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Chery T11 Service Manual Electric Injection System

Chapter

Electric Fuel Injection System

1

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Section Operating Principle of Key Components

1. Pressure and Intake emperature Sensor !E"P#

" $%electronic fuel injection system employs

the velocity-density-air metrological method to

detect the air capacity that flow into the engine,

and further accurately control the power output

of the engine !t the same time, this system

applies the Intake Pressure Cylinder

&etection technology The inta"e pressure

sensor is mounted near the air inta"e of #o 1

cylinder$s inta"e manifold There is an

instantaneous pressure drop in the position of

sensor on the moment when the air inta"e opens

The value of pressure drop is appro%imate

1&pa The EC' can detect this instantaneous

pressure drop, receive this signal from the

sensor, and then determine the signal of

compression upper dead center after the signal is

analy(ed and processed )y software

The Intake Pressure Sensor$s internal pressure

mem)rane connects with the magnetic core

placed in a coil The mem)rane will movetogether with the iron core when the inta"e air

pressure in the inta"e pipe changes In this case,

the output voltage of the sensor will also

change The EC' can convert the output voltage

of sensor to the inta"e capacity of the engine

*ased on this signal, another signals will )e

referred to control the fuel injection volume of

the engine

The intake temperature sensor element is aresistor with negative temperature coefficient

+#TC, the resistance value of which will

decrease as the increase of the inta"e

temperature The EC' of engine can monitor

the change of inta"e temperature through its

internal comparison circuit

Installation' Installed on the #o 1 cylinder$s

inta"e manifold, and the cylinders are detected

)ased on the instantaneous pressure drop whenthe air inta"e opens

!)solute pressureinta"e temperature sensor for

inta"e manifold

Circuit .iagram of the a)solute pressureinta"e

temperature sensor for inta"e manifold

/

T11 Inta"e pressure

temperature sensor

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rou(leshooting'

1 Mainly e%amine the short or open circuit

)etween the four wires on sensor and the

EC'

/ E%amine the clog of the sensor$s detection

hole

0 E%amine the short or open circuit and the

grounding among the harnesses of sensor

E%amine the sensor$s impact received to

cause the sensor failure

)# &etection pressure range' 1%kPa to 11%

kPa

rou(le &iagnosis'

1 Short circuit of the sensor$s wire +shorted to

earth, or shorted to supply2

/ 3pen circuit of the sensor$s wire2

0 The inta"e pressure detected )y sensor is

greater than its upper limit2

The inta"e pressure detected )y sensor is

less than its upper limit2

Pin'

1 #o1 +! for the signal from inta"e pressure

sensor +to EC' /42

/ #o/ +* for the standard 56 power supply

+to EC' 42

0 #o0 +C for the signal from the inta"e

temperature sensor +to EC' /742

#o +. for the ground wire of sensor +to

EC' /14

Operating temperature range' *+%

to 1$)

Operating ,oltage' ).%,

%.1,

0

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$. hrottle Position Sensor !PS#

-pplication' "$% T8S +Throttle 8osition

sensor is availa)le to provide the EC' with the

information a)out the throttle$s opening angle

and angular /elocity and the idle position of

the engine *ased on the information, EC' can

o)tain the engine$s information on load and

operating condition +such as startup, idle,

reverse towing, part load and full load as well

as acceleration and deceleration This sensor is a

three-wire sensor !nd the EC' detects the

opening of throttle through the monitoring on

the voltage change

8rofile of a throttle position sensor

Structure and Principle'This sensor is with

the slip resistance structure +ie the linear

varia)le resistance structure The EC'

monitors the voltage among the signal output

terminals and gets the opening signal of the

throttle through the circuits comparison

conducted inside the computer In the EC', the

voltage signal is not received directly )ut rather

the input-to-output signal ratio is detected,

which can avoid the signal fluctuation generated

due to the voltage fluctuation

rou(le &iagnosis'

The signal from throttle position sensor is

greater than the measuring range2

The signal from throttle position sensor is less

than the measuring range2

Short circuit of the throttle position sensor

signal connection2

3pen circuit of the throttle position sensor

signal connection2

0-2I23' It is generally prohi)ited to

disassem)le the throttle position sensor which

has adjusted to its optimal position )efore it

T11 Throttle 8osition Sensor

Circuit diagram of the throttle position sensor

Pin'

1 #o1 +! for the standard 56 power supply

+to EC' /942

/ #o/ +* for the ground wire of sensor +to

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leaves factory

Installation'The allowa)le tightening tor:ue of

the tightening screw is 15 #m to /5 #m

rou(leshooting'


)etween the three wires on sensor and the

EC'

/ E%amine the short or open circuit and the


0 E%amine the jump )etween the sensor signal

terminal and the ground wire, which is

detected with the universal meter

E%amine the sensor$s resistance which is

evidently greater than the standard value,

the season of which may )e that the interior

of sensor is dirty

EC' 54

0 #o0 +C for the signal from the sensor +to

EC' /42

Operating ,oltage' )4%.1 ,

Opening ange' 56 to 786

esistance of Sensor' 8 k9 to 1$ k9

Output signal during the close of throttle'

%.:1$ to %.);; ,

Output signal during the full open of throttle'

+.1) to +.:) ,

5

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8. Coolant emperature Sensor !

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The three >iresof the sensor are respectively;

a The 56 standard power supply wire2

) The sensor signal wire +for EC'2

c The sensor signal wire +for

instruments

rou(leshooting'


)etween the three wires on sensor and the

EC' or instruments

/ E%amine the short or open circuit and the


0 E%amine the )ad wire earth or earth, which

easily cause the over-high temperatureindicated on the water temperature gauge of

the engine

Characteristic Parameters !Standard ,alue#'

*1%

1:1$%

%

7877

$%

8)11

:%

:51

7%

$+1

Operating ,oltage' ), &C

Opening emperature ange' *+%

to 18)

+. Knock Sensor !KS= K2K#

-pplication' This sensor is used to provide the

EC' with the "noc" information of the engine to

conduct the "noc" control

Structure and Principle'The "noc" sensor is a

"ind of vi)ration acceleration sensor mounted on

the cylinder )ody of an engine It is generally

installed )etween the #o / cylinder and the #o 0

cylinder, which is in favor of the "noc" )alance of

the engine The EC' utili(es the vi)ration

fre:uency signal output from the "noc" sensor to

determine the "noc" of the engine through the

wave filtering inside the EC' ?hen the "noc"

signal is detected, the EC' will gradually reducethe "noc" till there is no "noc", and then gradually

resume the "noc" till up to the upper limit of

"noc" Aepeat this procedure a)ove

8rofile of a "noc" sensor with ca)le

7

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rou(le &iagnosis' The EC' monitors the

"noc" sensor, power amplification circuit and

testing circuit The fault flag of the "noc"

sensor will )e set if one of the following

conditions occurs;

1 The "noc" sensor fails2

/ The "noc" control data processing circuit

fails2

0 There are some insincere cylinder detection

signals2

The sensor wire fails

!fter the fault flag of the "noc" sensor is set,

the closed-loop control for "noc"ing closes and

then the ignition advance angle stored in the

EC' is identified as a safety angle )y the

software program The fault flag resets when

the error fre:uency drops down to the setting

value )elow

Installation

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). O@ygen Sensor !O$S#-pplication' This sensor is used to provide the

information a)out weather the o%ygen is

superfluous after the fuel injected into the

engine cylinder fully com)ust together with air

inta"e *ased on these information, the EC'

can conduct the fuel :uantitative closed-loop

control to convert and purify three main to%ic

components, ie DC, C3 and #o% which e%ist

in the engine e%haust, with the help of three-

way catalytic converter

Structure and Principle'The sensing element

of the o%ygen sensor is a "ind of ceramic tu)e

with small holes, which the outside of tu)e wall

is surrounded )y the engine e%haust while the

inside is full of air *ased on the o%ygen

concentration difference )etween the inside and

the outside, the sensor indirectly figure out the

pulse width of the fuel injection, transmit the

width to the EC', and then the EC' controls

the fuel injection again !t the same time, The

output data from the rear o%ygen sensor are

detected, and, in the EC', the data from thefront and rear o%ygen sensors are compared to

monitor the operation of three-way catalytic

converter

The operating voltage of the o%ygen sensor

fluctuates at the range of 91 to 9B 6, and

changes 5 to times every 19 seconds If the

change fre:uency is less than this specified

fre:uency, it indicates that the sensor is aged

which needs to replace This sensor is difficultto repair

rou(le &iagnosis'

The EC' detects the o%ygen sensor, wires and

the power amplification circuit and testing

circuit inside EC' The fault flag of o%ygen

sensor will )e set if one of the following

conditions occurs;

8rofile of a o%ygen sensor

T11 3%ygen Sensor

Circuit diagram of front o%ygen sensor

!ll front o%ygen sensors have the ca)les The

other end of a ca)le is the electrical connectionThere is a layer of as)estos fireproof covering

around the outside of the sensor

B

Main Aelay

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1 There is the insincere )attery voltage2

/ There are some insincere inta"e manifold

a)solute pressure signals2

0 There are some insincere engine coolant

temperature signals2

The fuel injector driving level fails

!fter the fault flag of the o%ygen sensor is set, the

fuel :uantitative closed-loop control closes, and

then the )asic injection time stored in the EC' is

applied to determine the fuel injection :uantity

Installation

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ear O@ygen Sensor !O$S#

The structure and detection of the rear o%ygen

sensor are similar to the front o%ygen sensor,

)ut the purpose that a vehicle e:uips with the

frontrear o%ygen sensor is considera)ly

different

Purpose'

Front O@ygen Sensoris mainly used to detect

the o%ygen content of the e%haust and further

determine the fuel injection :uantity The

sensor converts the o%ygen content of e%haust

after com)ustion into the electric signal, and

then transmits the signal to the EC' The EC'

utili(es these signals to control the pulse width

of fuel injection, regulate the air-fuel ratio, and

indirectly control the e%haust emission of the

engine

ear O@ygen Sensor is mainly used to detect

the o%ygen content of e%haust after thecompletion of three-way catalytic conversion

The sensor converts this signal into the point

signal, and transmits it to the EC' The EC'

compares the signals from the front and rear

o%ygen sensors and then determines the

operation of the three-way catalytic converter

The trou(le diagnosis= trou(leshooting=

signal detectionand other characteristics of the

rear o%ygen sensor are the same as the front

o%ygen sensor

Internal structural diagram of a o%ygen sensor

T11 3%ygen Sensor

Circuit diagram of rear o%ygen sensor

-ny connection has four pins'

1 #o 1 +! for the o%ygen sensor signal low

level +to EC' @42

/ #o / +* for the o%ygen sensor signal high

level +to EC' 042

0 #o 0 +C for the power supply of the main

relay2

#o +. for the sensor heater wire control

+to EC' @4

11

Main Aelay

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:. Electronic Control nit !EC#

-pplication'

!n EC' is an electric engine control center )ased

on the microprocessor, with the sensor signal input

interface and actuator drive circuit It receives and

processes the engine status signals from any

sensor, and transmits the control signal to the

actuators to ena)le the engine to operate in

accordance with the preset procedure It ma"es the

engine in the optimal condition and ensures the

)etter dynamics, fuel-effective and emission

2ormal operating /oltage' 7 to 1:,

O/er/oltage protection' A$+,B*1$, :% s

Structure' with the shielded casing and 8C*

+8rinted Circuit *loc" There are a majority of

electronic control units in a circuit )oard, which is

applica)le for the control of electronic fuel

injection system

Installation'Mounted under the water chute of the

front windscreen with the help of a support andvehicle computer +EC' 8ay more attention to

waterproof

Operating temperature' *+%

to 1%)

8rofile of a EC'

Functions'

Multipoint se:uential fuel injection system2

rouping ignition system2

Idle control2

!utomatic "noc" closed-loop control2

8rovide sensor with the power supply;

56199m!2

Fclosed-loop control, with the self-adapting2

.ual o%ygen sensors2Emission canister control2

!C EC' control2

Engine failure lamp2

Engine speed signal output2

Trou)le self-diagnosis, with the flash code

function2

Aeceive the engine load signal

rou(leshooting' EC' is an electronic

control unit .ue to its lower fault rate, in

general, it is not recommended to adapt the

EC' replacement to solve all pro)lems

Carefully e%amine the faults of the periphery

circuits, sensors and other components,

confirm that there is no fault in the periphery

components, and then it is considered to

replace the EC'

1/

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5. Electric Fuel Pump !P"P#

-pplication'?ith the specified fuel pressure and

flow rate, this pump transmits the fuel from the

fuel tan" to the engine$s main fuel supply pipe, and

"eeps the sta)le fuel pressure +)y the fuel pressure

regulator

Structure and Principle'The electric fuel pump

consists of the .C motor, vane pump, end cover

which integrates with the chec" valve,

decompression valve and EMI components and

other elements The pump is installed coa%ially

together with the motor, and sealed in the same

casing The ma%imum pressure of the electric fuel

pump outlet depends on the decompression valve,

the range of which is +)% kPa to :)% kPa

Dowever, the pressure of the whole fuel system

depends on the fuel pressure regulator, and, for the

" $% electronic fuel injection system= the

pressure is generally 8)% kPa.

C-IO2'In case that the fuel tan" of a vehicle

is short or lac" of fuel for a long time, the fuel

pump will )e difficult to o)tain the full lu)rication,

which ma"es the fuel pump sintered Especially,

for the engine ta"ing C# and G8 as its fuel, the

fuel tan" of this "ind of engine is generally in the

state of no fuelor lack fuelfor a long time, and its

fuel pump fails to )e fully lu)ricated for a long

time, which result in the damage of fuel pump

The temperature of fuel ma"es more influence on

the performance of fuel pump ?hen the fuel

pump operates at the high temperature for a long

time and the temperature of fuel is greater than the

specified temperature, the fuel pumping pressure

of the fuel pump will drop steeply Thus, if the

engine fails to start during the period of vehicle

warm up, please carefully e%amine and confirm

whether the high temperature operating

performance of the fuel pump is )ad

8rofile of a electric fuel pump

Circuit diagram of electric fuel pump

Pin' The electric fuel pump has two pins

which connect to the fuel pump relay There

are sym)ols HJ and H-H stamped on the fuel

pump casing near these two pins, which

means the connection to the positive and

negative electrode respectively

EC' @4 pin is applied to control the fuel

pump relay

10

Main Supply

.ynamic Aelay

T11 Kuel 8ump Control

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he fuel pump lu(ricating and cooling are

implemented >ith the help of the gasoline in

the fuel tank.

The fuel tan" of this vehicle is a saddle-shaped

tan", with two fuel pump openings

&ecompression pressure' 7%% kPa

Operating /oltage' ; to 1: ,

Fuel pump resistance' 18%

The injection pump in the reserve tan" is used

to pump the fuel return to the main fuel tan"

rou(leshooting' The fuel pump failures are

generally the fuel pressure shortage, non-

pumping and etc .uring the period of

trou)leshooting, e%amine the fuel pressure of

the system is within the specified range, and

also e%amine the lea"age of pipeline

In addition, )oth the positive and the negative

pressure will ma"e influence on the fuel

system

;. Electromagnetic Injector !I2D#-pplication' " $%employs the se:uential fuel

injection technology The se:uential injection

signals are provided )y the inta"e pressure sensor

+TEM8 If the TEM8 is damaged, the mode of

grouping injection is applied to control the fuel

injection in accordance with the ignition se:uence

*ased on the instructions from EC', the fuelinjector injects the fuel within the specified time,

offers engine the fuel and atomi(es them

Structure and Principle' The EC' emits the

electrical pulse to the injector coil, which forms

the magnetic field force ?hen the magnetic field

force rises up enough to con:uer the resultant force

of the return spring pressure, gravity force of

needle valve and frictional force, the needle valve

starts to rise, and the fuel injection process )egins?hen the fuel injection pulse ends, the pressure of

return spring ena)le the needle valve to )e closed

again

8rofile of a electromagnetic injector

T11 Kuel Injector roup

Circuit diagram of electromagnetic fuel

injector

1

Main Aelay

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Installation

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7. Idle -ctuator Stepper "otor !I&E#Function' Control the air flow area of )ypass

channel in the throttle valve, and further control

the air inta"e :uantity of the engine *ased on the

signals from all sensors, the EC' can control the

engine speed within the target speed range which

can )e cali)rated in accordance with the coolant

temperature

Structure and Principle' In fact, a stepper motor

is a micro-motor Since the coil of motor passes

through different directional currents, the motor

will rotate in different direction The rotary shaft of

the motor will drive the threaded spindle

movement and indirectly control the opening of

the valve MT /9' emits the digital s:uare wave

signal to control the ahead-reverse rotation and

further control the stro"e of the stepper motor

rou(le &iagnosis' The EC' can monitor the

short or open circuit of two coils of the idle stepper

motor, and light the engine failure lamp when

these trou)les occur, which means that the engine

switches to the failure mode

It also monitors the short or open circuit )etweenthe four wires of sensor and the EC'

EC' can$t monitor the trou)les generated )y the

mechanical part of the motor

rou(leshooting' E%amine the short or open

circuit of four wires connection )etween the

stepper motor and the EC'

E%amine the jamming of the stepper motor

E%amine the short or open circuit inside the

stepper motor

.isassem)le the stepper motor, power on, and

then e%amine the fle%i)ility of the stepper motor

The car)on deposit and dirty material in the

inta"e system will ma"e an influence on the

operating performance of stepper motor

esistance of motor coil' );.8 to +5.5

Operating /oltage' 5.) to 1:,

8rofile of idle actuator stepper motor

T11 Idle Stepper Motor

Circuit diagram of idle actuator stepper motor

Pin'1 #o 1 +* for idle actuator stepper motor

control +to EC' 0042

/ #o / +! for idle actuator stepper motor

control +to EC' 042

0 #o 0 +. for idle actuator stepper motor

control +to EC' 542

#o +. for idle actuator stepper motor

control +to EC' 5042

1@

Air

Throttle Valve Body

Idle Control Valve

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1%. Ignition Coil !COI#Function'The ignition coil changes the low

voltage passing through primary winding to the

high voltage through the secondary winding,

creates the spar"le with the help of the ignition

plug discharge to ignite the fuel-air mi%ture in

the engine

Structure and Principle'MT /9' adapts the

grouping ignition technology, which, )ased on

this principle that the mutual inductance of

electromagnetic coils can create higher energy,

controls the power on hours and power off time

of the primary coil It applies the high voltage

generated in the secondary coil to )rea" down

the ignition plug clearance, create strong

spar"le and ignite the mi%ture .ue to there are

many ioni(ed airs, lower electrical resistance

during the stro"e of engine e%haust, only lowest

voltage is re:uired to )rea" down the ignition

plug clearance Thus, this system employs the

grouping ignition technology, which can$t waste

the energy and may save cost

rou(le &iagnosis' The EC' doesn$t have the

function to conduct the trou)le diagnosis on the

ignition coil Thus, if the ignition coil fails to

operate, it doesn$t create any fault code 3nly

e%amination of ignition coil resistance is

availa)le to determine the normal operation of

ignition coil In the normal condition, the

heating value of ignition coil is great during the

operation of the coil, )ut the over-high

temperature of the ignition coil will result in theincrease of its resistance value, and further

cause the unsta)le engine operation, automatic

stop operation and other failures Dowever, the

EC' can monitor the control >ires of the

ignition coil;

1 Control wires short circuit to earth2

/ Control wires short circuit to power supply2

0 Control wires open circuit

8rofile of ignition coil

T11 Ignition Coil roup

Circuit diagram of ignition coil

Pin'

1 #o 1 +C for the coil primary winding +to

EC' 0/42/ #o / +! for the coil primary winding +to

EC' 5/42

0 #o 0 +* for the coil power supply +to the

main relay of the system

17

MainAelay

Digh-6oltagecoil

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"easures on trou(les'3nce one ignition coil

failure is detected, close the fuel injector of the

corresponding cylinder

C-IO2' The over-high temperature of

ignition coil may cause the )ad operation of

engine ignition system

esistance of ignition coil primary >inding'

%.)) to %.+) K

esistance of ignition coil secondary

>inding' ).: to +.; K

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C-IO2'

he pressure must (e released firstly (efore

the fuel system is repaired= and it must (e

ensured that there is no pressure oil in the

fuel pipeline. Pull out the connection of fuel

pump= and then put on the (rake till the

/ehicle stops. In this case= there is already no

pressure oil in this system. -fter repair= the

fuel shall (e pumped to the system firstly

>hen the /ehicle starts initially= the method

of >hich is' to turn on the ignition s>itch=

and turn off it after the completion of self*

checking. epeat this procedure 8 to + times.

1$. Crankshaft Position Sensor !Speed Sensor# !CKPS#-pplication' The cran"shaft position sensor is

used to provide the EC' with the engine$s

speed= turning angle= top dead center signals

which are applied in the engine ignition, fuel

injection and timing system

Structure and Principle' The MT /9'

electronic fuel injection system employs the

magnetic induction coil type speed sensor,

applies the rotation to cut the magnetic force

lines and generate the alternating current and

voltage signals The EC' receives the

alternating signals, shapes these signals, and

then changes them into the digital signals that

can )e identified )y the EC' and applied in the

system control of engine The flywheel ring

gear is installed together with the signal wheel

The latter adapts the 5L gear form, andprovides the EC' with speed= turning angle=

top dead center There is the #o 1 cylinder$s

top dead center in the continuous gap

8rofile of a cran"shaft position sensor

1B

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rou(le &iagnosis'

The EC' will real-time monitor the sensors and

wires;

1 The sensors has no signal output2

/ The sensor$s output signal is distorted2

0 The sensor signal wire is short circuit2

The sensor signal wire is open circuit

rou(leshooting'

1 E%amine the wires of sensor, and the earth

or short circuit of wire2

/ !pply the three-way instrument to connect

the joints )etween the sensor and harness

and e%amine the connection of power

supply, earth wire and signal wire

Operating temperature' *+% to 1)%

Clearance (et>een the sensor and ring gear'

%.8 to 1.) mm

esistance of sensor' )%+to :1:

T11 Cran"shaft 8osition Sensor

Circuit diagram of cran"shaft position sensor

Pin'

1 #o 1 +! for sensor signal wire high level

+to EC' 1/42

/ #o / +* for sensor signal wire low level

+to EC' /42

0 #o 0 +C for sensor earth +to EC' 704

18. Canister Control Solenoid ,al/e !E,-P#-pplication'It is used to control the rinse air

flow from the canister to the inta"e main pipe

The adsorptive capacity of the canister is

limited If the evaporated gasoline adhesive to

the canister aren$t used out, the gasoline will

volatili(e to the outside and pollute the air as

well as increase the insecure factors

8rofile of a canister control solenoid valve

/9

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Structure and Principle' There is a solenoid

valve organi(ation inside the canister control

solenoid valve The digitali(ed control pulse

s:uare wave from the engine will control the

opening of the solenoid valve *ased on the

different operation conditions of the engine, the

openings of the canister control solenoid valves

are different ?hen the engine is operating with

large load and idle, the canister control valve

doesn$t put into operation in order to ensure the

output power of engine

rou(le &iagnosis'

1 The sensor-earth wires are short circuit2

/ The sensor-supply wires are short circuit2

0 The sensor wires are open circuit

rou(leshooting'

1 E%amine the short or open circuit of sensor

wires2

/ E%amine the wire jumping among

harnesses2

0 E%amine the short circuit )etween the

sensor and power supply2

+# E%amine the jamming inside the canistercontrol solenoid valve and its ventilation

Operating temperature' *+% to 1$%

esistance of coil' 17 to $$

Operating /oltage' ; to 1: ,

ated operating /oltage' A1$,

T11 Canister Control Solenoid 6alve

Circuit diagram of canister control solenoid

valve

Pin'

1 #o 1 +! for the solenoid valve control +to

EC' @042

/ #o / +* for the power supply of main

relay

/1

Main Aelay

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1+. -ir Conditioning Control System !-BC#Principle'Turn on these !C switches If )oth

the !C pressure and the data detected )y the

evaporator temperature sensor are normal, the

!C re:uest signal will pass through these

switches and get to the EC' The EC' controls

the !C relay attracting after it detects this signal

!t the same time, it gives stepper motor a speed-

increasing signal, and switches on the electronic

fan !nd the !C system )egins to operate

Conditions to s>itch off -BC system'

1 Throttle position sensor failure2

/ 6ehicle speed sensor failure2

0 ?hen the engine is with large load2

Evaporator temperature sensor failure2

5 The evaporator temperature is less than

15;

@ The engine speed is overspeed2

7 The coolant temperature is greater than

192

Aefueling is too :uic"

rou(le &iagnosis'

1 Short circuit of !C relay wire to earth2

/ Short circuit of !C relay wire to power

supply2

0 3pen circuit of !C relay wire2

Too-low evaporator temperature sensor

temperature2

5 3ver-high evaporator temperature sensortemperature

rou(leshooting'

1 E%amine the wire of !C system2

/ E%amine the damage of !C system$s

evaporator temperature sensor2

0 E%amine the wire jumping inside the

harness

Circuit diagram of !C control system

Pin'

#o 1 for the !C re:uest signal +to EC'

0B42

#o / for the !C relay control +to EC' @4

//

!C Ae:uest Signal

8ower Supply

!C Compressor Clutch

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1). Fan Control !F-2#" $%controls the fan$s lowhigh speed *ased on

the water temperature, air conditioning and other

signals, the control system can control the fan$s low

and high speed operation If the condition is

applica)le, the " $%will control the fan system

delay

Control "ode'

Kor 1stgear, the fan is switched on at B and

switched off at B2

Kor /ndgear, the fan is switched on at 195and

switched off at 1912

If the water temperature is greater than 191

after the fan is switched off, the fan continues to

operate for 1 minute2

If the water temperature is greater than Bafter

the fan is switched off, the fan continues to

operate for 95 minute2

If the water temperature is less than 5after the

fan is switched off, the fan stops2

rou(le &iagnosis'

1 Short circuit of high-speed relay wire to power

supply2

/ Short circuit of high-speed relay wire to earth2

0 3pen circuit of high-speed relay wire2

Short circuit of low-speed relay wire to power

supply2

5 Short circuit of low-speed relay wire to earth2

@ 3pen circuit of low-speed relay wire2

rou(leshooting'

In EC' side, e%amine the short or open circuit of

these wires in accordance with the pins shown in the

left figure

Circuit diagram of fan control system

In this figure a(o/e= the highBlo> speed

pins are the same as the actual pins. Gut

the actual circuit diagram is different from

this circuit diagram a(o/e. he latter is for

reference only.

/0

Main Power Supply

.ual-Speed Kan

Digh-speed fan relay

Gow-speed fan relay

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1:. &efinition of EC Pins

8in Connection 8oint Type 8in Connection 8oint Type

1 Ignition switch control fire wire

+supply

Input / 'nused

0 Speed signal sensor Input 56 standard power supply 3utput

5 56 standard supply earth wire Earth @ Kront o%ygen sensor signal +low level Input

7 'nused 'nused

B 'nused 19 'nused

11 .iagnosis communication 3utput 1/ Speed sensor signal +high level Input

10 'nused 1 'nused

15 'nused 1@ 'nused

17 *attery supply +1/6 Input 1 *attery supply +1/6 Input

1B 'nused /9 56 standard power supply 3utput

/1 56 standard power supply earth wire Earth // 'nused

/0 'nused / Throttle position sensor signal Input

/5 'nused /@ !C evaporator temperature sensor Input

/7 Inta"e manifold temperature sensor Input / Speed sensor signal +low level Input

/B 'nused 09 .iagnosis re:uest Input

01 Engine failure lamp Input 0/ Ignition switch 1 and Input

00 Idle stepper motor drive coil * 3utput 0 Idle stepper motor drive coil ! 3utput

05 'nused 0@ 'nused

07 'nused 0 Aear o%ygen sensor signal +low level Input

0B !C re:uest signal Input 9 'nused

1 'nused / !ir inta"e pressure sensor signal Input

0 Coolant temperature sensor signal Input 'nused

5 Engine speed signal 3utput @ !C relay control 3utput

7 Kuel pump relay control 3utput 'nused

B 'nused 59 Kan high-speed control Input

51 'nused 5/ Ignition coil / and 0 Input

50 Idle stepper motor coil C 3utput 5 Idle stepper motor coil . 3utput

55 Kuel injector 14 Input 5@ Kuel injector /4 Input

57 'nused 5 'nused

5B 'nused @9 'nused

@1 Kront o%ygen sensor heating control Input @/ Kront o%ygen sensor signal +high level Input

@0 Canister control solenoid valve

control

Input @ Aear o%ygen sensor heating control Input

@5 'nused @@ 'nused

@7 Kan low-speed control Input @ 'nused

@B &noc" sensor signal Input 79 Kuel injector 04 Input

71 Kuel injector 4 Input 7/ 'nused

70 Motive earth Earth #o

/

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Section

Gasic Principles of rou(le &iagnosis

1. Gasic Principles1# Failure Information ecord

" $% electronic control unit continuously detect sensors, actuators, related circuits, failure

lamps, )attery voltage and etc, even detect the electronic control unit itself, and conduct the

relia)ility detection on the sensor output signal, actuator drive signal and internal signal +such

as o%ygen closed-loop control, "noc" control, idle speed control, )attery voltage control and

etc 3nce one failure in a certain process occurs, or one signal value is unrelia)le, the

electronic control unit will immediately set a failure information record in the failure register

of A!M The failure information record will )e stored with the form of failure code, and

displayed in the se:uence of failure occurrence

These failures can )e divided into HSta(le FailureJ and HChance FailureJ +such as the

failures caused )y the transient harness short-circuit or the )ad contact of connecting parts in

accordance with their fre:uency of occurrence

$# Failure State

If the duration of a identified failure occurrence is initially greater than the setting sta)ili(ed

time, the EC' will confirm it is a sta)le failure, and store it as the HSta)le KailureJ If this

failure disappears, it will )e stored as HChance KailureJ and H#one%istentJ If this failure is

identified again, it still )e a HChance KailureJ, )ut a He%istentJ history failure doesn$t ma"e an

influence on the normal operation of a engine

8# Failure ype

a Short circuit to the positive electrode of power supply2

) Short circuit to earth2

c 3pen circuit2

d Signal unrelia)le

+# Four Failure ypes

Failures of -ll Electronic Fuel Injection ,ehicle -re Gasically &efined -s hese ypes.

a Ma% failure, which means its signal is greater than the upper limit of normal

range

) Min failure, which means its signal is less than the lower limit of normal

range

c Signal failure, without signal

d 'nreasona)le failure, with signal, )ut the signal is unreasona)le

/5

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)# imp*home

Kor some identified important failures, when their duration e%ceeds the setting sta)ili(ed time,

the EC' will apply appropriate software countermeasure to maintain the operation of the

engine and ena)le the vehicle not to stop in its way

:# Failure -larm

" $% electronic fuel injection system is e:uipped with a failure lamp ?hen some

important parts, such as the EC', inta"e manifold a)solute pressure sensor, throttle position

sensor, coolant temperature sensor, "noc" sensor, o%ygen sensor, fuel injector, two drivers of

idle actuator stepper motor, !C relay, fan relay and etc, fail to operate and the corresponding

failure flags are set, the EC' will ena)le the failure lamp to flash and give alarm to warn the

owner of the vehicle that your vehicle has already entered into the failure mode, till the failure

flag is reset

5# &efinition of &iagnosis Connector Interface

5.

;# Failure eadout (y Engine Failure amp

?hen the engine system or its components failure occurs during the operation of engine, the

engine failure lamp will light automatically to remind the driver to e%amine and repair hisher

vehicle in time

.uring the emergency failure handling, you also may conduct some special operations to

ena)le the engine failure lamp to flash fre:uently so as to read the engine failure code, which

is the most economical means to o)tain the failure code Its operation method is as follows;

/@

.efinition of .iagnosis Connector Interface

#'GG 1@ 1/ 6

7 Communication 15 #'GG

@ #'GG 1 #'GG

5 Earth ?ire 10 #'GG

Earth ?ire 1/ #'GG

0 #'GG 11 #'GG/ #'GG 19 #'GG

1 .iagnosis B #'GG

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E%amine and Confirm;

a The voltage of )attery shall ensure the engine gets its startup speed2

) The engine and the whole vehicle$s accessories shall )e in the state of shutdown2

c The throttle is fully closed2

d The transmission is placed in the neutral gear2

e The ignition switch is turned off2

f !pply wires to ena)le the diagnosis reuest terminal 1 of the failure diagnosis

connectors to short circuit with the earth >ire terminal + or)2

g Turn the ignition switch to 3#, )ut don$t start up the engine2

In this case, if the system currently has a failureor a history failure codeuncleared after

the failure removal, the engine failure lamp will flash in accordance with a certain rule, and

the output system detects the code of failure2 +the failure code is read out and, at the same

time, the idle control /al/ewill conduct the reset action2

!fter the completion of failure code readout, the ignition switch is turned off and the

diagnosis re:uest short-circuit wire is removed2

The rules that the failure lamp flashes to report the failure are;

Aeport the failure in accordance with the se:uence of failure code memori(ed2

0/ s pause )etween two failure codes The digits flash at the fre:uency of light for

9 s and e%tinguish for 9s, with 1/ s pause )etween two digits2

The num)er 9 flashes19 times, and other num)ers corresponds to the flash

num)ers2

Ta"ing the failure code 9119 and 90 as an e%ample;

If the diagnosis re:uest doesn$t interrupt, restart to report 9119 failure code

C-IO2' !fter the removal of failure, it is recommended to apply the failure diagnosis

instrument to clear these failure codes so as not to ma"e an influence on the failure detectionduring the ne%t repair

/7

.iagnosis re:uest short circuit to earth Turn on the ignition switch

Kailure lamp flashes for one time 8ause for 0/s 19 times 8ause for 1/s

1 time 8ause for 1/s 19 times 8ause for 0/s 19 times 8ause for 1/s

times 8ause for 1/s times 8ause for 1/s 0 times

8ause for 0/s

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IS3 B11-/ Standard .iagnosis Connector

7# emo/al of Failure Information ecord

!fter a failure is removed, the failure information record stored in a memory shall )e cleared

!lthough failure information has occurred when the ignition switch is turned on, it isn$t

recorded if it isn$t "ept up to the end of sta)ili(ed time

!fter the engine starts up successfully the specified times, the failure code will )e cleared

automatically

!pply a failure diagnosis instrument and the HKailure Memory AesetJ instruction to clear the

failure information record

8ull out the connector from EC' or remove the wires of )attery to clear the failure

information record stored in the e%ternal A!M

1%# Failure Search

!fter a failure information record is o)tained with the help of the means a)ove, only the

appro%imate location where the failure occurs is "nown, )ut it doesn$t mean that the failure is

found )ecause the reason to create a failure information may )e the damage of a electrical

component +such as sensor or actuator or EC', etc, open circuit of a wire, short circuit of a

wire to earth or the positive electrode of )attery, even may )e a mechanical fault

The failure is inherent, and its e%ternal e%pressive results are various "inds of symptoms

!fter a symptom is found, it is re:uired firstly to use a failure diagnosis instrument or some

flash codes to chec" whether there are some failure information records !nd, )ased on these

information records, the related failure shall )e removed Then, you can search the failure in

accordance with the symptom of the engine

/

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$. Engine Failure Code a(le&elphi " $% Engine "anagement System Failure Code a(le

Code .escription Code .escription

89195-1 3ver-high inta"e manifold a)solute

pressure sensor signal

890-1 Short-circuit )etween the wire of canister

control solenoid valve and the positive of

electrode power supply

89195-/ Too-low inta"e manifold a)solute

pressure sensor signal

890-/ 3pen circuit of the wire of canister

control solenoid valve or short circuit to

earth

89119-1 Too-low inta"e temperature sensor signal 899-1 Short circuit of radiator low-speed fan

relay drive circuit to the positive

electrode of power supply

89119-/ 3ver-high inta"e temperature sensor

signal

899-/ 3pen circuit of radiator low-speed fan

relay drive circuit or short circuit to earth

89115-1 Too-low coolant temperature sensor

signal

891-1 Short circuit of radiator high-speed fan

relay drive circuit to the positive


89115-/ 3ver-high coolant temperature sensor

signal

891-/ 3pen circuit of radiator high-speed fan

relay drive circuit or short circuit to earth

891/9-1 3ver-high throttle position sensor signal 89/-1 Short circuit of !C cooling fan relay

/B

.iagnosis Interface

8ower Supply

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drive circuit to the positive electrode of

power supply

891/9-/ Too-low throttle position sensor signal 89/-/ 3pen circuit of !C cooling fan relay

drive circuit or short circuit to earth

89109- #o o%ygen sensor signal 89599-9 #o vehicle speed sensor signal89105-1 Short circuit of o%ygen sensor heating

circuit to the positive electrode of power

supply

89595-9 Idle control error

89105-/ 3pen circuit of o%ygen sensor heating

circuit or short circuit to earth

895@9-1 3ver-high system voltage

89179-1 3ver-long o%ygen sensor indication of

time of rich air-fuel-ratio

89@97-9 &noc" control system failure

89179-/ 3ver-long o%ygen sensor indication of

time of lean air-fuel-ratio

89@59-1 Short circuit )etween the failure lamp

wire and the positive electrode of power

supply

89/91-9 Kuel injector ! +#o 1 cylinder circuit

failure

89@59-/ 3pen circuit of the failure lamp wire or

short circuit to earth

89/9/-9 Kuel injector * +#o 0 cylinder circuit

failure

81/09-1 Short circuit of main relay circuit to the

positive electrode of power supply

89/90-9 Kuel injector C +#o cylinder circuit

failure

81/09-/ 3pen circuit of main relay circuit or


89/9-9 Kuel injector . +#o / cylinder circuitfailure

81509-1 Short circuit of !C compressor relaycircuit to the positive electrode of power

supply

89/09-1 Short circuit of fuel pump relay to the

positive electrode of power supply

81509-/ 3pen circuit of !C relay circuit or short

circuit to earth

89/09-/ 3pen circuit of fuel pump relay or short

circuit to earth

81@9-9 EE8A3M error

890/5-9 *ad connection to the "noc" sensor 81@19-9 !nti-theft controller error

89005-9 #o 5L cran"shaft position sensor signal 81@19- ECM and anti-theft controller

communication error

89005- 5L cran"shaft position sensor signal

error

8/999-1 3ver-high temperature of front !C

evaporator

890/-9 Gow camshaft position signal 8/999-/ Too-low temperature of front !C

evaporator

890/-/ Digh camshaft position signal 8/991-1 3ver-high temperature of rear !C

evaporator

89051-1 Short circuit )etween the ignition coil 1-

cylinder drive circuit and the positive


8/991-/ Too-low temperature of rear !C

evaporator

89051-/ 3pen circuit of the ignition coil 1-

cylinder drive circuit or short circuit to

8/199-/ Short circuit of rear !C trip relay to

)attery

09

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earth

8905/-1 Short circuit )etween the ignition coil /-

0 cylinder drive circuit and the positive


8/199- 3pen circuit of rear !C trip relay or


8905/-/ 3pen circuit of the ignition coil /-0cylinder drive circuit or short circuit to

earth

8. "ethod of rou(le Shooting

Kailure Code; P%1%)*1 O/er*high intake manifold a(solute pressure sensor signal

Set emergency control scheme; Switch on the failure lamp till the failure disappears

01

T11 Inta"e 8ressureTemperature Sensor

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?hen the engine stops; B9 "8a

?hen the engine idles; N 5 "8a

?hen the engine operates; the pressure of manifold changes

as the opening of throttle

If the cylinder pressure detection technology is applied,

there is 59= of pro)a)ility that the fuel injection se:uence

has 0@9 degree of ram off

Connection terminal; MT

/9'

8ressureTemperature

Sensor

#ormal Measurement

Signal

56 reference voltage; 9 * 56

Manifold pressure signal; / ! 95 to 56

Sensor signal earth; /1 . 96

Condition for .etermination 8ossi)le Aeason !ctions

Engine operation

#o T8S failure

M!8 O B117 "8a

T8S P 1B11=

Kailure duration O /5 s

1 Short circuit of harness pressure

signal circuit to 56 reference

voltage circuit or the positive


/ Sensor damaged

0 ECM$s pressure signal input

interface failure

1 Aepair harness

/ Aeplace sensor

0 Aeplace ECM

Kailure Code; P%1%)*$ oo*lo> intake manifold a(solute pressure sensor signal


?hen the engine stops; B9 "8a

?hen the engine idles; N 5 "8a

?hen the engine operates; the pressure of manifold changes

as the opening of throttle

If the cylinder pressure detection technology is applied,

there is 59= of pro)a)ility that the fuel injection se:uence

has 0@9 degree of ram off


/9'

8ressureTemperature

Sensor

#ormal

Measurement Signal

56 reference voltage; 9 * 56

Manifold pressure signal; / ! 95 to 56



0/

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#o T8S failure

M!8 P 197 "8a

A8M P 1959 rpm

T8S O 175=

Kailure duration O /5 s

1 'nrelia)le connection of the

connecting parts

/ 3pen circuit of harness pressure

signal circuit

0 Short circuit of harness pressure

signal circuit to earth

3pen circuit of 56 reference

voltage circuit

5 3pen circuit of sensor signal earth

wire

@ Darness 56 reference voltage

direction is reverse with the

reference earth wire +this failure

may cause the damage of sensor

7 Sensor damaged

ECM$s pressure signal input

interface failure

1 Connect again

/ Aepair harness

0 Aepair harness

Aepair harness

5 Aepair harness

@ Aepair harness

7 Aeplace sensor

Aeplace ECM

Kailure Code; P%11%*1 oo*lo> intake temperature sensor signal


The air inta"e temperature shall )e e:ual to the coolant

temperature, )ut not more than /5


/9'

8ressureTemperature

Sensor

#ormal

Measurement Signal

Inta"e temperature signal; /7 C 95 to 56



00

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Engine operation time O 1/9 s

M!T P -0/5

Kailure duration O / s

1 'nrelia)le connection of the connecting

parts

/ 3pen circuit of temperature signal

circuit

0 3pen circuit of sensor signal earth

Short circuit of temperature signal wire

to the positive electrode of power

supply

5 Sensor damaged

@ ECM$s this signal input interface failure

1 Connect again

/ Aepair harness

0 Aepair harness

Aepair harness

5 Aeplace sensor

@ Aeplace ECM

Kailure Code; P%11%*$ O/er*high intake temperature sensor signal


The air inta"e temperature shall )e e:ual to the coolant

temperature, )ut not more than /5


/9

MT

/9'

Inta"e Temp

Sensor

8ressureTemperat

ure

Sensor

#ormal

Measurement Signal

Inta"e temperature signal; 05 /7 C 95 to 56

Sensor signal earth; / /1 . 96


Engine operation time O @9 s

M!T O 15


1 Short circuit of temperature signal

circuit to earth

/ Sensor damaged

0 ECM$s this signal input interface failure

1 Aepair harness

/ Aeplace sensor

0 Aeplace ECM

0

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T11 ?ater Temperature Sensor

Kailure Code; P%11)*1 oo*lo> coolant temperature sensor signal


!pply the inta"e temperature during startup, gradually

increase up to 7B5and then "eep this temperature


/9'

Coolant

Temperature

Sensor

#ormal

Measurement Signal

Coolant temperature signal; 0 * 95 to 56

Sensor signal earth; 95 ! 96


Engine operation time O 19 s

CTS P -0/5



connecting parts

/ 3pen circuit of temperature signal

circuit

0 3pen circuit of sensor signal to

earth

Short circuit of temperature signal

circuit to the positive electrode of

power supply

5 Sensor damaged

@ ECM$s this signal input interface

failure

1 Connect again

/ Aepair harness

0 Aepair harness

Aepair harness

5 Aeplace sensor

@ Aeplace ECM

05

To Instrument

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Kailure Code; P%11)*$ O/er*high coolant temperature sensor signal


!pply the inta"e temperature during startup, gradually

increase up to 7B5and then "eep this temperature


/9

MT

/9'

Coolant

Temperature

Sensor

#ormal

Measurement Signal

Coolant temperature signal; 0 0 * 95 to 56

Sensor signal earth; 07 95 ! 96


Engine operation time O / s

CTS O 105


1 Short circuit of temperature

signal circuit to earth

/ Sensor damaged

0 ECM$s this signal input interface

failure

1 Aepair harness

/ Aeplace sensor

0 Aeplace ECM

0@

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T11 Throttle 8osition Sensor

Kailure Code; P%1$%*1 O/er*high throttle sensor signal


.uring idle, set the opening of throttle position sensor as

9=2 for other speeds, the opening of throttle position sensor

changes as speed

The throttle position sensor automatic reset function pauses

The function to clear the remained fuel and air in a cylinder

pauses


/9'

Throttle 8osition Sensor #ormal

Measurement Signal

56 reference voltage; /9 ! 56

Throttle position signal; / C 95 to 56

Sensor signal earth; 95 * 96


Engine operation, )ut speed P 0999

rpm

#o M!8 failure, and M!8 P 79 "8a


1 Short circuit of sensor signal

circuit to the positive electrode of

power supply or the 56 reference

voltage circuit

/ Sensor damaged


failure

1 Aepair harness

/ Aeplace sensor

0 Aeplace ECM

07

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Kailure Code; P%1$%*$ oo*lo> throttle sensor signal


.uring idle, set the opening of throttle position sensor as

9=2 for other speeds, the opening of throttle position sensor

changes as speed

The throttle position sensor automatic reset function pauses

Clear function pauses

Connection terminal; MT /9 MT

/9'

Throttle 8osition Sensor #ormal

Measurement Signal

56 reference voltage; 0@ /9 ! 56

Throttle position signal; /@ / C 95 to 56

Sensor signal earth; 07 95 * 96


Kailure duration O / s 1 'nrelia)le connection of the

connecting parts

/ 3pen circuit of sensor signal circuit


circuit to earth

Sensor damaged


failure

1 Connect again

/ Aepair harness

0 Aepair harness

Aeplace sensor

5 Aeplace ECM

0

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T11 3%ygen Sensor

Kailure Code; P%18%*+ 2o o@ygen sensor signal


The air-fuel-ratio can$t )e closed-loop controlled


/9'

Deating-type

3%ygen Sensor

#ormalMeasurement Signal

System main power supply; Q C 1/6

Deating drive; @1 . 96

3%ygen sensor$s high signal; @/ * 9 to 1999m6

fluctuation

3%ygen sensor$s low signal; 9@ ! 96


0@9/m6 P o%ygen sensor signal P

501Bm6


#o T8S and M!8 failure

Coolant temperature O 7/

Enter the closed-loop fuel control state

T8S O 1915@=

Kailure duration O 15 s


connecting parts

/ 3pen circuit of sensor signal

circuit

0 Sensor poisoning or failure due

to over-heating

ECM$s this signal input interface

failure

1 Connect again

/ Aepair harness

0 Aeplace sensor

Aeplace ECM

0B

Main Aelay

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Kailure Code; P%18)*1 Short circuit of o@ygen sensor heating circuit to the

positi/e electrode of po>er supply

Set emergency control scheme; Switch on the failure lamp till the failure disappears, and

turn off the ignition switch

System closed-loop operating time postponed

Connection terminal; MT /9' Deating-type

3%ygen Sensor





fluctuation



Kailure duration O 1 s 1 Short circuit of heating drive

circuit to the positive electrode

of power supply

/ Sensor damaged


failure

1 Aepair harness

/ Aeplace sensor

0 Aeplace ECM

Kailure Code; P%18)*$ Open circuit of o@ygen sensor heating circuit or short

circuit to earth

Set emergency control scheme; Switch on the failure lamp till the failure disappears, and

turn off the ignition switch

System closed-loop operating time postponed


/9'

Deating-type

3%ygen Sensor





fluctuation



9

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#o main relay failure



connecting parts

/ 3pen circuit of harness$s this

heating drive circuit

0 Short circuit of harness$s this

heating drive circuit to earth

Sensor damaged


failure

1 Connect again

/ Aepair harness

0 Aepair harness

Aeplace sensor

5 Aeplace ECM

Kailure Code; P%15%*1 O/er*long o@ygen sensor indication of time of rich air*

fuel*ratio




/9'

Deating-type

3%ygen Sensor





fluctuation

3%ygen sensor$s low signal; 9@ ! 96Condition for .etermination 8ossi)le Aeason !ctions

3%ygen sensor signal O BB/@m6


#o T8S and M!8 failure


Enter the closed-loop fuel control state

T8S O 1915@=



circuit to 56 or 1/6 circuit

/ Sensor damaged


failure

1 Aepair harness

/ Aeplace sensor

0 Aeplace ECM

Kailure Code; P%15%*$ O/er*long o@ygen sensor indication of time of lean air*

fuel*ratio




/9'

Deating-type

3%ygen Sensor



Deating drive; @1 . 963%ygen sensor$s high signal; @/ * 9 to 1999m6

1

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fluctuation



3%ygen sensor signal P 5/90m6

Engine operation time O 9 s #o T8S and M!8 failure


Enter the closed-loop fuel control

state

T8S O 1915@=



circuit to earth/ Sensor highlow signal circuit

reverse

0 Sensor damaged


failure

1 Aepair harness

/ Aepair harness

0 Aeplace sensor

Aeplace ECM

T11 Kuel Injector roup

Kailure Code; P%$%1*% Fuel injector - !2o 1 cylinder# circuit failure

P%$%$*% Fuel injector G !2o 8 cylinder# circuit failure

P%$%8*% Fuel injector C !2o + cylinder# circuit failure

P%$%+*% Fuel injector & !2o $ cylinder# circuit failure


#'GG


/9'

Kuel #o((le #ormalMeasurement Signal

System main power supply; Q ! 1/6

Kuel injector ! +#o 1 cylinder; 55 * 9 to 1/6 appro%

s:uare

Kuel injector * +#o 0 cylinder; 5@ * 9 to 1/6 appro%

s:uare

Kuel injector C +#o cylinder; 71 * 9 to 1/6 appro%

s:uareKuel injector . +#o / cylinder; 79 * 9 to 1/6 appro%

/

Main Aelay

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s:uare


Ignition switch is turn on

Kuel pump operation normal

Ignition voltage O 196

1 Short circuit of

corresponding no((le circuit

to the positive electrode ofpower supply or to earth

/ 3pen circuit of

corresponding no((le circuit

0 'nrelia)le Sensor highlow

signal circuit reverse

#o((le circuit damaged

5 ECM$s this signal output

interface failure

1 Aepair harness

/ Aepair harness

0 Connect again

Aeplace

5 Aeplace ECM

Kailure Code; P%$8%*1 Short circuit of fuel pump relay to the positi/e electrode of

po>er supply


#'GG


/9'

Kuel 8ump Aelay #ormal MeasurementSignal

System main power supply; Q Aefer to Electrical

System .escription

1/6

Aelay drive; 7 Aefer to ElectricalSystem .escription

96 +3perating and 1/6+Stop

0

.ynamic Aelay

Main 8ower Supply

T11 Kuel 8ump Control

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Kailure duration O 15@/5 s 1 Short circuit of relay drive

circuit to the positive


/ Aelay damaged

0 ECM$s this signal output

control interface failure

1 Aepair harness

/ Aeplace relay

0 Aeplace ECM

Kailure Code; P%$8%*$ Open circuit of fuel pump relay or short circuit to earth


#'GG


/9'

Kuel 8ump Aelay #ormal MeasurementSignal

System main power supply; Q Aefer to Electrical

System .escription

1/6

Aelay drive; 7 Aefer to ElectricalSystem .escription

96 +3perating and1/6 +Stop


Kailure duration O 15@/5 s 1 'nrelia)le connection of the

connecting parts

/ 3pen circuit of the

connection system main

power supply circuit

0 Short circuit of relay drive

circuit to the negative


3pen circuit of relay drive

circuit

5 Aelay damaged

@ ECM$s this signal output


1 Connect again

/ Aepair harness

0 Aepair harness

Aepair harness

5 Aeplace relay

@ Aeplace ECM

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T11 &noc" Sensor

Kailure Code; P%8$)*% Gad connection to knock sensor

Set emergency control scheme; Switch on the failure lamp till the ignition switch is

turned off

!pply the safety ignition advance angle ta)leConnection terminal; MT

/9'

&noc" Sensor #ormal MeasurementSignal

&noc" signal; @B 9 to 1 6

Sensor signal earth; 95 96


5

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Kailure duration O 15@/5 s 1 'nrelia)le connection of the

connecting parts

/ 3pen circuit of "noc" signal

circuit


circuit to earth

Short circuit of "noc" signal

circuit to other circuits

5 Sensor damaged

@ ECM$s this signal output


1 Connect again

/ Aepair harness

0 Aepair harness

Aepair harness

5 Aeplace relay

@ Aeplace ECM

T11 Cran"shaft 8osition Sensor

Kailure Code; P%88)*% 2o );H crankshaft position sensor signal


#'GG

Engine is difficult to start up


/9'

Cran"shaft 8ositionSensor

#ormal MeasurementSignal

Digh signal from cran"shaft; 1/ ! O 99m6 sinusoidal

wave +with senor *

Gow signal from cran"shaft; / * O 99m6 sinusoidal

wave +with senor !System earth wire; 70 C 96

@

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Start up the engine

#o engine speed signal

M!8 decreases )y /B59B "8a

System voltage decreases )y 96

6ehicle speed P "mh



connecting parts

/ Aeserve connection of

highlow signal

0 3pen circuit of signal circuit

Short circuit of signal circuit to

other circuits

5 Sensor damaged

@ ECM$s this signal input

interface failure

1 Connect again

/ Aepair harness

0 Aepair harness

Aepair harness

5 Aeplace relay

@ Aeplace ECM

Kailure Code; P%88)*% 2o );H crankshaft position sensor signal


#'GG


/9'

Cran"shaft 8osition Sensor #ormal MeasurementSignal

Digh signal from cran"shaft; 1/ ! O 99m6 sinusoidal

wave +with senor *

Gow signal from cran"shaft; / * O 99m6 sinusoidal

wave +with senor !

System earth wire; 70 C 96


Engine operation

The num)er of teeth entering into

ECM isn$t e:ual to 5 during 5

continuous cycles

1 *ad shielding of signal circuit

/ Koreign metal materials in the

5L gear ring

1 !pply the

shielded wire

/ Clean the 5L

gear ring

7

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T11 Ignition Coil roup

Kailure Code; P%8)1*1 Short circuit (et>een the ignition coil 1*+ cylinder dri/e

circuit and the positi/e electrode of po>er supply


Stop the fuel injection for 1- cylinder

The target idle steps up to 1,/99 rpm

Connection terminal; MT Ignition Coil #ormal Measurement Signal

Main Aelay

Digh-6oltage Coil

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/9'

System main power

supply;

Q * 1/6

1- cylinder drive; 0/ C 9 to 1/ 6 appro% s:uare wave

signalInduction pea" value O 099 6

/-0 cylinder drive; 5/ ! 9 to 1/ 6 appro% s:uare wave

signal

Induction pea" value O 099 6


Kailure duration O 1/5 s 1 Short circuit of 1-

cylinder drive circuit to the

positive electrode of power

supply

/ Ignition coil damaged

0 ECM failure

1 Aepair harness

/ Aeplace ignition coil

0 Aeplace ECM

Kailure Code; P%8)1*$ Open circuit of the ignition coil 1*+ cylinder dri/e circuit or


Set emergency control scheme; Switch on the failure lamp till the failure disappears Stop the fuel injection for 1- cylinder


/9'

Ignition Coil #ormal MeasurementSignal

System main power supply; Q * 1/6

1- cylinder drive; 0/ C 9 to 1/ 6 appro% s:uare

wave signal

Induction pea" value O

099 6

/-0 cylinder drive; 5/ ! 9 to 1/ 6 appro% s:uare

wave signal

Induction pea" value O

099 6



connecting parts

/ Short circuit of 1- cylinder

drive circuit to the negative

electrode of system power

supply0 3pen circuit of 1- cylinder

1 Connect again

/ Aepair harness

0 Aepair harness

B

Kailure duration O 1/5 s

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drive circuit

Ignition coil damaged

5 ECM failure

Aeplace ignition coil

5 Aeplace ECM

Kailure Code; P%8)$*1 Short circuit (et>een the ignition coil $*8 cylinder dri/ecircuit and the positi/e electrode of po>er supply


Stop the fuel injection for /-0 cylinder

The target idle steps up to 1,/99 rpm


/9'

Ignition Coil #ormal MeasurementSignal



wave signal

Induction pea" value O 099

6


wave signal


6


59

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Kailure duration O 1/5 s 1 Short circuit of /-0 cylinder

drive circuit to the positive


/ Ignition coil damaged

0 ECM failure

1 Aepair harness

/ Aeplace ignition coil

0 Aeplace ECM

Kailure Code; P%8)$*$ Open circuit of the ignition coil $*8 cylinder dri/e circuit or



Stop the fuel injection for 1- cylinder


/9'

Ignition Coil #ormal Measurement Signal



wave signal

Induction pea" value O 099 6


wave signal


6


51

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Kailure duration O 1/5 s 1 'nrelia)le connection of

the connecting parts

/ Short circuit of /-0

cylinder drive circuit to the

negative electrode of

system power supply

0 3pen circuit of /-0

cylinder drive circuit

Ignition coil damaged

5 ECM failure

1 Connect again

/ Aepair harness

0 Aepair harness

Aeplace ignition coil

5 Aeplace ECM

5/

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T11 Canister Control Solenoid 6alve

Kailure Code; P%++8*

1

Short*circuit (et>een the >ire of canister control solenoid

/al/e and the positi/e of electrode po>er supply


Shut off the canister control solenoid valve


/9'

Canister ControlSolenoid 6alve



Solenoid valve drive; @0 ! 9 to 1/ 6 s:uare wave

signal


Kailure duration O / s 1 Short circuit of solenoid

valve drive circuit to the

positive electrode of power

supply

/ Solenoid valve damaged

0 ECM failure

1 Aepair harness

/ Aeplace solenoid

valvel

0 Aeplace ECM

50

Main Aelay

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Kailure Code; P%++8*$ Open circuit of the >ire of canister control solenoid /al/e or



Shut off the canister control solenoid valve


/9'

Canister ControlSolenoid 6alve



Solenoid valve drive; @0 ! 9 to 1/ 6 s:uare wave

signal


Kailure duration O 5 s 1 'nrelia)le connection of the

connecting parts

/ Short circuit of solenoid

valve drive circuit to the

negative electrode of system

power supply

0 3pen circuit of solenoid

valve drive circuit

3pen circuit with system

main power supply

connection circuit

5 Solenoid valve damaged

@ ECM failure

1 Connect again

/ Aepair harness

0 Aepair harness

Aepair harness

5 Aeplace solenoid valve@ Aeplace ECM

5

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Kailure Code; P%+;%*1 Short circuit of radiator lo>*speed fan relay dri/e

circuit to the positi/e electrode of po>er supply


#'GG

Kan doesn$t operate, till the water temperature increases

to Band then the high-speed fan activates


/9'

Gow-speed Kan Aelay #ormalMeasurement Signal

*attery; Q Aefer to Electrical

System .escription

1/6

Aelay drive; @7 Aefer to Electrical

System .escription

96 +3perating and

1/6 +Stop


Kailure duration O 0 s 1 Short circuit of relay drive

circuit to the positive electrode

of power supply

/ Aelay damaged

0 ECM failure

1 Aepair harness

/ Aeplace relay

0 Aeplace ECM

55

Main 8ower Supply

.ual-speed Kan

Digh-speed Kan Aelay

Gow-speed Kan Aelay

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Kailure Code; P%+;%*$ Open circuit of radiator lo>*speed fan relay dri/e circuit or



#'GG

Kan doesn$t operate +open circuit, till the water temperature

increases to Band then the high-speed fan activates

Kan operates normally +short circuit to earth

Connection terminal; MT /9' Gow-speed Kan Aelay #ormalMeasurement Signal

*attery; Q Aefer to Electrical System

.escription

1/6

Aelay drive; @7 Aefer to Electrical System.escription

96 +3perating and1/6 +Stop


Kailure duration O 0 s 1 'nrelia)le connection of the

connecting parts

/ Short circuit of relay drive circuit to

the negative electrode of power

supply

0 3pen circuit of relay drive circuit

3pen circuit with the )attery

connection circuit

5 Aelay damaged

@ ECM failure

1 Connect again

/ Aepair harness

0 Aepair harness

Aepair harness

5 Aeplace relay

@ Aeplace ECM

Kailure Code; P%+;1*1 Short circuit of radiator high*speed fan relay dri/e circuit to

the positi/e electrode of po>er supply


#'GG

Connection terminal; MT /9' Digh-speed Kan Aelay #ormal MeasurementSignal

*attery; Q Aefer to Electrical System

.escription

1/6

Aelay drive; 59 Aefer to Electrical System

.escription

96 +3perating and

1/6 +Stop


5@

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Kailure duration O 0 s 1 Short circuit of relay drive circuit

to the positive electrode of power

supply

/ Aelay damaged

0 ECM failure

1 Aepair harness

/ Aeplace relay

0 Aeplace ECM

Kailure Code; P%+;1*$ Open circuit of radiator high*speed fan relay dri/e circuit or



#'GG

Kan operates normally +short circuit to earth

Connectionterminal;

MT /9' Digh-speed Kan Aelay #ormalMeasurement Signal

*attery; Q Aefer to ElectricalSystem .escription

1/6

Aelay drive; 59 Aefer to Electrical

System .escription

96 +3perating and

1/6 +Stop


Kailure duration O 0 s 1 'nrelia)le connection of the connecting

parts

/ Short circuit of relay drive circuit to the

negative electrode of power supply

0 3pen circuit of relay drive circuit

3pen circuit with the )attery connection

circuit

5 Aelay damaged

@ ECM failure

1 Connect again

/ Aepair harness

0 Aepair harness

Aepair harness

5 Aeplace relay

@ Aeplace ECM

57

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T11 6ehicle Speed Sensor

Kailure Code; P%)%%*% 2o /ehicle speed sensor signal


#'GG

It is possi)le to ta"e some driving limit measures


/9'

6ehicle Speed Sensor #ormalMeasurement Signal

Sensor signal earth; 90 9 to 1/6 s:uare

wave


Engine operation

6ehicle speed P / "mh

M!8 P /5/ "8a

1,/99 rpm P engine speed P 5999 rpm

Throttle closed



connecting parts

/ Interrupt of signal circuit from

the automatic transmission to

instruments

0 Interrupt of harnesses from

instruments to ECM

6ehicle speed sensor damaged

5 Instrument failure

1 Connect again

/ Aeplace fle%i)le

shaft or signal

wire

0 Aepair harness

Aeplace vehicle

speed sensor

5 Aepair or

replaceinstrument

5

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@ ECM failure @ Aeplace ECM

T11 Idle Stepper Motor

Kailure Code; P%)%)*% Idle Control Error


8ause the idle control

Connection terminal; MT /9' Idle Control 6alve #ormal MeasurementSignal

Idle control valve !-high; 5 . 9 to 1/6 s:uare wave

+with idle valve C

Idle control valve !-low; 50 C 9 to 1/6 s:uare wave

+with idle valve .

Idle control valve *-high; 00 * 9 to 1/6 s:uare wave

5B

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+with idle valve !

Idle control valve !-low; 0 ! 9 to 1/6 s:uare wave

+with idle valve *


Engine idle operation?ater temperature reaches the normal

value

#o T8S and 6SS failure

.eviation from the target speed O 19

rpm


1 'nrelia)le connection of theconnecting parts

/ 3pen circuit of any circuit of

idle valve

0 Error of corresponding relation

)etween the idle valve

connecting parts and ECM

connecting parts

Inta"e manifold lea"age

5 Idle control valve damaged

@ ECM failure

1 Connect again

/ Aepair harness

0 Aepair harness

Aemove the lea"age

failure

5 Aeplace idle control

valve

@ Aeplace ECM

Kailure Code; P%):%*1 O/er*high system /oltage


The system stops fuel injection


/9'

Ignition Switch #ormal Measurement Signal

Ignition switch; 91 Aefer to Electrical

System .escription

1/6


Turn on the ignition switch

System voltage O 17/ 6


1 enerator regulator

damaged

/ Mista"enly apply the

high-voltage )attery

1 Aeplace the damaged

voltage regulator

/ !pply proper )attery

@9

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T11 &noc" Sensor

Kailure Code; P%:%5*% Knock control system failure

Set emergency control scheme; Switch on the failure lamp till the ignition switch is turned off

The ignition advance angle will postpone +apply safety

ignition advance control

Connection terminal; @B4 MT /9' ECM #ormal Measurement Signal

ECM; ECM internal failure Q


1 ECM failure 1 Aeplace ECM

@1

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Kailure Code; P%:)%*1 Short circuit (et>een the failure lamp >ire and the positi/e

electrode of po>er supply

Set emergency control scheme; #o light

Connection terminal; MT /9' System Kailure Gamp #ormal MeasurementSignal

Ignition switch; Q Aefer to Electrical System.escription

1/ 6

Gamp drive; 01 Aefer to Electrical System.escription

1/ 6 +3# and 9 6+3KK

Cond

Documents

CHAPTE~1