replace fuel inlet/return pipe, pressure resistant fuel pipe against bursting pressure higher than
2MPa shall be used.

(3) When removing and repairing parts of electronic control system:

(a) Electronic-Controlled Fuel Injection System parts is reliable, when the vehicle or engine works
abnormally, check related mechanical parts, system connectors and harness, grounding wire, high
pressure line connector of spark plug and vacuum pipe of oil pressure adjustor etc.; perform
replacement test repeatedly to check before determining that Electronic-Controlled Fuel Injection parts
are damaged;

(b) When battery voltage is low or engine fails, do not start the engine with external force for a long
period in order to prevent three-way catalystic convertor from being damaged;

(c) If repair is essential, cut off ignition switch or disassemble battery cathode first, it is prohibited to
assemble or disassemble electronic parts with power switched on;

(d) Do not check electric signal of the system in the manner of

detecting the harness with probe;

(e) When the engine in operation, do not plug out battery connector;

(f) When it is required to perform electric welding etc. using tools from
external electric system, battery and ECM connector must be
disconnected;

(g) Do not check that ignition system by plugging out spark plug lead,
because the nozzle is still working, gasoline injected but not used will
burn in three-way catalystic convertor thus resulting in damage quickly;

(h) When checking during ECM replacement, please note whether the vehicle is equipped with computer
burglar alarm. If so, cut off the power supply to burglar alarm, and replace a new ECM, or else the new
ECM will be locked by the burglar alarm and can not work on other vehicles;
 Engine – Electronic fuel injection part – Typical troubles and troubleshooting
(i) Prevent parts from violet knocking during assembling and disassembling;

(j) Do not open ECM cover;

(k) When replacing and removing oxygen sensor, do not let the sensor touch water or other liquid.

(l) Fuel pump shall not run for a long period without fuel or run with gasoline in the air

(m) Most of electronically-controlled fuel injection parts are unrepairable, after determining that the part is
damaged, it is usually replaced;

(n) The system shall use anti-interference spark plug and high-pressure wire, non-anti-interference spark
plug and high-pressure wire may not only release interference wave,
but also may make affect influence on drive module of ignition coil
inside the ECM, and it may even damage ECM.

(4) End of work:

(a) Check that all wire connectors and fuel pipeline are connected and
fixed appropriately;

(b) If there is any damage on the pipeline, the damage part must be
wrapped during repair;

(c) High-voltage conductor must be connected appropriately;

(d) When connecting battery connector, please note: never connect anode and cathode reversely, and
ensure that the lamp on battery connector is connected securely.

2. Detection procedure for off-line vehicle

Detection unit for off-line vehicle or after-sales service station can detect vehicle operating condition
using computer equipped with PCHUD monitor software or trouble diagnosis tester. Appendix 1: "Typical
datastream of DELPHI electronic fuel injection system" lists operating parameters of the vehicle at
normal condition and possible causes in abnormal condition.

3. Trouble diagnosis with trouble code and corresponding troubleshooting

When trouble lamp illuminates, use the diagnosis tester to read trouble code, and repair according to
trouble code description in “On-board diagnosis system”.

After finishing troubleshooting at service station, perform trial driving as per the following procedures to
ensure that trouble is repaired completely.
 Engine – Electronic fuel injection part – Typical troubles and troubleshooting

90km/h, Gear 5 or D
Vehicle speed

70km/h, Gear 5 or D for 5min

for 5min

50km/h, Gear 3 for

5min

Idle
speed Idle speed Idle speed Idle speed

Time (Min)

4. Trouble diagnosis without trouble code and corresponding troubleshooting

Trouble 01: Trouble diagnosis tester can not communicate with the system

Possible cause Troubleshooting for reference

1. Diagnosis wire is not connected securely 1. Reconnect diagnosis wire

2. Functions of diagnosis tester do not conform to 2. Use a diagnosis tester conforming to the vehicle
the system model and system

3. Diagnosis tester trouble 3. Eliminate diagnosis tester trouble

4. corresponding relation between diagnosis 4. Repair the harness

interface and ECM connector terminal is wrong
5. Repair the harness
5. shorted to the lead relevant to diagnosis port
6. Replace ECM
6. ECM communication trouble
 Engine – Electronic fuel injection part – Typical troubles and troubleshooting

Trouble 02: Start trouble

Possible cause Troubleshooting for reference

Trouble lamp:

1. Flashing 1. Whether the key is correct or damaged

1) Anti-theft key error 1) Re-learn the key

2) Circuit trouble of anti-theft system 2) Check the line and reconnect the connector

3) Alarm is damaged 3) Replace alarm, and perform learning steps

according to the procedure

2.
2. Off
1) Replace
1) Fuse/fusible line
2) Check and repair
2) Grounding wire is open
3) Reconnect
3) ECM connector
4) Repair harness and lamp
4) Lamp and circuit
5) Replace ECM
5) ECM trouble
3. Diagnose with trouble diagnosis tester
3. On – check with diagnosis tester
1) Eliminate the existing trouble
1) With trouble code
2) Check: system power supply, signal acquisition
2) Without trouble code
system, fuel supply system, ignition system,
idle-speed control system, engine and whole
vehicle mechanical system

System power supply:

1. System voltage when starter is working 1. Diagnose with trouble diagnosis tester

1) ＜8V 1) Replace battery or charge

2) ＞8V 2) Check other systems

Signal acquisition system:

1. Without rotating speed datastream 1.

1） Harness of crank position sensor is open 1) Repair the harness

2) Connector terminal of crank position sensor is 2) Repair the harness

connected reversely
3) Adjust the clearance: 0.3～1.5mm
3) Clearance between sensor and 58× target gear
4) Clean sensor
is incorrect
5) Replace sensor
4) Foreign matter is attached with the sensor

5) Sensor magnetic force is degenerated or sensor

 Engine – Electronic fuel injection part – Typical troubles and troubleshooting
is damaged 2. With rotating speed datastream

2. With rotating speed datastream 1) Check: falling edge of Gear 20 is the top dead
point of Cylinder 1-4
1) Relative position of 58×gear to top dead point is
incorrect

Fuel supply system: 1. Connect in correct manner

1. Inlet/return pipe is connected reversely 2. Repair vehicle harness, and reconnect oil pump
connector
2. Fuel pump open circuit
3. Slight overflowing: Open the throttle fully and
3. Cylinder is overflowing
start the engine
4.
Serious overflowing: remove spark plug and start
the engine, recover them after the cylinder and
residual oil in the spark plug is dry
5. Inlet pipe pressure ＞250kpa
4.
1) Nozzle is blocked
1) Replace nozzle
6. Inlet pipe pressure ＜250kpa
5.
1) Insufficient fuel in the tank
1) Fill oil
2) Fuel filter is blocked
2) Replace fuel filter
3) Inlet pipe is leaking
3) Replace inlet pipe
4) Fuel pressure adjuster is damaged
4) Replace fuel pressure adjuster
5) Fuel pump pressure is not sufficient
5) Replace fuel pump
6) Fuel evaporability is proper or not
6) Use fuel with proper evaporability as per season

Ignition system:

1. Connector of ignition coil 1. Reconnect connector

2. Cylinder sequence is incorrect 2. Connect coil and spark plug according to coil tip

3. Spark plug is damaged 3. Replace spark plug

4. Ignition coil is damaged 4. Replace ignition coil

Idle speed control system:

1. Unable to start by depressing the throttle slightly 1. Check other reasons

2. Able to start by depressing the throttle slightly 2.

1) Idle valve plug falls off 1) Reconnect

2) Connector terminal of idle valve does not 2) Repair the harness

conform to ECM terminal
3) Clean throttle body
3) Idle valve is blocked
4) Repair the harness
4) ECM common power is interrupted
5) Replace idle valve
 Engine – Electronic fuel injection part – Typical troubles and troubleshooting
5) Idle valve is damaged 6) Replace ECM

6) ECM trouble

Air intake/exhaust system:

1. Air filter is blocked 1. Clean up air intake pipeline, and replace filter
element
2. Three-way catalystic convertor is blocked
2.
1) Catalystic convertor is broken
1) Replace three-way catalystic convertor
2) Blocked due to foreign matter burning
2) Repair engine and replace three-way catalystic
convertor

Trouble 03: Engine is ignited but can not start

Possible cause Troubleshooting for reference

Fuel supply system:

1. Inlet pipe pressure ＜250kpa 1.

1) Insufficient fuel in the tank 1) Fill fuel

2) Fuel filter is blocked 2) Replace fuel filter

3) Inlet pipe is leaking 3) Replace inlet pipe

4) Oil pressure adjuster is damaged 4) Replace fuel pressure adjuster

5) Fuel pump pressure is not sufficient 5) Replace fuel pump

6) Fuel evaporativty is proper or not 6) Use fuel with proper eveporativity as per season

Idle speed control system:

1. Able to start by depressing the throttle 1.

1) Idle valve plug falls off 1) Reconnect

2) Connector terminal of idle valve does not 2) Repair the harness

conform to ECM terminal
3) Clean throttle body
3) Idle valve is blocked
4) Repair the harness
4) ECM common power is interrupted
5) Replace idle valve
5) Idle valve is damaged
6) Replace ECM
6) ECM trouble

Air intake/exhaust system:

1. Air filter is blocked 1. Clean up air intake pipeline, and replace filter
2. Three-way catalystic convertor is blocked element

1) Catalystic convertor is broken 2.

 Engine – Electronic fuel injection part – Typical troubles and troubleshooting
2) Blocked due to foreign matter burning 1) Replace three-way catalystic convertor

2) Repair engine and replace three-way catalystic

convertor

Trouble 04: Idle speed is abnormal

Possible cause Troubleshooting for reference

1. Whole vehicle is power-off 1. Switch off ignition switch and restart it 10s later

2. ECM common power is switched off during 2. Recover ECM common power supply
parking

Trouble 05: Idle speed is low

Possible cause Troubleshooting for reference

1. Idle valve plug falls off 1. Reconnect

2. Connector terminal of idle valve does not 2. Repair the harness

conform to ECM terminal
3. Clean throttle body
3. Idle valve hole is blocked
4. Replace idle valve
4. Idle valve is damaged
5. Fill fuel
5. Insufficient fuel in the tank
6. Replace fuel filter
6. Whether the fuel filter is blocked
7. Replace inlet pipe
7. Inlet pipe is leaking
8. Replace catalystic convertor, if necessary, repair
8. Three-way catalystic convertor is blocked or not the engine

9. Air ntake system is blocked or not 9. Clean up intake pipeline, and replace filter
element
10. Fuel pressure adjuster is damaged
10. Replace fuel pressure adjuster
11. Fuel pump pressure is not sufficient
11. Replace fuel pump
12. ECM trouble
12. Replace ECM

Trouble 06: Idle speed is high

Possible cause Troubleshooting for reference

1. Consistent with target idle speed 1.

1) Reading on coolant temperature sensor is 1) Replace coolant temperature sensor

abnormal
2) Normal phenomena
2) Reading on coolant temperature sensor is
2.
normal
 Engine – Electronic fuel injection part – Typical troubles and troubleshooting
2. Inconsistent with target idle speed 1) Adjust throttle cable

1) Throttle does not return to the home position 2) Eliminate leaking trouble for intake pipe; refer to
“Idle speed is low” for trouble of idle-speed control
2) Step pitch of idle valve ＜ 5 steps – intake pipe
system
leaking; trouble of idle-speed control system

3) 5 steps ＜ step pitch of idle valve ＜150 steps -

trouble of idle-speed control system

Trouble 07: Idle speed is not stable

Possible cause Troubleshooting for reference

1. Poor connection to spark plug lead 1. Reconnect

2. Clearances between spark plugs are not 2. Adjust all of them to 1.0～1.2mm
consistent
3. Repair or replace vacuum pipe
3. Vacuum pipe of oil pressure adjuster falls off or
is damaged 4. Clean or replace troubley fuel injector

4. Certain fuel injector is blocked 5. Check: falling edge of Gear 20 is the top dead
point of Cylinder 1-4
5. 58× ring gear is mis-positioned

Trouble 08: Engine flames out suddenly during normal operation

Possible cause Troubleshooting for reference

1. Poor connection of electric system 1. Check all related connectors in anode and
cathode circuits of power supply
2. Insufficient fuel in the tank
2. Fill fuel
3. Inlet pipe is leaking
3. Replace inlet pipe

Trouble 09: Engine flames out during deceleration

Possible cause Troubleshooting for reference

1. ECM common power is switched off during 1. Recover ECM common power supply
parking
2. Repair the harness
2. Connector terminal of idle valve does not
3. Clean throttle body
conform to ECM terminal
4. Replace idle valve
3. Idle valve is blocked
5. Replace ECM
4. Idle valve is damaged

5. ECM trouble
 Engine – Electronic fuel injection part – Typical troubles and troubleshooting
Trouble 10: Powerless/lagging acceleration

Possible cause Troubleshooting for reference

1. Air intake system is not smooth 1. Clean up air intake pipeline, and replace filter
element
2. Pressure sensor hole of air intake manifold is
blocked 2. Clean up detecting hole on the pressure sensor
of air intake manifold, if necessary, replace the
sensor
3. Throttle can not be opened fully
3. Adjust retaining screws of the throttle to ensure
4. Fuel injector is blocked that it is opened fully

5. Exhaust system is not smooth 4. Clean or replace troubley fuel injector

5. Check exhaust system and three-way catalystic

convertor

Trouble 11: Engine power is insufficient

Possible cause Troubleshooting for reference

1. Air intake system is not smooth 1. Clean up air intake pipeline, and replace filter
element
2. Throttle can not be opened fully
2. Adjust retaining screws of the throttle to ensure
3. Exhaust system is not smooth
that it is opened fully
4. Resistance of power transmission system is too
3. Check exhaust system and three-way catalystic
large
convertor
5. Engine is overheat
4. Repair parts relevant to power transmission
6. Fuel injector is blocked system

5. Repair engine cooling system

6. Clean or replace troubley fuel injector

Trouble 12: Idle speed unstable during servicing

Possible cause Troubleshooting for reference

1. High-pressure circuit creepage of ignition 1. Reconnect all connectors and replace damaged
system parts

2. Nozzle is blocked 2. Clean or replace troubley fuel injector

Trouble 13: Vibration during acceleration

Possible cause Troubleshooting for reference

1. High-pressure circuit creepage of ignition 1. Reconnect all connectors and replace damaged
system parts
 Engine – Electronic fuel injection part – Typical troubles and troubleshooting

Trouble 14: Knocking

Possible cause Troubleshooting for reference

1. Fuel does not conform to the standard 1. Ensure that fuel with octane rating greater than
90 is used
2. Engine is overheat
2. Repair engine cooling system
3. 58× ring gear is mispositioned
3. Check: falling edge of Gear 20 is the top dead
point of Cylinder 1-4

Trouble 15: Post-ignition (and exhaust temperature is too high)

Possible cause Troubleshooting for reference

1. Cylinder fuel shortage of engine ignition system 1. Recover ignition of that cylinder, if it is
impossible temporarily, plug out the nozzle control
plug of that cylinder to protect the three-way
2. Trouble of engine exhaust valve catalystic convertor

3. 58× ring gear is mis-positioned 2. Repair engine

3. Check: falling edge of Gear 20 is the top dead

point of Cylinder 1-4

Trouble 16: Testing excessive emission by measurement method

Possible cause Troubleshooting for reference

1. Abnormal condition of the engine 1. Repair engine

2. Control of electronic fuel injection system is 2. Repair electronic fuel injection system according
abnormal to “Off-line trial driving procedure and detecting
technical conditions for 462/465 series vehicles”

3. Secure relevant bolts, if necessary, replace

3.Connector between cylinder head and three-way
gasket
catalystic convertor is air-leaking
4. Secure oxygen sensor
4. Screws of oxygen sensor is air-leaking
5. Repair or replace
5. Vacuum pipe of oil pressure adjuster falls off
6. Replace fuel pressure sensor
6. Trouble of fuel pressure adjuster
7. Lifecycle is longer than 80000km under
7. Usage term of three-way catalystic convertor
standard condition, if necessary, replace it
and oxygen sensor has been exceeded
8. Replace catalystic convertor and oxygen sensor
8. Heavy metal poisoning of three-way catalystic
convertor and oxygen sensor, or they are damaged 9. Run it for 10 minutes at 70km/h at 3rd gear
due to overheating
 Engine – Electronic fuel injection part – Typical troubles and troubleshooting
9. Sulfur poisoning of three-way catalystic 10. Improve position of system grounding wire
convertor and oxygen sensor
11. Isolate ECM housing
10. Poor grounding of ECM or electronic fuel
12. Check: falling edge of Gear 20 is the top dead
injection system
point of Cylinder 1-4
11. ECM housing is grounded

12. 58× ring gear is mis-positioned

Trouble 19: Emission of fuel vapor is abnormal

Possible cause Troubleshooting for reference

1. Canister connecting pipe is broken 1. Replace connecting pipe

2. Canister is damaged 2. Replace canister

3. Canister specification is too small 3. Choose proper canister

4. Harness of canister solenoid valve trouble 4. Repair the harness

5. Connector is not connected securely 5. Reconnect

6. Canister solenoid valve is damaged 6. Replace canister solenoid valve

7. ECM trouble 7. Replace ECM

Trouble 20: Fuel consumption is abnormal

Possible cause Troubleshooting for reference

1. Measurement method is not correct 1. Use reliable measurement method

2. Whole vehicle condition 2. Repair the vehicle

3. Engine condition 3. Repair engine

4. Thermostat is damaged 4. Replace thermostat

5. Coolant temperature sensor is troubley 5. Replace coolant temperature sensor

6. Condition of electronic fuel injection system 6. Repair electronic fuel injection system according
to “Off-line trial driving procedure and detecting
technical conditions for 462/465 series vehicles”
7. Nozzle is oil-leaking
7. Replace damaged nozzle
8. Fuel pressure adjuster is damaged
8. Replace thermostat
9. oxygen sensor is troubley
9) Replace oxygen sensor
10. ECM trouble
10. Replace ECM

The vehicle not equipped with air conditioner displays trouble relevant to air
Trouble 21:
conditioning system
 Engine – Electronic fuel injection part – Typical troubles and troubleshooting
Possible cause Troubleshooting for reference

1. Spare plug for air conditioning control of 1. Clean spare plug of air conditioner, provide
electronic fuel injection system is contaminated proper dustproof and waterproof protection, cut off
power supply to ECM for 10 minutes

Trouble 22: ECM is locked by alarm

Possible cause Troubleshooting for reference

1. Alarm-related harness is troubley 1. Repair the harness

2. Connector is not connected securely 2. Reconnect

3. Anti-theft key is damaged 3. Replace and relearn new anti-theft key

4. Unlocking is required 4. ECM sends back DELPHI decoding

5. Others 5. Contact alarm supplier, and request

corresponding services

Trouble 23: Anti-theft key gets lost or alarm is damaged

Possible cause Troubleshooting for reference

1. Anti-theft key gets lost or alarm is damaged 1. Contact alarm supplier, and request
corresponding services; Send back ECM to
DELPHI for unlocking

Trouble 24: Trouble lamp is on/off rulelessly during vehicle running

Possible cause Troubleshooting for reference

1. Connector is connected poorly 1. Check all connector terminals of electronic fuel

injection system, and then reconnect connectors
 Engine – Electronic fuel injection – Appendix 1: Typical datastream of DELPHI electronic fuel injection system
Appendix 1: Typical datastream of DELPHI electronic fuel injection system
1. Routine inspection

(1) Harness connectors are connected reliably

(2) Oil pipe and vacuum pipe are fixed reliably

(3) Secure end bolts of oxygen sensor and three-way catalystic convertor interface, ensure tightness of
interface end; if necessary, check the exhaust system with atmospheric pressure of 1.3, there should be
no obvious leakage.

2. System initialization setting

(1) Initialization of electronic fuel injection control system: turn the ignition switch to running position, and
turn off 3s later, system initialization setting will be finished 10s later.

(2) Initialization of fuel supply system: turn the ignition switch to running position, and turn off 3s later,
restart it after 1s and repeat it 5 times, then initialization setting of fuel supply system will be finished.

3. Inspection of system and vehicle condition

(1) Step 1: cold vehicle, turn the key switch to “ON” position, deactivate the engine (for about 30s)

No. Detection items

1 Display trouble code No

2 Engine trouble indicator On

3 Battery voltage 11.5～13V

4 Coolant temperature sensor Normal temperature

5 Air intake temperature sensor Ambient temperature

6 Absolute pressure sensor for intake manifold Ambient atmosphere (about 100kpa)

Working range of air intake valve position

7 0～99.6%
sensor

8 Oxygen sensor 1127mV

40～159 steps (coolant temperature: high～

9 Idle control valve
low)

(2) Step 2: Key switch turns to “OFF" position

Detection items

1 Actual position of idle-speed motor Remain at 128 steps after about 8s

2 ECM power supply is cut off or not PCHUD/diagnosis tester stops display

3 Engine trouble check indicator OFF

(3) Step 3: Start engine (Note: do not operate any mechanism and throttle on the engine during start)

Detection items
 Engine – Electronic fuel injection – Appendix 1: Typical datastream of DELPHI electronic fuel injection system
1 Start time ＜5s

2 Starting speed at normal temperature ＜1600RPM

3 Engine trouble check indicator OFF

(4) Step 4: Idle speed inspection (after start, warm up engine to normal coolant temperature)

(a) Low idle speed

Detection items

1 Engine trouble check indicator OFF

2 Display trouble code or not No

3 Coolant temperature 80～94℃

Coolant temperature Cooling fan condition

Cooling fan 92.25 low-speed fan ON

4 (Single-speed fan is only used for data of 87.00 low-speed fan OFF
low-speed fan) 98.25 high-speed fan ON

93 high-speed fan OFF

5 Battery voltage 13.5～14.5V

850±30RPM
6 Rotating speed 900±30RPM (when cooling fan, head lamp
and blower are on)

7 Ignition advance angle 5～13°

8 Air intake manifold pressure 35～55kpa

9 Actual position of idle-speed motor 15～30 steps

10 Pulse width of fuel injection 2～4ms

11 Oxygen sensor/jump times within 10s 100～900mV/≥6 times

(b) High idle speed (depress the throttle to accelerate the engine to 2000RPM)

Detection items

1 Engine trouble check indicator OFF

2 Display harness trouble code or not No

3 Coolant temperature 80～94℃

5 Battery voltage 13.5～14.5V

Actual value (it should be controlled within

6 Rotating speed
2000±50RPM)
 Engine – Electronic fuel injection – Appendix 1: Typical datastream of DELPHI electronic fuel injection system
7 Ignition advance angle 20～30°

8 Pulse width of fuel injection 2～4ms

9 oxygen sensor/jump times within 10s 100～900mV/≥10 times

(5) Step 5: Air conditioning system inspection

(a) Normal idle speed, air conditioning system is OFF

Detection items

1 Status 3 - A/C system Appearing

2 Status 5 – front evaporator Appearing

(b) Start air conditioner, after keep stable for 10s

Detection items

1 Engine idle speed 1000±50RPM

2 Status 3 - A/C request signal Appearing

3 Status 3 - A/C relay Appearing

4 Status 3 - A/C system Appearing

5 Status 4 – Fan 1 Appearing

6 Status 5 – Fan 2 Appearing

7 Status 5 – front evaporator Appearing

(6) Step 6: Driving inspection

The following operation must be performed during driving inspection:

(a) Throttle opening is larger than 10% and remain above 15s

(b) Direct gear, when the speed reaches 80km/h, release the throttle and slip for over 5s

Detection items

1 Engine trouble check indicator OFF

2 Display harness trouble code or not No

3 Coolant temperature 80～94℃

4 Battery voltage 13.5～14.5V

Absolute pressure sensor for air intake

5 20kpa～ atmosphere pressure
manifold

6 Working range of throttle position sensor 0～99.6%

7 oxygen sensor 50～950mV

4. Description

(1). Routine inspection

 Engine – Electronic fuel injection – Appendix 1: Typical datastream of DELPHI electronic fuel injection system
(a) Loose connection of connectors will cause misalignment of signal transmission and control;

(b) Fuel inlet/return pipes can not be connected reversely, pressure balancing vacuum pipe of the oil
pressure adjustor can not be omitted, or it may lead to abnormal exhaust and increase fuel consumption;

(c) Canister cleaning pipe should not be connected reversely or omitted, otherwise it may lead to
abnormal idle speed;

(d) If tightness from engine cylinder head to three-way catalystic convertor is poor, outer air will get in
during engine operation, which will destroy the balance of air/fuel ratio, thus reduce converting efficiency
of three-way catalystic convertor.

(2) System initialization setting

(a) When the first power supply to ECM is cut off after ECM is installed, ECM will perform initialization
setting for the system

(b) Every time the key switch is turned on, fuel pump will work for 1.5s. When the vehicle is off line, there
is no fuel in fuel pipeline, therefore fuel shall be filled into the pipeline first.

(3) Inspection of system and vehicle condition

(a) Turn key switch to running position, and leave the engine static.

● Engine trouble indicator is on, but there should be no trouble code

● Absolute pressure sensor of air intake manifold should display local atmosphere pressure value at
that time

● Adjust throttle cable and pedal screw, ensure enclosure and full opening of the throttle

● When warming up the oxygen sensor, its display should decrease from 450mV and keep balance
below 200mV after warm-up;

● The position of idle valve is based on engine temperature, its opening is small when warming up
and large when the engine gets cold.

(b) Turn key switch to parking gear

● After turning off key switch, if idle control valve does not act, ECM power supply should be cut off
immediately at the same time, check that ECM common power wire is connected incorrectly to ignition
switch; it may cause difficult engine restarting and flame-out during deceleration, as well as affecting
exhaust performance.

(c) Idle speed inspection

● Engine trouble indicator is OFF without trouble code;

● Battery voltage indicates that whether the generator operates normally

Too high: maybe generator adjustor is troubley

Too low: maybe generator wiring is inappropriate or generator trouble;

● Air intake manifold pressure can indicate leakage of air intake and throttle clearance problem. If
throttle clearance is too small, this value is higher, which will affect engine dynamics, in addition,
because exhaust valve is open too early and exhaust temperature increases, lifecycles of oxygen sensor
and three-way catalystic convertor will be shortened greatly.

In addition, blockage of exhaust system (e.g. there is foreign matter in exhaust pipeline or three-way
 Engine – Electronic fuel injection – Appendix 1: Typical datastream of DELPHI electronic fuel injection system
catalystic convertor is broken inside) will cause this value higher too;

● Actual position value of idle-speed motor is too low, which indicates that intake system is leaking,
and too high indicates throttle body and idle control valve are blocked;

● Changing times of oxygen sensor value is too few, it indicates that oxygen sensor fails.

(d) A/C system inspection

When air conditioner starts, target idle speed increases by 100RPM, and when air conditioning fan is
turned on, it increases by 50RPM additionally, in general they start at the same time, therefore, after the
air conditioner starts, idle speed of the engine should increases by 150RPM on the basis of the original
idle speed.

(e) Driving inspection

Diagnose vehicle speed trouble and sensor trouble during this course, meanwhile the alternative control
solution will become effective after the trouble is detected.
 Engine —Electronic fuel injection part — Appendix 2: Gear information learning procedure of EOBD system

Appendix 2: Gear information learning procedure of EOBD system

Operation 1: Learn target gear teeth error of crank position sensor

1. When the vehicle installed new computer has not learned gear information, trouble lamp will be on
after it starts, and diagnosis tester displays trouble of P1336.

2. When water temperature reaches 60℃ after starting, vehicle running time is longer than 10s, and
other onboard loading should be closed;

3. Send “Gear information learning” command by diagnosis tester (Command “30 2c 07 ff”)

4. Depress the throttle to the extreme position and remain, ECM should perform gear information
learning at this time, engine speed circulates 2-5 cycles within 1300-4500, and finally hunting at about
4500rpm, learning is completed;

(The content above is typical characteristics of engine speed when performing gear information learning,
it can be used to determine whether learning is in process or completed)

5. Send “Stop gear information learning” command by diagnosis tester (Command “30 2c 00”)

6. Engine flames out, key-on after about 15s, then eliminate trouble code, key-off;

7. Start the engine after 15s, check that P1336 is qualified by diagnosis tester;
 73-pin
73针接插件
connector
Battery power MT20U2 F22 15A
F12 10A supply 电瓶电源 J1-17 5V power supply No.1 B
Battery power J1-20 1号5V电压源正
positive
Ignition switch MT20U2 Ignition coil A 1 List of Fuses
点火开关IG1
supply 电瓶电源 J1-18 J1-05 5V power supply No.1
1号5V电压源地 保险丝使用表
IG1 F22 15A switch power
Ignition 点火开关电源 ground J1-32 点火线圈A驱动
drive A
supply J1-01 Dual-core shielded 4 ECM battery
5V power supply No.2 双芯屏蔽线
J1-04 2号5V电压源正 wire 3 ECM电瓶电源
power
F6 20A positive
Main relay
J1-21 2号5V电压源地
5V power supply No.2
Ignition coil B
点火线圈B驱动 C F12 10A 诊断接口
diagnostic
主继电器输出
output J1-52 drive
ground 2 interface
ECM ignition
Main relay J1-58 ECM点火开关电源
output F22 15A switch power
PCP ignition coil supply
点火线圈 ignition
PCP点火线圈 coil
主继电器
Main relay o A/C A/C A/C A/C Fuel injector,
fuel
喷嘴、 pump,
Idle speed control A
怠速空气控制A高 D Idle speed air Spark plug F6 20A oxygen
油泵、 sensor
J1-54 火花塞
high 怠速空气
control valve 氧传感器加热、
怠速空气控制B高 B heating, and
J1-33 Idle speed control B 1 2 3 4 碳罐电磁阀
Battery 怠速空气控制A低 控制阀 Injection canister
电瓶 System J1-53 high C 喷嘴 solenoid valve
Earthing point at 系统接地
earthing Idle speed control A
怠速空气控制B低
nozzle
接地点选发动机 J1-73 J1-34 A
generator body or low
机体或电瓶负极
battery negative B A B A B A B A
pole Cylinder 1
1缸喷嘴
Dual-core shielded J1-55
nozzle
wire双芯屏蔽线 58-tooth signal 2缸喷嘴
Magnetoelectric A
J1-70 Cylinder 2
磁电式曲轴 high58齿信号高 J1-12 3缸喷嘴
crankshaft 58-tooth signal J1-56 nozzle
58X C
position
位置传感器 sensor high58齿信号低 J1-28 Cylinder
4缸喷嘴 2
B Diagnostic interface J1-71
F12 10A 18 诊断接口 nozzle
Serial data
J1-11
KW2000 串行数据
7 Main relay
Vehicle speed 30 87
52
72

Vehicle speed sensor signal 车速信号 output

主继电器输出
车速传感器 J1-03 5 Fuel relay
73

油泵继电器控制
control 85 86
J1-47
4 Fuel pump
Single-core M 油泵
单芯屏蔽线
shielded wire Knock 5V power supply No.2 B
16
32

Knock sensor 爆震信号

signal Intake air positive2号5V电压源正
J1-69 Intake manifold absolute
爆震传感器 进气压力
pressure A 进气歧管绝对压力 Canister solenoid
J1-42 pressure/temperature Canister solenoid valve 碳罐电磁阀
sensor valve
温度传感器 J1-63 碳罐电磁阀控制
control Main relay output
A B 主继电器输出
1号5V电压源地
5V source No. 1 5V power supply No.2 D
2号5V电压源地
ground ground
Main relay output
主继电器输出 Intake air Tachom
转速表 Instrument
仪表电源 power
Front oxygen sensor 进气温度
J1-27 temperature C eter supply
OSP D B signal 前氧传感器信号高
high J1-62
Front
加热式前 Front oxygen sensor Tachometer
RPM
heated A signal low氧传感器信号低 转速表
J1-06 J1-45 Malfunction
氧传感器
oxygen C Front oxygen sensor Malfunction
故障指示灯 诊断指示灯
indicator
sensor heating 前氧传感器加热 J1-61 J1-31 indicator
EOBD
Main relay output
主继电器输出
Rear oxygen sensor
D B signal 后氧传感器信号高
high
OSP J1-38
Rear heated Battery 30
A/C
87 空调压缩机
加热式后
oxygen sensor A 电瓶电源
power compressor
A/C
1

C 空调压缩机 85 86
33

17

Rear oxygen sensor

53

氧传感器 J1-46 compressor IG2

heating 后氧传感器加热 J1-64
5V source No. 1 空调压缩机继电器
A/C compressor
positive relay
A 1号5V电压源正 Throttle position
Throttle position sensor 节气门位置信号
signal Schematic of
节气门位置传感器 C J1-24
5V source No. 1 接插件针脚示意
connection pins
B
1号5V电压源地
ground A/C high/low pressure
switch空调高低压开关 A/C request
A/C request high 空调请求开关
switch
Coolant temperature
冷却液温度信号
signal 空调请求高有效
valid Blower relay Low-speed fan
3 J1-43 J1-39 鼓风机继电
低速风扇控制
control
To water Medium pressure signal output
器输出（+） (+) J1-67
Coolant temperature 2 中压信号高有效
冷却液温度传感器 temperature
去水温表 gauge
J1-41 high valid S2 20A
sensor Battery
Appendix 3: Circuit Schematic Diagram for MT20U2 System

1 5V source No. 1
1号5V电压源负 电瓶电源
power
negative A/C medium pressure
空调中压开关 Low-speed fan
低速风扇继电器
switch relay
Blower high valid
J1-57 鼓风机高有效 High-speed fan
Front evaporator 高速风扇控制
control
J1-50
B 前蒸发器温度信号
temperature signal J1-26
Front
前蒸发器温度传感器 evaporator
temperature sensor
A 5V source No. 1 negative High-speed
高速风扇继电器 fan
1号5V电压源地 Fan
relay 风扇
Engine —Electronic fuel injection part —Appendix 3: Circuit Schematic Diagram for MT20U2 System
Engine—Fuel System—Carbon Canister Replacement