CONTENTS

Technician’s Notes

P020C Failure with Yusheng

Yusheng JMC

Zhai Hongzhi, Hebei Fujiang Automobile Trading Co., Ltd

P020C Failure with Yusheng

VEHICLE INFORMATION
Model: Yusheng
Mileage: 7,470km

Failure Description:When the engine was started from cold, blue smoke emitted from the rear
exhaust pipe; the engine jittered abnormally while the fault light was ON. The fault code is
P020C, which means that the injector of the 2nd cylinders has been powered for too long. This
fault code could not be deleted via KT600. It was judged as a computer program fault. The
engine was then mailed to the manufacturer in Nanchang for computer re-programming.
However, after the updated engine was assembled, the fault light didn’t come on, and the
engine emitted heavier blue smoke when started from cold along with more violent jitter.
Failure Analysis & Elimination:The car was previously repaired at a local service station and
later transferred to the central workshop. Based on the prompt of the fault that the injector of
the 2nd cylinder had been powered for too long, checks were then made. It was found that the
fuel return volume of the injectors of the four cylinders was within 10ml for 1 minute at idle
speed. Moreover, all four cylinders had the same quantity of return fuel. The fuel filter element
was found the original one and the fuel was clear and free of visible dirt. It was therefore
judged that the injectors had no fault.
Given the blue smoke problem with the car, we suspected that the pressure of the 2nd cylinder
of the engine was too low. Cylinder pressure gauge readings showed that the cylinder
pressure of the 1st, 3rd and 4th cylinders was 20kg, while the 2nd cylinder had a pressure of
18kg, which was significantly lower. We judged that there was a fault inside the 2nd cylinder.
After dismantling it, we found that the top dead center of the second piston was markedly lower
than that of the third cylinder. After dismantling the engine, we discovered that the connecting
rod of the 2nd cylinder was apparently bent. We then judged that after this connecting rod was
bent, the compression pressure in the 2nd cylinder of the cold car became insufficient and fuel
burning was poor.
Incompletely burnt mixed gases were directly discharged, causing blue smoke to emit from the
exhaust pipe. When the car was warmed up, cylinder sealing improved. As temperature rose,
the cylinder pressure also increased compared with the pressure when the car was cold. That
was why after the car was warmed up, the blue smoke disappeared and emission performance
was improved.
When a certain cylinder of the car engine malfunctions, the engine will increase the fuel
injection pulse width of the injector of the failed cylinder to inject more fuel and maintain
operation balance. However, the pulse width of the injector cannot be increased without a limit.
If after the injection pulse has been increased to the maximum and the engine still cannot
maintain the operation balance of individual cylinders, the corresponding fault code will be
reported, indicating that a certain cylinder does not work properly, a fault which is similar to the
“injector compensation” fault with the Delphi common rail fuel system.
The reason may be that the injector does not work properly and gets stuck, causing too little
fuel injection and poor atomization. It may also be caused by poor cylinder sealing, abnormal
wear of piston ring end, piston ring or piston, cylinder gasket damage, poor air valve sealing,
insufficient air valve opening, insufficient intake, injector gasket leak, etc. In the current case,
the connecting rod of the 2nd cylinder was bent, resulting in lower compression ratio and
insufficient cylinder pressure. After the failed connecting rod was replaced, the fault of engine
jitter and exhaust pipe smoke in cold vehicle was eliminated.
As for the fault code “injector powered for too long”, the KT600 cannot be used to directly
remove it. A version released following KT600 V81 (previous editions must be upgraded) must
be used. After entering Yusheng’s Special Functions, select a ZFC (zero fuel calibration)
learning value and then eliminate the fault code. After existing, switch off the ignition and turn
power on, then the fault light will go off and the system works normally. The fault code is
eliminated. The fault can be eliminated without replacing the engine ECU. If the above
operations are not followed, the fault code cannot be directly deleted from KT600.
As for the fault of "injector powered for too long", JMC released a notice and gave relevant
guidance on October 25, 2011. For the New Era Transit and Yusheng diesel models, it is
suggested that after the injector was dismantled, a new copper pad should be replaced when
the injector is re-assembled. I once came across a case in which a New Era Transit with a
Puma diesel engine was overhauled only after a mileage of 50,000km. Checks found
abnormal wear on the cylinder barrel, piston and bearing of the car. Engine oil quality was
extremely poor. The car had complete service records, but why the oil quality was so poor?
When checking the cylinder head, I found handfuls of accumulated carbon around the injector.
It was simply shocking. After repeated inquiries, I learned that the car was once sent to a local
repair station because its engine could not start. The fuel injector was then removed and
checked, but no fault was found. The problem was that the station did not replace the cooper
pad of the injector. Because the injector of the Puma diesel engine is mounted inside the valve
chamber cover, if the injector copper pad leaks, there is no way to find the leakage with the
valve chamber covered. When gas inside the hot cylinder is leaked from the injector pad into
the valve chamber, it will cause serious carbon accumulation in the engine oil of the valve
chamber. Part of the carbon flows back into the sump, which in turn leads to the serious
deterioration of the engine oil inside the oil sump and the abnormal early wear of the engine.
Conclusion: The direct cause of “injector powered for too long” with the Yusheng diesel car in
the current case was that one of its cylinders did not work properly. Under certain working
conditions, the corresponding fault code was reported. The cylinder failure may be caused by
an abnormal injector, stagnation, abnormal wear, too little fuel injection or poor atomization, or
low cylinder pressure. The fault needs to be eliminated according to its cause. It is necessary
both to fix the fault, clear the fault code and to find the root cause of the cylinder failure. Various
reasons may lead to this result. Careful screening is required.
 Technology & Exchanges JiangLing

Deng Renhong, Chongqing JMC

Fault Elimination for Black Smoke

from Cold Engine of Yusheng Diesel
Car
VEHICLE INFORMATION
Model: Yusheng Diesel
Mileage: 15,000km
Failure Description:
The car owner reported that black smoke came out of the exhaust pipe of his car after it was
started from a cold engine. It was also mentioned that the engine did not run stably and the
black smoke only disappeared after the engine temperature rose. When we received the car, it
was warm. We waited for it to completely cool down to the ambient temperature before we
made inspections. We found that heavy smoke indeed came from the exhaust pipe of the car
and the engine was unstable.
Failure Analysis & Elimination:
Based on what we saw and the fact that the fault light was not ON, we guessed that the fault
might be with the fuel circuit, the electronic control system or a mechanical problem of the
engine. Because the engine did not work stably and the exhaust pipe emitted fairly strong black
smoke, we preliminarily suspected that one of the engine cylinders did not work properly. We
then disconnected the injector plug and found that the 2nd cylinder did not work properly. After
the injector plug of the 2nd cylinder was disconnected, the smoke from the exhaust pipe smoke
was significantly reduced. From this, we judged that the fuel injected into the 2nd cylinder did not
burn completely. The problem might be with the injector or a mechanical problem of the engine.
We then changed an injector and started the engine, but black smoke remained. Because the
fault light was not ON, it was unlikely to be the circuit problem. KT600 data showed that rail
pressure and other indicators were normal at idle speed (240ba). No problem was found there.
Smoke from the exhaust pipe decreased after the car was warmed up, and the engine also
worked relatively stably. Fuel requires a sufficient cylinder pressure (>30ba) and temperature
(around 500 degrees) to burn after entering the cylinder. Given that the car emitted no black
smoke when it was warm but did emit black smoke when it was cold, we suspected that the
problem might lie with engine cylinder pressure. So we decided to check the engine cylinder
pressure. After removing the intake manifold and the glow plug and checking, we found that the
pressure was 27ba for the 1st cylinder, 22ba for the 2nd cylinder, and 27ba for the 3rd and 4th
cylinder. It was clear that the 2nd cylinder did not have enough pressure. This might be a valve
problem or due to cylinder dragging. We then removed the valve chamber cover but saw no
problem there. After removing the cylinder head, we checked the cylinder and found no cylinder
dragging. After rocking the piston of the 2nd cylinder to the top dead point, we found that the
piston was significantly lower than the 3rd cylinder. Because the engine had no abnormal noise,
we suspected that the connecting rod was bent. So, we dissembled the engine and found that
the connecting rod of the 2nd cylinder was bent. Then we suspected that it was caused by water
entrance. Because the car was still under warranty, we checked its maintenance records and
found that the car once had an accident and its intercooler was damaged during a cross-country
contest. Later its intercooler was replaced. Water might have entered at that time, causing the
bending of the connecting rod. We changed the rod and installed the engine in accordance with
the overhaul standard. In the trial run, the engine ran smoothly and there was no black smoke.
The fault was eliminated.
Conclusion:
In the repair process, we followed the detailed examination procedures and found the problem
step by step. So, when we determine any problem, we must carefully examine the fault in
order to accurately find the problem spot and avoid detours. Because the car was still under
warranty, we found the root cause of the problem based on the maintenance records of the car.
This enabled us to prevent unnecessary losses to the service station.
 
 
JMC Yusheng · MAINTENANCE MANUAL

VII. Brake Fluid (Clutch Fluid)

When we are ill and need a

drip, the nurse will carefully
empty the air in the transfusion
pipe and check whether there
is any leakage.
Once excessive air enters, it may
endanger the patient’s life.

Introduction

The brake fluid transmits the force applied on the brake

pedal to the various brakes to stop the vehicle.
The clutch fluid has the same operating principle as the
brake fluid.

Location of Brake System

REPLACEABL
E PARTS 

 
 JMC Yusheng · MAINTENANCE MANUAL

Brake fluid (clutch fluid) requires regular

replacement
WARNING: Irregular replacement
may cause:

After a long period of use, the brake fluid will

absorb moisture in the air and gradually degrade,
thus affecting performance and braking safety.

Low braking performance

The first replacement of the brake fluid (clutch

fluid) shall be made after a mileage of 30,000km
and afterwards replacement shall be made every
36,000km.  

Failed braking function

The driver may routinely observe the bake liquid level.
Open the engine compartment cover, and check the
level of the fluid reservior. If the liquid level is between
MAX and MIN, it is fine. If the level falls under the MIN,
the braking effect will fall.
After degradation, brake fluid can easily evaporate. At
this time, even if you apply the brake pedal, the
pressure will still not reach the four wheels. The brakes
will then lose effect. This phenomenon is called vapor
sealing.
Brake fluid shall not be repetitively used. All brake fluid
discharged from the system should be properly
collected and treated.
DRIVING TIPS:
When selecting brake fluid, the driver should
note the following aspects:
1. The chosen brake fluid type should match
with your car model;
2. It is recommended that the brake fluid
designated by JMC should be used to provide
full protection to your car;
3. Once there is leakage or poor braking or
braking failure with the brake system, please
immediately go to the designated JMC service
station for repair.

REPLACEABLE
PARTS  
JMC Yusheng · MAINTENANCE MANUAL

VIII. Axle (Gear oil)

We can walk, run and jump, because we

have legs. We can carry and pull things,
because we have arms. If we damage our
joints, we cannot move freely. Therefore,
we must well protect out arms and legs.

Introduction

The axle connects with the frame via the suspension. Both ends of the
axle are mounted on the wheels.
It is used to bear the action force between the frame and the wheels.
Axle gear oil is used to lubricate the bearings of the axle deceleration
and differential gears.

Location of Axle

Axle

By driving mode, axles can also be divided into 4 types: steering axle, drive
axle, steering drive axle and support axle. REPLACEABLE
PARTS 
 JMC Yusheng · MAINTENANCE MANUAL

Axle gear oil requires regular

replacement
WARNING: Irregular replacement
may cause:
If not regularly replaced, axle gear oil will
degrade in quality and diminish in quantity,
and metal scraps will accumulate, generating
abnormal wear to axle gears and shortening
axle life.
 

Abnormal noise or jitter

The first replacement of the axle gear oil shall be

made after a mileage of 3,000km and afterwards
replacement shall be made every 36,000km.

Insufficient oil & overheated

Falling transmission power

1. If the axle generates continuous sound when the car

is driving and the drive axle housing is hot, it is likely DRIVING TIPS
that lubricant has run out. At this time, you should stop
the car and check the oil level. If axle oil has run out,
replenish it before continuing to drive. It is suggested
Regularly remove mud and dust on
that you should add the axle oil designated by JMC so
the axle ventilation plug and oil
as to offer full protection of your car.
release hole plug. If oil leakage is
2. If a rhythmic collision sound occurs during driving, it
found, immediately tighten it, or
is usually caused by too big gear clearances. If the
replace the surface seal gasket.
sound is big, you should dismantle and check the
decelerator and look for gear wear. In case of serious
wear, replace the gears.
3. If the drive axle makes noises when steering, it is
mostly generated by too big gear clearances. In case
of severe wear with the semi-axis gear key slot and
semi-axis gear, dismantle and replace the differential
planetary gears, planetary gear pad, semi-axis gear
and semi-axis gear pad. 

REPLACEABLE
PARTS  
Engine Start Failure after Repair
Lai Xiaosheng, Zhanjiang Shunling Auto Sales & Service Co., Ltd.
VEHICLE INFORMATION
Model: SUV Yusheng
Mileage: 35,000km
Failure Description:
After its clutch plate was replaced, the
vehicle could not be started. When the
ignition switched was turned on, the ABS
generated (buzzing) noise. Vibration could
be felt on the ABS.
Failure Analysis:
KT600 test resulted in the following fault
codes: P1011——Rail pressure controller
exceeds upper limit for deviation; and
P1193——Rail pressure sensor output
voltage exceeds upper limit (line connected or
over high level short-circuit).
Fault code analysis suggested that both the
rail pressure sensor and the line had
problems. But, no abnormality was found
from the rail pressure sensor to the ECU
line.
After the high voltage supply rail assembly
was replaced, the engine could be started.
When the engine ran normally, abnormal
noise was found on the ABS. The battery
light was ON. The measured power output
was 12.2V, which was insufficient. The CD
player did not work either.
1. After the ABS was replaced, abnormal
noise disappeared.
2. After the generator was replaced, power
output reached 14.3V, which was normal.
3. After the CD player was removed, it was
found that the fuse on the back of the CD
player blew out. After the fuse was replaced,
the problem was fixed.
Upon closer examination, it was found that
the harness dust cover under the right front
engine compartment, the cab and the wiper
motor was found to be damaged. The realigned
warning lamp wire was not treated. As
shown in the picture below, after it was
treated, no fault has occurred till today.
Reflections: hy there were so many
components damaged after the clutch plate
was replaced? I asked the technician about
the question and the technician confessed
that he carelessly broken a screw when
installing the transmission. The broken side
of the screw was left on the engine. To take
out the screw, the technician used welding.
The technician also confessed that he
dismantled the battery anode when he did
the welding. Usually, welding was also
used in body repair. But, no such problem
had occurred before.
One possibility that could be drawn from
the welding method used by the technician
and the wiring diagram is that the
technician connected the grounding wire of
the welder ground wire to the girders above.
Then, after the gearbox was removed,
there was no grounding from the battery
harness to the engine. When welding was
done at this time, current would flow from
the welding gun to the electric equipment
and the girders, forming a loop. Because
welding current was extremely big, it could
damage many components.
Failure Elimination: During welding, the
welding point and the welding grounding line
should be connected directly. The grounding
line must not pass by other electrical
equipment to avoid similar problems.
Conclusion:
During repair, one error or careless operation
may cause unexpected problem. It is these
unexpected problems that enable us to
accumulate valuable experience.
Treated with
Warning
lamp glass tape 
wire