Maintenance Manual of 1.

5GDI Engine 2-1 General Contents

General Contents

2 Maintenance Manual of 1.5GDI Engine ................... 2-1

2.1 Warning and Caution ................................... 2-7
2.2 Measurement ............................................... 2-8
2.3 Fuel system ............................................... 2-24
2.4 Auxiliary emission control equipment ......... 2-49
2.5 Exhaust system ......................................... 2-73
2.6 Intake system............................................. 2-88
2.7 Ignition system ......................................... 2-106
2.8 Control system ......................................... 2-126
2.9 Cooling system ........................................ 2-468
2.10 Turbocharger system ............................. 2-489
2.11 Engine assembly ................................... 2-512
2.12 Engine mounting .................................... 2-525
2.13 Mechanical system ................................ 2-532
2.14 Lubrication system ................................. 2-576
2.15 Start and charging systems ................... 2-597

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-1 General Contents

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine
Maintenance Manual of 1.5GDI Engine
2.1 Warning and Caution............................................. 2-7
2.1.1 Warning and Caution ................................ 2-7
2.1.1.1 Warning and Caution ........................ 2-7
2.2 Measurement ........................................................ 2-8
2.2.1 Cylinder block ........................................... 2-8
2.2.1.1 Measuring crankshaft radial clearance2-8
2.2.1.2 Measuring crankshaft axial clearance 2-8
2.2.1.3 Measuring crankshaft runout............. 2-8
2.2.1.4 Measuring cylinder bore .................... 2-9
2.2.1.5 Measuring piston ring end clearance 2-9
2.2.1.6 Measuring piston ring groove clearance2-
10
2.2.1.7 Measuring piston diameter .............. 2-10
2.2.1.8 Measuring the clearance between piston
and cylinder block ....................................... 2-10
2.2.1.9 Measuring the clearance between piston
pin and piston pin bore................................ 2-11
2.2.1.10 Measuring the clearance between piston
pin and piston pin bore in connecting rod small
end .............................................................. 2-11
2.2.1.11 Measuring warpage of cylinder block2-12
2.2.2 Cylinder head.......................................... 2-13
2.2.2.1 Measuring warpage of cylinder head from
cylinder block .............................................. 2-13
2.2.2.2 Measuring camshaft axial clearance 2-14
2.2.2.3 Measuring the coaxiality and cylindricity of
intake/exhaust camshaft ....................................
.................................................................... 2-14
2.2.2.4 Measuring intake/exhaust camshaft lobe
height .......................................................... 2-14
2.2.2.5 Measuring the clearance between valve
and guide .................................................... 2-15
2.2.2.6 Measuring the mounting height of valve
stem, valve guide and valve oil seal............ 2-16
2.2.2.7 Measuring valve tappet height ........ 2-17
2.2.2.8 Repairing valve seat ....................... 2-18
2.2.2.9 Measuring cylinder pressure ........... 2-19
2.2.3 Lubrication system .................................. 2-20
2.2.3.1 Measuring lubrication system pressure2-
20
2.2.4 Fuel supply system ................................. 2-21
2.2.4.1 Measuring fuel system pressure ..... 2-21
2.2.5 Cooling system ....................................... 2-22
2.2.5.1 Measuring cooling system tightness 2-22
2.2.6 Intake/exhaust system ............................ 2-23
2.2.6.1 Measuring the plane warpage of cast
exhaust manifold and cylinder head on intake and
exhaust sides .............................................. 2-23
2.3 Fuel system ......................................................... 2-24
2.3.1 Specifications.......................................... 2-24
2.3.1.1 Fastener specifications ................... 2-24
2.3.2 Description and operation ....................... 2-25
2.3.2.1 Overview ......................................... 2-25
2.3.2.2 Component description ................... 2-25
2.3.3 System working principles ...................... 2-26
2-1 General Contents
2.3.3.1 System working principles ............... 2-26
2.3.4 Location of components .......................... 2-27
2.3.4.1 Location of components .................. 2-27
2.3.5 Exploded view ......................................... 2-28
2.3.5.1 Exploded view of fuel tank assembly2-28
2.3.5.2 Exploded view of fuel injection device2-29
2.3.6 Electrical schematic diagram .................. 2-30
2.3.6.1 Electrical schematic diagram........... 2-30
2.3.7 Diagnostic information and procedure .... 2-31
2.3.7.1 Diagnostic instructions .................... 2-31
2.3.7.2 Visual inspection ............................. 2-31
2.3.7.3 Low fuel pressure ............................ 2-31
2.3.7.4 Excessive fuel consumption ............ 2-31
2.3.8 Special tools............................................ 2-33
2.3.8.1 List of special tools .......................... 2-33
2.3.9 Removal and installation ......................... 2-34
2.3.9.1 Releasing fuel system pressure ...... 2-34
2.3.9.2 Removing and installing fuel pump . 2-36
2.3.9.3 Removing and installing high-pressure
fuel pump .................................................... 2-39
2.3.9.4 Removing and installing fuel filler pipe
assembly ..................................................... 2-40
2.3.9.5 Removing and installing fuel rail injector
assembly ..................................................... 2-42
2.3.9.6 Removing and installing fuel tank
assembly ..................................................... 2-45
2.4 Auxiliary emission control equipment .................. 2-49
2.4.1 Specifications .......................................... 2-49
2.4.1.1 Fastener specifications.................... 2-49
2.4.2 Description and operation ....................... 2-50
2.4.2.1 Overview ......................................... 2-50
2.4.3 System working principles ...................... 2-51
2.4.3.1 System working principles ............... 2-51
2.4.4 Location of components .......................... 2-52
2.4.4.1 Location of components .................. 2-52
2.4.5 Exploded view ......................................... 2-54
2.4.5.1 Exploded view ................................. 2-54
2.4.6 Schematic diagram ................................. 2-55
2.4.6.1 Schematic diagram ......................... 2-55
2.4.7 Diagnostic information and procedure .... 2-56
2.4.7.1 Diagnostic instructions .................... 2-56
2.4.7.2 Visual inspection ............................. 2-56
2.4.7.3 Inoperative canister control valve .... 2-56
2.4.8 Special tools............................................ 2-61
2.4.8.1 List of special tools .......................... 2-61
2.4.9Removal and installation
......................................................................... 2-62
GAC Motor 2019
General Contents 2-2
2.4.9.1 Removing and installing upstream oxygen
sensor ......................................................... 2-62
2.4.9.2 Removing and installing downstream
oxygen sensor ............................................ 2-63
2.4.9.3 Removing and installing canister control
valve ........................................................... 2-64
2.4.9.4 Removing and installing canister
desorption pressure sensor ........................ 2-65
2.4.9.5 Removing and installing canister
assembly ..................................................... 2-66
2.4.9.6 Removing and installing canister filter2-68
2.4.9.7 Removing and installing oil-gas separator
.................................................................... 2-69
2.4.9.8 Removing and installing PCV pipeline
pressure sensor .......................................... 2-71
2.5 Exhaust system ................................................... 2-73
2.5.1 Specifications.......................................... 2-73
2.5.1.1 Fastener specifications ................... 2-73
2.5.2 Description and operation ....................... 2-74
2.5.2.1 Description and operation ............... 2-74
2.5.3 Location of components .......................... 2-75
2.5.3.1 Location of components .................. 2-75
2.5.4 Exploded view......................................... 2-76
2.5.4.1 Exploded view ................................. 2-76
2.5.5 Diagnostic information and procedure .... 2-77
2.5.5.1 Diagnostic instructions .................... 2-77
2.5.5.2 Visual inspection ............................. 2-77
2.5.5.3 Clogged exhaust system ................. 2-77
2.5.5.4 Leaking exhaust system.................. 2-78
2.5.5.5 Noisy exhaust system ..................... 2-79
2.5.6 Removal and installation ......................... 2-81
2.5.6.1 Removing and installing cast exhaust
manifold ...................................................... 2-81
2.5.6.2 Removing and installing catalytic
converter assembly ..................................... 2-82
2.5.6.3 Removing and installing GPF differential
pressure sensor and connecting pipe ......... 2-84
2.5.6.4 Removing and installing particulate filter2-
84
2.5.6.5 Removing and installing middle exhaust
pipe assembly ............................................. 2-85
2.5.6.6 Removing and installing rear exhaust
pipeline with muffler assembly .................... 2-86
2.5.6.7 Removing and installing exhaust
temperature sensor ..................................... 2-88
2.6 Intake system ...................................................... 2-88
2.6.1 Specifications.......................................... 2-88
2.6.1.1 Fastener specifications ................... 2-88
2.6.2 Description and operation ....................... 2-89
2.6.2.1 Description and operation ............... 2-89
2.6.2.2 Electronic throttle body self-learning 2-89
2.6.3 System working principles ...................... 2-90
2.6.3.1 System working principles............... 2-90
2.6.4 Location of components .......................... 2-91
2.6.4.1 Location of components .................. 2-91
2.6.5 Exploded view......................................... 2-92
2.6.5.1 Exploded view ................................. 2-92
2.6.6 Diagnostic information and procedure .... 2-94
2.6.6.1 Diagnostic instructions .................... 2-94
2.6.6.2 Visual inspection ............................. 2-94
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
2.6.6.3 Clogged intake system .................... 2-94
2.6.6.4 Leaking intake system ..................... 2-94
2.6.7 Removal and installation ......................... 2-96
2.6.7.1 Removing and installing air cleaner
assembly ..................................................... 2-96
2.6.7.2 Removing and installing air cleaner
element ....................................................... 2-97
2.6.7.3 Removing and installing intake pipe
assembly ..................................................... 2-98
2.6.7.4 Removing and installing air pipe assembly
.................................................................... 2-99
2.6.7.5 Removing and installing intake manifold2-
200
2.6.7.6 Removing and installing electronic throttle
body .......................................................... 2-203
2.7 Ignition system .................................................. 2-106
2.7.1 Specifications ........................................ 2-106
2.7.1.1 Fastener specifications.................. 2-106
2.7.2 Description and operation ..................... 2-107
2.7.2.1 Overview ....................................... 2-107
2.7.3 System working principles .................... 2-108
2.7.3.1 System working principles ............. 2-108
2.7.4 Location of components ........................ 2-109
2.7.4.1 Location of components ................ 2-109
2.7.5 Exploded view ....................................... 2-110
2.7.5.1 Exploded view ............................... 2-110
2.7.6 Electrical schematic diagram ................ 2-111
2.7.6.1 Electrical schematic diagram......... 2-111
2.7.7 Diagnostic information and procedure .. 2-113
2.7.7.1 Diagnostic instructions .................. 2-113
2.7.7.2 Visual inspection ........................... 2-113
2.7.7.3 No power output from main relay .. 2-113
2.7.7.4 Spark plug not sparking................. 2-114
2.7.8 Removal and installation ....................... 2-116
2.7.8.1 Removing and installing ignition coil2-116
2.7.8.2 Removing and installing spark plug2-117
2.7.8.3 Removing and installing knock sensor 2-
120
2.7.8.4 Removing and installing speed sensor 2-
121
2.7.8.5 Removing and installing phase sensor 2-
122
2.8 Control system .................................................. 2-126
2.8.1 Specifications ........................................ 2-126
2.8.1.1 Fastener specifications.................. 2-126
2.8.2 Description and operation ..................... 2-127
2.8.2.1 Overview ....................................... 2-127
2.8.3 System working principles .................... 2-128
2.8.3.1 System working principles ............. 2-128
2.8.4 Location of components ........................ 2-129
2.8.4.1 Location of components ................ 2-129
2.8.5 Electrical schematic diagram ................ 2-131
2.8.5.1 Electrical schematic diagram......... 2-131
2.8.6 Diagnostic information and procedure .. 2-132
Maintenance Manual of 1.5GDI Engine
2.8.6.1 Diagnostic instructions .................. 2-132
2.8.6.2 Visual inspection ........................... 2-132
2.8.6.3 ECU terminals ............................... 2-133
2.8.6.4 Data list ......................................... 2-136
2.8.6.5 List of diagnostic trouble codes (DTCs)2-
137
2.8.6.6 DTC: P000A00, P001000.............. 2-185
2.8.6.7 DTC: P000B00, P001300.............. 2-151
2.8.6.8 DTC: P001676, P001678 .............. 2-189
2.8.6.9 DTC: P001776, P001778 .............. 2-196
2.8.6.10 DTC: P003000, P003100 ............ 2-198
2.8.6.11 DTC: P003300, P003400 ............ 2-203
2.8.6.12 DTC: P003600, P003700 ............ 2-207
2.8.6.13 DTC: P008700, P008800 ............ 2-211
2.8.6.14 DTC: P009700, P009800 ............ 2-215
2.8.6.15 DTC: P00C721, P00C722 ........... 2-219
2.8.6.16 DTC: P00CE24, P00CE23 .......... 2-223
2.8.6.17 DTC: P011623, P011626 ............ 2-227
2.8.6.18 DTC: P012100, P012200 ............ 2-231
2.8.6.19 DTC: P013100, P013200 ............ 2-235
2.8.6.20 DTC: P013600, P013700 ............ 2-239
2.8.6.21 DTC: P019000, P019128 ............ 2-242
2.8.6.22 DTC: P020100, P026100 ............ 2-246
2.8.6.23 DTC: P020200, P026400 ............ 2-250
2.8.6.24 DTC: P020300, P026700 ............ 2-254
2.8.6.25 DTC: P020400, P027000 ............ 2-258
2.8.6.26 DTC: P021900 ............................ 2-262
2.8.6.27 DTC: P022100, P022200 ............ 2-264
2.8.6.28 DTC: P023400, P029900 ............ 2-268
2.8.6.29 DTC: P023700, P023800 ............ 2-272
2.8.6.30 DTC: P024300, P024500 ............ 2-275
2.8.6.31 DTC: P030000, P030100 ............ 2-279
2.8.6.32 DTC: P032500, P032700 ............ 2-283
2.8.6.33 DTC: P033500, P033900 ............ 2-286
2.8.6.34 DTC: P034100, P034200 ............ 2-289
2.8.6.35 DTC: P035100, P230000 ............ 2-292
2.8.6.36 DTC: P035200, P230300 ............ 2-297
2.8.6.37 DTC: P230600, P230700 ............ 2-301
2.8.6.38 DTC: P035400, P230900 ............ 2-306
2.8.6.39 DTC: P036600, P036700 ............ 2-310
2.8.6.40 DTC: P042000 ............................ 2-314
2.8.6.41 DTC: P044200, P044400 ............ 2-315
2.8.6.42 DTC: P044700, P049800 ............ 2-320
2.8.6.43 DTC: P045128, P04512A............ 2-324
2.8.6.44 DTC: P046000, P046129 ............ 2-328
2.8.6.45 DTC: P046700, P046800 ............ 2-332
2.8.6.46 DTC: P048000, P063400 ............ 2-335
2.8.6.47 DTC: P050000, P050166 ............ 2-339
2.8.6.48 DTC: P050500, P050600 ............ 2-342
2.8.6.49 DTC: P051300, P161000 ............ 2-347
2.8.6.50 DTC: P051C00, P051D00 ........... 2-348
2-3 General Contents
2.8.6.51 DTC: P055700, P055800 ............ 2-352
2.8.6.52 DTC: P056000, P056200 ............ 2-355
2.8.6.53 DTC: P057100 ............................ 2-358
2.8.6.54 DTC: P057500, P057800 ............ 2-361
2.8.6.55 DTC: P05BD00 ........................... 2-365
2.8.6.56 DTC: P060D00, P061A00 ........... 2-368
2.8.6.57 DTC: P061500, P061600 ............ 2-370
2.8.6.58 DTC: P062700, P062800 ............ 2-373
2.8.6.59 DTC: P064500, P064600 ............ 2-377
2.8.6.60 DTC: P068600, P069000 ............ 2-380
2.8.6.61 DTC: P06DA00 ........................... 2-384
2.8.6.62 DTC: P070000 ............................ 2-389
2.8.6.63 DTC: P0A9400, P141800 ............ 2-392
2.8.6.64 DTC: P120200, P120300 ............ 2-394
2.8.6.65 DTC: P140000, P140100 ............ 2-398
2.8.6.66 DTC: P141400, P141500 ............ 2-401
2.8.6.67 DTC: P14AC00, P14AD00 .......... 2-404
2.8.6.68 DTC: P14AE00, P14AF00 ........... 2-406
2.8.6.69 DTC: P150000, P150100 ............ 2-409
2.8.6.70 DTC: P155000, P155100 ............ 2-411
2.8.6.71 DTC: P161400 ............................ 2-415
2.8.6.72 DTC: P217700, P217800 ............ 2-416
2.8.6.73 DTC: P227900 ............................ 2-419
2.8.6.74 DTC: P212200, P212300 ............ 2-421
2.8.6.75 DTC: P214700, P214800 ............ 2-426
2.8.6.76 DTC: P215000, P215100 ............ 2-431
2.8.6.77 DTC: P26F000, P26F100 ............ 2-437
2.8.6.78 DTC: U007300, U350100 ............ 2-439
2.8.6.79 DTC: U010100 ............................ 2-441
2.8.6.80 DTC: U012200 ............................ 2-444
2.8.6.81 DTC: U012600 ............................ 2-446
2.8.6.82 DTC: U014000 ............................ 2-449
2.8.6.83 DTC: U100100 ............................ 2-452
2.8.6.84 DTC: U015500 ............................ 2-454
2.8.6.85 DTC:P129000,P12B100. ............. 2-458
2.8.7 Removal and installation ....................... 2-462
2.8.7.1 Removing and installing MAP/IAT sensor
.................................................................. 2-462
2.8.7.2 Removing and installing water
temperature sensor ................................... 2-463
2.8.7.3 Removing and installing oil control valve2-
464
2.8.7.4 Removing and installing electronic
accelerator pedal assembly ...................... 2-465
2.8.7.5 Removing and installing ECM ....... 2-466
2.9 Cooling system .................................................. 2-468
2.9.1 Specifications ........................................ 2-468
2.9.1.1 Fastener specifications.................. 2-468
2.9.2 Description and operation ..................... 2-469
2.9.2.1 Description and operation ............. 2-469
2.9.3 System working principles .................... 2-470
2.9.3.1 System working principles ............. 2-470
2.9.4 Location of components ........................ 2-473
GAC Motor 2019
General Contents 2-4
2.9.4.1 Location of components ................ 2-473
2.9.5 Exploded view....................................... 2-474
2.9.5.1 Exploded view ............................... 2-474
2.9.6 Electrical schematic diagram ................ 2-475
2.9.6.1 Electrical schematic diagram ........ 2-475
2.9.7 Diagnostic information and procedure .. 2-476
2.9.7.1 Diagnostic instructions .................. 2-476
2.9.7.2 Visual inspection ........................... 2-476
2.9.7.3 High engine water temperature ..... 2-476
2.9.7.4 Cooling fan fails to work ................ 2-477
2.9.8 Removal and installation ....................... 2-479
2.9.8.1 Changing coolant .......................... 2-479
2.9.8.2 Removing and installing expansion tank
assembly ................................................... 2-480
2.9.8.3 Removing and installing thermostat
assembly ................................................... 2-481
2.9.8.4 Removing and installing water pump
assembly ................................................... 2-482
2.9.8.5 Removing and installing radiator ... 2-484
2.9.8.6 Removing and installing cooling fan
assembly ................................................... 2-487
2.10 Turbocharger system ...................................... 2-489
2.10.1 Specifications...................................... 2-489
2.10.1.1 Fastener specifications ............... 2-489
2.10.2 Description and operation ................... 2-490
2.10.2.1 Overview ..................................... 2-490
2.10.3 System working principles .................. 2-491
2.10.3.1 System working principles........... 2-491
2.10.4 Location of components ...................... 2-492
2.10.4.1 Location of components .............. 2-492
2.10.5 Exploded view..................................... 2-494
2.10.5.1 Exploded view ............................. 2-494
2.10.6 Electrical schematic diagram .............. 2-496
2.10.6.1 Electrical schematic diagram ...... 2-496
2.10.7 Diagnostic information and procedure 2-497
2.10.7.1 Diagnostic instructions ................ 2-497
2.10.7.2 Visual inspection ......................... 2-497
2.10.7.3 Sudden shutdown of turbocharger2-497
2.10.7.4 Oil leakage of turbocharger ......... 2-498
2.10.8 Removal and installation ..................... 2-499
2.10.8.1 Removing and installing turbocharger
assembly ................................................... 2-499
2.10.8.2 Removing and installing boost pressure
control solenoid valve ............................... 2-503
2.10.8.3 Removing and installing electronic intake
air recirculation valve ................................ 2-505
2.10.8.4 Removing and installing intercooler
assembly ................................................... 2-506
2.10.8.5 Removing and installing MAP/IAT sensor
(charge air pressure)................................. 2-508
2.10.8.6 Removing and installing intercooler air
outlet tube ................................................. 2-509
2.10.8.7 Removing and installing intercooler air
intake tube ................................................ 2-510
2.11 Engine assembly ............................................. 2-512
2.11.1 Specifications...................................... 2-512
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
2.11.1.1 Fastener specifications................ 2-512
2.11.2 Location of components ...................... 2-513
2.11.2.1 Location of components .............. 2-513
2.11.3 Special tools........................................ 2-514
2.11.3.1 List of special tools ...................... 2-514
2.11.4 Removal and installation ..................... 2-515
2.11.4.1 Installing engine stand................. 2-515
2.11.4.2 Removing and installing powertrain2-516
2.11.4.3 Separating engine assembly and
transmission assembly .............................. 2-522
2.12 Engine mounting ............................................. 2-525
2.12.1 Specifications ...................................... 2-525
2.12.1.1 Fastener specifications................ 2-525
2.12.2 Location of components ...................... 2-526
2.12.2.1 Location of components .............. 2-526
2.12.3 Exploded view ..................................... 2-527
2.12.3.1 Exploded view ............................. 2-527
2.12.4 Removal and installation ..................... 2-528
2.12.4.1 Removing and installing left mounting
assembly ................................................... 2-528
2.12.4.2 Removing and installing right mounting
assembly ................................................... 2-529
2.12.4.3 Removing and installing torsion rod
assembly ................................................... 2-531
2.13 Mechanical system .......................................... 2-532
2.13.1 Specifications ...................................... 2-532
2.13.1.1 Fastener specifications................ 2-532
2.13.1.2 Specifications of mechanical system . 2-
533
2.13.1.3 Selection method of piston, main bearing
shell and connecting rod bearing shell ...... 2-533
2.13.2 Description and operation ................... 2-537
2.13.2.1 Overview ..................................... 2-537
2.13.3 System working principles................... 2-538
2.13.3.1 Working principle of engine ......... 2-538
2.13.4 Location of components ...................... 2-539
2.13.4.1 Location of components .............. 2-539
2.13.5 Exploded view ..................................... 2-541
2.13.5.1 Exploded view ............................. 2-541
2.13.6 Electrical schematic diagram .............. 2-547
2.13.6.1 Electrical schematic diagram....... 2-547
2.13.7 Diagnostic information and procedure 2-549
2.13.7.1 Diagnostic instructions ................ 2-549
2.13.7.2 Visual inspection ......................... 2-549
2.13.7.3 Noise from engine with load ........ 2-549
2.13.7.4 Engine vibration when engine is idling or
hot ............................................................. 2-550
2.13.7.5 Engine misfire with abnormal noise2-551
2.13.8 Special tools........................................ 2-553
2.13.8.1 List of special tools ...................... 2-553
2.13.9 Removal and installation ..................... 2-555
2.13.9.1 Removing and installing V-ribbed belt2-
555
Maintenance Manual of 1.5GDI Engine
2.13.9.2 Removing and installing accessory
tensioner ................................................... 2-555
2.13.9.3 Removing and installing cylinder head
cover assembly ......................................... 2-556
2.13.9.4 Removing and installing cylinder head
assembly ................................................... 2-560
2.13.9.5 Removing and installing timing chain
cover ......................................................... 2-563
2.13.9.6 Removing and installing timing chain 2-
566
2.13.9.7 Removing and installing timing tensioner
.................................................................. 2-570
2.13.9.8 Removing and installing camshaft2-572
2.13.9.9 Removing and installing valve oil seal2-
573
2.13.9.10 Removing and installing phase
regulator .................................................... 2-576
2.13.9.11 Removing and installing drive plate 2-
578
2.13.9.12 Removing and installing crankshaft rear
oil seal assembly....................................... 2-579
2.13.9.13 Removing and installing crankshaft
front oil seal .............................................. 2-582
2.13.9.14 Removing and installing oil cooling
nozzle assembly ....................................... 2-583
2.13.9.15 Removing and installing crankshaft
speed ring gear ......................................... 2-584
2.13.9.16 Removing and installing connecting rod
.................................................................. 2-585
2.13.9.17 Removing and installing piston ring 2-
587
2.13.9.18 Tightening sequence of main bearing
cap bolts ................................................... 2-589
2.13.9.19 Assembly relationship of main bearing
caps .......................................................... 2-590
2.13.9.20 Assembly relationship of main bearing
shells ......................................................... 2-590
2.13.9.21 Assembly relationship of piston and
connecting rod .......................................... 2-592
2.13.9.22 Assembly position of piston ring 2-592
2.13.9.23 Description of cylinder block and
crankshaft barcodes.................................. 2-593
2.14 Lubrication system .......................................... 2-596
2.14.1 Specifications ................................. 2-596
2.14.1.1 Fastener specifications .................... 2-596
2.14.2 Description and operation ................... 2-597
2.14.2.1 Overview ..................................... 2-597
2.14.3 System working principles .................. 2-598
2.14.3.1 System working principles........... 2-598
2.14.4 Location of components ...................... 2-599
2.14.4.1 Location of components .............. 2-599
2.14.5 Exploded view..................................... 2-601
2.14.5.1 Exploded view ............................. 2-601
2.14.6 Diagnostic information and procedure 2-602
2.14.6.1 Diagnostic instructions ................ 2-602
2.14.6.2 Visual inspection ......................... 2-602
2.14.6.3 Low oil pressure .......................... 2-602
2.14.6.4 Abnormal engine oil consumption 2-603
2.14.7 Special tools ....................................... 2-605
2.14.7.1 List of special tools ...................... 2-605
2-5 General Contents
2.14.8 Removal and installation ..................... 2-606
2.14.8.1 Removing and installing oil pan ... 2-606
2.14.8.2 Removing and installing oil pump
assembly ................................................... 2-607
2.14.8.3 Removing and installing oil cooler2-609
2.14.8.4 Removing and installing oil pressure
switch ........................................................ 2-611
2.14.8.5 Removing and installing oil pump
solenoid valve ........................................... 2-613
2.14.8.6 Removing and installing dipstick tube ..
.................................................................. 2-614
2.14.8.7 Inspecting oil level ....................... 2-615
2.15 Start and charging systems ............................. 2-617
2.15.1 Specifications ...................................... 2-617
2.15.1.1 Fastener specifications................ 2-617
2.15.2 Description and operation ................... 2-618
2.15.2.1 Overview ..................................... 2-618
2.15.3 System working principles................... 2-619
2.15.3.1 System working principles ........... 2-619
2.15.4 Location of components ...................... 2-620
2.15.4.1 Location of components .............. 2-620
2.15.5 Exploded view ..................................... 2-624
2.15.5.1 Exploded view ............................. 2-624
2.15.6 Electrical schematic diagram .............. 2-625
2.15.6.1 Electrical schematic diagram....... 2-625
2.15.7 Diagnostic information and procedure 2-628
2.15.7.1 Diagnostic instructions ................ 2-626
2.15.7.2 Visual inspection ......................... 2-626
2.15.7.3 Alternator output fault .................. 2-626
2.15.7.4 Abnormal operation of starter ...... 2-626
2.15.8 Removal and installation ..................... 2-628
2.15.8.1 Removing and installing alternator2-628
2.15.8.2 Removing and installing starter ... 2-628
2.15.8.3 Removing and installing battery .. 2-630
2.15.8.4 Removing and installing EBS ...... 2-632
2.15.8.5 Removing and installing battery tray . 2-
633
2.15.8.6 Removing and installing DC-DC
converter assembly ................................... 2-635
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General Contents 2-6 Maintenance Manual of 1.5GDI Engine

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-7 Warning and Caution

2.1 Warning and Caution

2.1.1 Warning and Caution
2.1.1.1 Warning and Caution
Warning about disconnecting battery
WARNING!
Before repairing electrical components, turn off all electrical consumers and set the ENGINE
START/STOP button to "OFF" position, unless otherwise specified in the operating procedures. If tools
or equipment tends to come into contact with the exposed electrical terminals, disconnect the negative
battery terminal. Failure to follow these safety warnings may result in severe personal injuries or vehicle
damage.
Warning about repairing exhaust system
WARNING!
To avoid burns, do not repair the exhaust system when it is very hot. Allow the exhaust system to cool
down before performing maintenance.
Warning about releasing fuel system pressure
WARNING!
Before repairing the fuel system, release the fuel system pressure to reduce the risk of personal injuries.
When repairing the pipeline, fuel pump or joint, place a shop towel below to absorb the leaked fuel.
Warning about repairing fuel system
WARNING!
To avoid the risk of fire or personal injuries, please observe the following points:
– When removing or installing the fuel system or its pipeline, it is strictly forbidden to use power tools
which are prone to sparks.
– All fuel pipes that have been bumped, scratched or damaged during the installation should be
replaced. Do not attempt to repair the fuel pipes.
– When installing a new fuel pipe, do not directly knock the fuel pipe clamp with a hammer.
– Before connecting the fuel pipe fittings, be sure to apply lubricating grease to the pipe fittings to
ensure correct reconnection and avoid fuel leakage.
Warning about fuel storage
WARNING!
Gasoline or gasoline vapor is very flammable. In order to prevent fire or explosion, it is strictly forbidden
to store or drain fuel into an open container, and dry powder fire extinguishers should be equipped
nearby.
Warning about removal of expansion tank cap
WARNING!
To avoid burns, do not remove the expansion tank cap before the engine has cooled down. If the
expansion tank cap is removed before the engine and radiator have cooled down, the cooling system
will release high-pressure hot liquid and vapor.
Warning about road test
WARNING!
On the premise of ensuring safety, carry out road test and comply with all traffic laws. Do not try any
operation that may endanger the control of the vehicle. Failure to follow the above safety warnings may
cause serious personal injury and damage to the vehicle.

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Measurement 2-8 Maintenance Manual of 1.5GDI Engine

2.2 Measurement
2.2.1 Cylinder block
2.2.1.1 Measuring crankshaft radial clearance
Measurement method
– Remove the main bearing cap and clean the
main bearing cap and journal.
– Place the plastic clearance gauge on the journal
and in the bearing shell according to the width of
the bearing (the plastic clearance gauge should be
located in the center of bearing shell).
– Install the main bearing cap (avoid mixture of the
used bearing shells) and tighten it to the specified
torque, and do not run the crankshaft.
– Remove the main bearing cap again.
– Compare the width of plastic clearance gauge
with the measurement scale.
• Radial clearance: 0.02～0.041mm
• Wear limit: 0.12mm
2.2.1.2 Measuring crankshaft axial clearance
Measurement method
– Tighten the fixing bolts of crankshaft main
bearing cap to the standard tightening torque.
– Install the dial indicator ① on the dial indicator
magnetic stand ② (8910590BAC0000).
– Put the measuring rod of dial indicator against
the front end of crankshaft and reset the dial
indicator.
– Push the crankshaft axially (do not turn the
crankshaft) and read the axial clearance on the
dial indicator.
• Standard axial clearance: 0.055～0.255mm
• Wear limit: 0.4mm
2.2.1.3 Measuring crankshaft runout
Measurement method
– Place a V-block on a workbench with a level
surface, and place the crankshaft ③ on the V-
block.
– Install the dial indicator ① on the dial indicator
magnetic stand ② (8910590BAC0000).
– Place the measuring rod of dial indicator on the
workbench, and check the total runout of the
crankshaft ③.
– Measure the radial runout of all main journals,
rotate the crankshaft two turns as arrowed, and
read the crankshaft runout on the dial indicator.
The deviation of the measurement for each journal
shall not exceed the maintenance limit.
• Standard value (new): 0.05mm
• Maintenance limit: 0.07mm max

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Maintenance Manual of 1.5GDI Engine 2-9Measurement

2.2.1.4 Measuring cylinder bore

Measurement method
– Use a precision cylinder bore gauge (50 ～
100mm) to measure the cylinder bore.
– Measure the cylinder bore in the horizontal (B)
and vertical (A) directions on the planes a, b, and
c in each cylinder.
• The deviation from the rated dimension shall not
be more than 0.01mm (cylindricity)

2.2.1.5 Measuring piston ring end clearance

Measurement method
– Use a piston without a piston ring to push the
piston ring vertically into the cylinder along the
cylinder wall until it is about 15～20mm from the
bottom of the cylinder.
– Use a feeler gauge to measure the piston ring
end clearance.
Standard
value (new)/ Maintenance
Piston ring
limit/mm
mm
First
compression 0.15~0.3 0.5
ring
Second
compression 0.4~0.6 0.8
ring
Oil control
0.2~0.7 0.9
ring

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Measurement 2-10 Maintenance Manual of 1.5GDI Engine

2.2.1.6 Measuring piston ring groove clearance

Measurement method
– Clean the piston ring groove and piston ring
before measurement.
– Insert the piston ring and the feeler gauge
vertically into the piston ring groove, and measure
the clearance.
Standard value
Piston ring groove
(new)/mm
First compression ring 0.02~0.07
Second compression
0.02~0.06
ring
Oil control ring 0.01~0.18
2.2.1.7 Measuring piston diameter
Measurement method
– Measure the piston skirt diameter approximately
10～16mm from the bottom of the piston.
Standard
value (new)/ Maintenance
Piston class
limit/mm
mm
ClassA 74.965~74.975 4.96
ClassB 74.975~74.985 74.97
ClassC 74.985~74.995 74.98

2.2.1.8 Measuring the clearance between piston

and cylinder block
Measurement method
– Use feeler gauge ① to measure the clearance
(a) between the piston and cylinder block.
• Standard clearance: 0.025～0.045mm
• Maintenance limit: 0.05mm

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Maintenance Manual of 1.5GDI Engine 2-11Measurement

2.2.1.9 Measuring the clearance between piston

pin and piston pin bore
Measurement method
– As shown in the figure, use an outside
micrometer (0～25mm) to measure the piston pin
diameter and take a reading.

– As shown in the figure, use an inside micrometer

to measure the diameter of piston pin bore on the
piston and take a reading.
– The clearance between the piston pin and the
piston pin bore.
• Standard clearance: 0.006~0.014mm

2.2.1.10 Measuring the clearance between piston

pin and piston pin bore in connecting rod small
end
Measurement method
– As shown in the figure, use an outside
micrometer (0～25mm) to measure the piston pin
diameter and take a reading.

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Measurement 2-12 Maintenance Manual of 1.5GDI Engine

– As shown in the figure, use an inside micrometer

to measure the diameter of piston pin bore in
connecting rod small end and take a reading.
– The clearance between the piston pin and the
piston pin bore in connecting rod small end.
• Standard value: 0.006~0.018mm

2.2.1.11 Measuring warpage of cylinder block

Measurement method
– As shown in the figure, check the plane warpage
along the edges and four straight lines passing
through the center.

– Use a precision straightedge ① and feeler

gauge ② to check the deformation of cylinder
block at different positions on each straight line.
– If the warpage of cylinder block is less than
0.15mm, there is no need to grind the joint surface
of cylinder block. If the warpage of cylinder block
is more than 0.15mm, the surface of cylinder block
needs to be repaired.

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Maintenance Manual of 1.5GDI Engine 2-13Measurement

2.2.2 Cylinder head

2.2.2.1 Measuring warpage of cylinder head from
cylinder block
Measurement method
– As shown in the figure, check the plane warpage
along the edges and 3 straight lines passing
through the center.

– Use a precision straightedge ① and feeler

gauge ② to check the deformation of cylinder
head at different positions on each straight line.
– If the warpage of cylinder head is less than
0.2mm, there is no need to grind the joint surface
of cylinder head. If the warpage of cylinder head is
more than 0.2mm, the surface of cylinder head
needs to be repaired.

• The standard height of cylinder head (a):

106±0.05mm.

GAC Motor 2019

Measurement 2-14 Maintenance Manual of 1.5GDI Engine

2.2.2.2 Measuring camshaft axial clearance

Measurement method (applies to both intake
camshaft and exhaust camshaft)
– Tighten the fixing bolts of camshaft bearing cap
to the specified torque.
– Install the dial indicator ① on the dial indicator
magnetic stand ② (8910590BAC0000).
– Put the measuring rod of dial indicator against
the front end of camshaft and reset the dial
indicator.
– Push the camshaft axially (do not turn the
camshaft) and read the axial clearance on the dial
indicator.
• Axial clearance (new): 0.075～0.175mm
• Maintenance limit: 0.175mm
2.2.2.3 Measuring the coaxiality and cylindricity of
intake/exhaust camshaft
Measurement method
– Place a V-block on a workbench with a level
surface, and place the intake/exhaust camshaft on
the V-block.
– Install the dial indicator ① on the dial indicator
magnetic stand ② (8910590BAC0000).
– Place the measuring rod of dial indicator on the
workbench, and check the coaxiality and
cylindricity of the intake/exhaust camshaft ③.
– Measure the coaxiality and cylindricity of all
cams, rotate the camshaft two turns as arrowed,
and read the coaxiality and cylindricity of the cams
from the dial indicator. The deviation of the
measurement for each cam shall not exceed the
maximum standard value.
2.2.2.4 Measuring intake/exhaust camshaft lobe
height
Measurement method
– Use an outside micrometer (25 ～ 50mm) to
measure the intake/exhaust camshaft lobe height.
• Standard height: 40.885mm (intake side)
• Standard height: 40.359mm (exhaust side)

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Maintenance Manual of 1.5GDI Engine 2-15Measurement

2.2.2.5 Measuring the clearance between valve

and guide
Measurement method
– Install the dial indicator ① on the dial indicator
magnetic stand ② (8910590BAC0000).
– Install the intake valve or exhaust valve into the
valve guide to be checked.
– Pull the valve 10mm out of the cylinder head,
swing the valve slightly, and measure the
clearance between the valve and guide.
Normal
Valve stem Wear limit
clearance
and guide (mm)
(mm)
Intake side 0.013～0.039 0.039
Exhaust side 0.028～0.054 0.054
Tip:
If the wear limit is exceeded, carry out the
measurement with a new valve. If the wear limit is
still exceeded, replace the cylinder head.
If a new valve has been installed during repair, the
new valve must be used for measurement.

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Measurement 2-16 Maintenance Manual of 1.5GDI Engine

2.2.2.6 Measuring the mounting height of valve

stem, valve guide and valve oil seal
Valve dimensions to be measured
Intake valve Exhaust valve
Dimension
(standard) (standard)
Φa (mm) 30.1 26.3
Φb (mm) 5.48 5.465
c (mm) 103.5 102.4
α (＜°) 44°37′ 44°37'

Measure the mounting height of valve guide

– Insert the valve guide into the cylinder head, and
measure the mounting height of valve guide (a).
• Standard mounting height of intake valve guide
(new): 14.65mm
• Standard mounting height of exhaust valve guide
(new): 12.9mm

Measure the mounting height of valve oil seal

– Use vernier calipers to measure the mounting
height of valve oil seal (a).
• Mounting height of valve oil seal (intake):
20.15mm
• Mounting height of valve oil seal (exhaust):
18.4mm

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-17Measurement

2.2.2.7 Measuring valve tappet height

Measurement method
– As shown in the figure, place the valve tappet to
be measured in the cylinder head, and measure
the mounting height of valve tappet (a).
Standard Maintenance
Mounting height limit
height
(mm) (mm)
Intake valve
45.1～46.41 46.41
tappet
Exhaust valve
43.66～44.97 44.97
tappet

GAC Motor 2019

Measurement 2-18 Maintenance Manual of 1.5GDI Engine

2.2.2.8 Repairing valve seat

Valve seat repair method
– Check the clearance between the valve tappet
and guide.
– If the valve guide is worn, replace it before
reaming the valve seat.
– As shown in the figure, use a valve seat reamer
to repair the valve seat in the cylinder head.
– Carefully ream the valve seat with a 45°reamer,
removing only the minimum amount of metal and
make sure the valve seat is smooth and
concentric.

– As shown in the figure, bevel the upper and

lower edges at the corner.
– Check the valve seat width and adjust
accordingly.
– Perform another light reaming with the 45°
(Intake side) reamer to remove all possible burrs caused by
(Exhaust side) other reamers.
– The valve seat width is shown in the table:
Dimension Intake (mm) Exhaust (mm)
Standard
1.5±0.2 1.5±0.2
value (new)
Maintenance
1.7 1.7
limit
– After re-dressing the valve seat, check whether
the valve seat is smooth, and apply Prussian blue
compound (arrow A) to the valve cone.
– Insert the valve into its original position in the
cylinder head, then lift the valve and place it
against the valve seat several times.
– As shown by the Prussian blue compound, the
actual joint surface (arrow B) of valve seat should
be in the center of the valve seat.
Tip: Always use the 45° reamer for the last
reaming.
If it is too high (closer to the valve tappet), use a
60° reamer (intake valve seat) or 50° reamer
(exhaust valve seat) for a second reaming to
move it downward, and then use the 45° reamer
for another reaming to restore the valve seat
width.
If it is too low (closer to the valve edge), use a 30°
reamer for a second reaming to move it upward,
and then use the 45°reamer for another reaming
to restore the valve seat width.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-19Measurement

2.2.2.9 Measuring cylinder pressure

Measurement method
– Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
– Remove the fuel pump and injector power
supply fuse.
– Remove the spark plugs of all cylinders to be
checked.
– Connect the cylinder pressure tester ① to the
threaded hole of spark plug and pre-tighten it.
– Depress the accelerator pedal fully.
– Start and run the engine until the tester no
longer shows a pressure rise.
– Read the pressure value of the checked
cylinder.
Pressure
Standard Wear difference
pressure limit between
(kPa) (kPa) cylinders
(kPa)
Cylinder 1000
pressure
value ±100 200 <100

GAC Motor 2019

Measurement 2-20 Maintenance Manual of 1.5GDI Engine

2.2.3 Lubrication system

2.2.3.1 Measuring lubrication system pressure
Prerequisites for measurement
– The engine oil level is normal.
– When the coolant temperature reaches 90℃ or
higher and the cooling fan is running, measure the
engine oil pressure.
Measure the lubrication system pressure
– Remove the oil pressure switch. Refer to
2.14.8.4 Removing and installing oil pressure
switch
– Screw the oil pressure test connector ①
(8910235BAC0000) into the threaded hole of oil
pressure switch.
– Connect the oil pressure test tool-test gauge ②
(8910230BAC0000) and the oil pressure test
connector ① (8910235BAC0000).
– Install the starter. Refer to 2.15.8.2 Removing
and installing starter
– Start the engine and read the oil pressure when
the engine runs smoothly.
Standard oil pressure
Engine speed (r/min)
(kPa)
Idle speed Not less than 65kPa
3000r/min Not less than 270kPa

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Maintenance Manual of 1.5GDI Engine 2-21Measurement

2.2.4 Fuel supply system

2.2.4.1 Measuring fuel system pressure
Prerequisites for measurement
– The battery voltage is at least 12.5V.
– The fuel tank should be at least 25% full.
Measure fuel pressure
– Release the fuel system pressure. Refer to
2.3.9.1 Releasing fuel system pressure
– Undo the fixing clip (arrow A) of engine fuel inlet
hose ①.
– Press the quick connector (arrow B) to
disconnect the engine fuel inlet hose ① from the
fuel supply hose.

– Connect the test gauge ① (8910205BAC0000)

and the test connector ② (8910210BAC0000),
and connect the other ends of the test connector
② (8910210BAC0000) to the engine fuel inlet
hose ③ and the fuel supply hose respectively.
– Start the engine and read the fuel pressure
value.
Engine speed (r/min) Standard fuel
pressure (kPa)
(Idle speed) ≥500(kPa)
(4000r/min) ≥500(kPa)

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Measurement 2-22 Maintenance Manual of 1.5GDI Engine

2.2.5 Cooling system

2.2.5.1 Measuring cooling system tightness
Measurement method
– Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
– Allow the engine to cool down to ambient
temperature.
– Unscrew the expansion tank cap ① as
arrowed.

– Connect the cooling system test tool-system

connector ① (8910250BAC0000) to the
expansion tank.
– Connect the cooling system test tool-test gauge
② (8910245BAC0000) to the cooling system test
tool-system connector ① (8910250BAC0000),
and use the cooling system test tool-test gauge ②
(8910245BAC0000) to apply a pressure of more
than 140kPa to the system.
– After several minutes, if the pressure drops, it
indicates that the cooling system is leaking.
Locate the leakage and do troubleshooting.

Check the relief valve of expansion tank cap

– Connect the cooling system test tool-expansion
tank cap connector ② (8910255BAC0000) to the
expansion tank cap ③.
– Connect the cooling system test tool-test gauge
① (8910245BAC0000) to the expansion tank cap
connector ② (8910255BAC0000), and apply
pressure to the expansion tank cap ③.
– When the pressure is above 150kPa, the relief
valve must be opened. If the relief valve in the
expansion tank cap ③ is not opened, replace the
expansion tank cap ③.

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Maintenance Manual of 1.5GDI Engine 2-23Measurement

2.2.6 Intake/exhaust system

2.2.6.1 Measuring the plane warpage of cast
exhaust manifold and cylinder head on intake and
exhaust sides
Measurement method
– As shown in the figure, check the warpage of the
cast exhaust manifold along the edges and
diagonally.
• If the plane warpage is greater than 0.3mm,
replace the cast exhaust manifold.

– As shown in the figure, check the warpage of the

cylinder head along the edges and 3 straight lines
passing through center.
– If the plane warpage on exhaust side is greater
than 0.3mm, replace the cylinder head.
– If the plane warpage on intake side is greater
than 0.3mm, replace the cylinder head.

GAC Motor 2019

Fuel system 2-24 Maintenance Manual of 1.5GDI Engine

2.3 Fuel system

2.3.1 Specifications
2.3.1.1 Fastener specifications
Location Specification Tightening torque (N.m)
High-pressure fuel pipe High-pressure fuel pipe 22.5±2.5
Engine harness [harness guard Hexagon flange bolt M6×16 8±2
plate 1] Hexagon flange bolt M6×16 22±2
High-pressure fuel pump Hexagon flange bolt M6×20 9±0.9
Hexagon flange bolt M6×16 8±2
Fuel filler pipe assembly
Fuel tank fastening bolt M8×35 8±2
Water inlet pipe Hexagon flange bolt M6×16 25±2.5
Fuel rail injector assembly Hexagon flange bolt M6×50 25±2.5
Hexagon bolt and extra large
Rear floor right bottom guard 6±2
washer assembly M6×20
plate
Hexagon flange nut M6 6±2
Fuel tank assembly Hexagon flange bolt M6×25 25±3

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Maintenance Manual of 1.5GDI Engine 2-25Fuel system

2.3.2 Description and operation

2.3.2.1 Overview
Overview of fuel system
The fuel system is used to store, filter, and deliver fuel, inject fuel into the cylinder in accordance with a
certain spray pattern at a fixed time, quantity and pressure according to the requirements of the engine,
so that the fuel can mix with air quickly and well and participate in combustion, and then discharge the
exhaust gas into the atmosphere.
This engine uses an electronically controlled GDI system, which is composed of the fuel tank assembly,
fuel pump, high-pressure fuel pump, fuel rail injector assembly, fuel pipes, fuel filler cap assembly, etc.
The fuel tank assembly stores fuel. The fuel pump is installed in the fuel tank assembly. It is featured
with integration of fuel pump, fuel filter, pressure regulating valve, and fuel level sensor; it pumps fuel
from the fuel tank to the high-pressure fuel pump. The fuel filter contains a filter element to filter
impurities from the fuel. The pressure regulating valve regulates the fuel pressure so that it is always
maintained at the optimal level for stable fuel injection. The high-pressure fuel pump is driven by an
additional cam on the camshaft, which increases the fuel pressure before directing the fuel into the fuel
rail injector assembly. The fuel rail injector assembly is composed of the high-pressure fuel rail, high
pressure sensor and high-pressure fuel injector nozzle. The fuel injector nozzle injects fuel into the
corresponding cylinder under the control of the ECU. The fuel rail injector assembly is featured with
porous technology for more thorough mixing of fuel with air and a variety of fuel spray patterns; the fuel
spray pattern is mainly adjusted according to the geometry of the combustion chamber. The excellent
spray pattern improves the combustion efficiency and effectively reduces the fuel consumption; and in
the control, the multi-injection can be adopted to ensure stable combustion while speeding up the
initiation of the catalytic converter, further reducing engine emissions.
GDI technology
The 1.5T GDI engine adopts 20MPa GDI technology. The excellent spray pattern improves the
combustion efficiency and effectively reduces the fuel consumption; and in the control, the multi-
injection can be adopted to ensure stable combustion while speeding up the initiation of the catalytic
converter, further reducing engine emissions.
2.3.2.2 Component description
High-pressure fuel pump
The working pressure of the high-pressure fuel pump system is 20MPa.
Zero evaporative emissions can be achieved.
The optimized flow control valve design has good NVH performance.
The integrated fuel inlet damper suppresses the fuel pressure pulsation on the low-pressure side.
High-pressure fuel rail
The high-pressure fuel from the fuel pump is evenly distributed to the injector of each cylinder.
Brazed connection, compact structure.
No return line.
Integrated rail pressure sensor
High-pressure injector
The porous high-pressure solenoid valve injector realizes fuel injection based on the control signal from
the ECM. When the high-pressure injector is energized, the needle valve opens, and at this time, the
high-pressure fuel is injected through the valve seat hole.
The valve seat is drilled by laser (fs class), with high consistency and precise injection target.
Stepped hole design, laser drilling, good carbon deposition resistance.
The working pressure of the high-pressure injector system is 20MPa.
The response is fast, and multiple injections can be achieved.

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Fuel system 2-26 Maintenance Manual of 1.5GDI Engine

2.3.3 System working principles

2.3.3.1 System working principles
High-pressure fuel pump
The high-pressure fuel pump is used to build up high fuel pressure by compressing the fuel though the
plunger driven by the intake camshaft, and deliver the high-pressure fuel to the high-pressure fuel rail,
with output flow of the high-pressure fuel pump controlled based on the input signal of the ECM.
High-pressure fuel rail
The high-pressure fuel rail used in the GDI EMS is made of stainless steel through copper brazing. The
main components include main distribution pipe, fuel inlet neck, end cap, fastening bracket block,
pressure sensor and injector holder. The high-pressure fuel rail is connected with the high-pressure fuel
pipe, so that the high-pressure fuel from the high-pressure fuel pump can be delivered to the high-
pressure fuel rail through the high-pressure fuel pipe, and then distributed to each injector.
The high-pressure fuel rail pressure sensor is a piezoresistive sensor. A certain input voltage is required
during use. When the pressure in the high-pressure fuel rail compresses the stainless steel diaphragm
inside the sensor, the resistance value of the silicon strain gauge on the diaphragm will change,
resulting in a change in the output voltage of the sensor. The ECM can judge the fuel pressure in the
fuel rail according to the output voltage value.
High-pressure injector
The main function of the high-pressure injector is to accurately provide the required amount of atomized
fuel to the cylinder. This high-pressure injector is actually an solenoid valve unit. The top fuel supply
structure is adopted. The high-pressure fuel flows into the high-pressure fuel rail through the high-
pressure fuel pump, and then is supplied to the high-pressure injector.
The inside of the high-pressure injector is designed with a solenoid coil surrounding the iron core, and
the two electrodes from the solenoid coil are the input control connectors of the injector. The high-
pressure injector is directly connected to the ECM control circuit and system power supply through the
engine harness. The high-pressure injector drive waveform adopts the drive voltage and peak hold
current waveforms.
The solenoid coil of the high-pressure injector directly receives the output control voltage signal from
the ECM, that is, the solenoid coil is directly driven by the ECM to control the opening and closing time
of the lower ball valve of the high-pressure injector. When the solenoid coil is energized, the generated
electromagnetic force overcomes the spring force of the ball valve and the fuel pressure, so that the ball
valve is raised, and the high-pressure fuel in the high-pressure fuel rail can pass through the valve seat
of the high-pressure injector and flow through the fuel injection hole to be directly injected into the
cylinder. When the high-pressure injector is powered off, the electromagnetic force of the solenoid coil
disappears, and the ball valve of the high-pressure injector closes automatically under the action of the
return spring, so that the fuel injection is stopped.

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Maintenance Manual of 1.5GDI Engine 2-27Fuel system

2.3.4 Location of components

2.3.4.1 Location of components

Fuel tank
assembly

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Fuel system 2-28 Maintenance Manual of 1.5GDI Engine

2.3.5 Exploded view

2.3.5.1 Exploded view of fuel tank assembly

Fuel pump
mounting cap

Fuel pump cap

sealing ring

Fuel tank heat

shield
Fuel
pump

Fuel tank
mounting strap
Fuel tank
assembly

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Maintenance Manual of 1.5GDI Engine 2-29Fuel system

2.3.5.2 Exploded view of fuel injection device

High-pressure
fuel pump

High-pressure
fuel pipe

High-pressure fuel
pump tappet

(2 pcs in total)
(2 pcs in total)

Fuel rail injector

assembly

(6 pcs in total)

Fuel rail sound shield

Disposable part:
Tightening torque is in N.m

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Fuel system 2-30 Maintenance Manual of 1.5GDI Engine

2.3.6 Electrical schematic diagram

2.3.6.1 Electrical schematic diagram

To engine

Fuel filler cap closed

Liquid trap

Canister filter

Canister

ICV closed

Gasoline vapor flow path

Note: FLVV is closed when the max. fuel level is reached

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Maintenance Manual of 1.5GDI Engine 2-31Fuel system

2.3.7 Diagnostic information and procedure

2.3.7.1 Diagnostic instructions
Familiarize yourself with the system functions and operations before starting the system diagnosis,
which will help you correctly determine the fault cause when a fault occurs, and more importantly, help
determine whether the situation described by the customer is normal.
2.3.7.2 Visual inspection
• Check the aftermarket parts that may affect the operation of the fuel system.
• Check the accessible or visible system components for obvious damage or external leakage.
• Check whether the fuel in the fuel tank is of the recommended grade and enough.
2.3.7.3 Low fuel pressure
1. Diagnostic procedure
Step 1 Check whether the status of the fuel pipeline is normal.

N Check and repair the fuel pipeline.

Step 2 Check whether the fuel filter is dirty or clogged.

Y Replace the fuel pump assembly.

Step 3 Check whether the filter screen of fuel pump suction pipe is clogged or if the fuel pump
motor is damaged.

Y Clean the filter screen of fuel pump

suction pipe or replace the fuel
pump.

Next
step
Step 4 End.
2.3.7.4 Excessive fuel consumption
1. Diagnostic procedure
Step 1 Check whether the status of the fuel pipeline is normal.

N Check and repair the fuel pipeline.

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Fuel system 2-32 Maintenance Manual of 1.5GDI Engine

Step 2 Check whether the water temperature sensor is working normally.

N Replace the water temperature

sensor.

Step 3 Check whether the electronic throttle has excessive carbon deposits.

Y Clean up the carbon deposits in the

electronic throttle.
N

Step 4 Check whether the fuel pressure is normal.

N Check and repair the fuel system.

Y

Step 5 Check whether the MAP/IAT sensor is normal.

N Replace the MAP/IAT sensor.

Y

Step 6 Check whether the fuel rail injector assembly is leaking or the spray pattern is incorrect.

Y Replace the fuel rail injector

assembly.
Next step

Step 7 End.

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Maintenance Manual of 1.5GDI Engine 2-33Fuel system

2.3.8 Special tools

2.3.8.1 List of special tools

No. Legend Tool No. Name

Disassembling tool of
1 8910001ARX0000
fuel pump mounting cap

Injector disassembling
2 8910001ADE0000
tool

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Fuel system 2-34 Maintenance Manual of 1.5GDI Engine

2.3.9 Removal and installation

2.3.9.1 Releasing fuel system pressure
Removal procedure
1. Release the fuel system pressure.
a. Open the fuel filler flap.
b. Unscrew the fuel filler cap assembly ① as
arrowed to release the fuel vapors in the fuel tank
and reduce the pressure in the fuel tank, and then
reinstall the fuel filler cap.

c. Press the clip as arrowed and remove the

engine compartment PDU cover ①.

d. Remove the fuel pump fuse EF23 in the engine

compartment PDU as arrowed.
e. Start and run the engine until the remaining fuel
in the fuel pipeline is consumed. In this case, the
fuel pipes are in a safe maintenance state.
Note:
The engine should not be started repeatedly after
it is shut down, otherwise the MIL may light up.

Installation procedure

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Maintenance Manual of 1.5GDI Engine 2-35Fuel system

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
– After the repair, reinstall the fuel pump fuse
EF23 as arrowed.

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Fuel system 2-36 Maintenance Manual of 1.5GDI Engine

2.3.9.2 Removing and installing fuel pump

Removal procedure
1 Release the fuel system pressure. Refer to
2.3.9.1 Releasing fuel system pressure
2 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
3 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery
4 Remove the rear seat cushion assembly.
Refer to 11.2.4.1 Removing and installing rear
seat cushion assembly
5 Remove the fuel pump
a. Disconnect the harness sealing plug (arrow A),
and prise off the fuel pump access cover ①
(arrow B).

b. Disconnect the fuel pump connector (arrow A),

and remove the fuel pump access cover ①.
c. Press the quick connectors (arrows B and C) to
disconnect the fuel pump connecting pipe.

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Maintenance Manual of 1.5GDI Engine 2-37Fuel system

d. Align the disassembling tool of fuel pump

mounting cap ① (8910001ARX0000) with the
fuel pump mounting cap ② slot as arrowed and
install it.
e. Rotate the disassembling tool of fuel pump
mounting cap ① (8910001ARX0000)
counterclockwise, and remove the fuel pump
mounting cap ②.

f. Remove the fuel pump ①.

Note: Before removing the fuel pump, note the
installation direction of the fuel pump.
Before removing the fuel pump, properly swing the
lever on the short side of the level sensor float to
raise the float and make it easier to remove the
fuel pump assembly.
Do not bend the float arm of the fuel level sensor
when taking off the fuel pump.
Be careful not to drip gasoline on the floor or
interiors during removal, otherwise it will corrode
the floor sealant and interiors.

g. Remove the fuel pump seal ring ①.

Installation procedure

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Fuel system 2-38 Maintenance Manual of 1.5GDI Engine

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
- Before installing the fuel pump, check whether
the seal ring ① is damaged or aging. If so,
please replace the seal ring ①.

– Install the fuel pump access cover toward the

front of the vehicle as arrowed.

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Maintenance Manual of 1.5GDI Engine 2-39Fuel system

2.3.9.3 Removing and installing high-pressure fuel

pump
Removal procedure
1 Release the fuel system pressure. Refer to
2.3.9.1 Releasing fuel system pressure
2 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
3 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery
4 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly
5 Remove the high-pressure fuel pump
a. Undo the fixing clip (arrow A) of vacuum pipe.
b. Press the quick connector (arrow B) to
disconnect the vacuum brake hose assembly ①
from the mechanical vacuum pump.

c. Unscrew the lock nuts (arrow A) of high-

pressure fuel pipe.
d. Unscrew the fixing bolt (arrow B) and remove
the high-pressure fuel pipe ①.
• Tightening torque of nut (arrow A): 22.5±2.5Nm
• Tightening torque of bolt (arrow B): 8±2Nm
Tip:
Before removing the high-pressure fuel pipe
connector, place a clean shop towel under the
connector to prevent the residual gasoline from
dripping on other accessories.
After removing the high-pressure fuel pipe, seal
the fuel rail port to prevent debris from entering
the fuel rail.
The high-pressure fuel pipe can only be used
once, and must be replaced with a new one after
removal.

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Fuel system 2-40 Maintenance Manual of 1.5GDI Engine

e. Undo the quick connector detent, press the

quick connector (arrow A) to disconnect the
engine fuel inlet hose from the high-pressure fuel
pump.
f. Disconnect the high-pressure fuel pump
connector (arrow B).

g. Unscrew the fixing bolts as arrowed, and

remove the high-pressure fuel pump ①.
• Tightening torque of bolt: 9±0.9Nm
Tip:
After removing the high-pressure fuel pump, seal
the mounting hole of the high-pressure fuel pump
to prevent debris from entering.
The high-pressure fuel pump is a precision part
and must be properly placed after removal to
prevent scratches, impacts and contamination.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
– Clean the oil dirt and impurities off the surface of
the high-pressure fuel pump.
– Replace the high-pressure fuel pump O-ring ①.
– The high-pressure fuel pump can be installed
and removed 10 times.
– When installing the high-pressure fuel pipe, pre-
tighten the rail end and pump end nuts, then
tighten the rail end nut to the specified torque, and
then tighten the pump end nut.
– The 2 bolts of high-pressure fuel pump should
be pre-tightened at the same time, and tightened
in 2 to 3 steps to ensure that they are tightened at
the same time, so as to prevent the spring of high-
pressure fuel pump from breaking.
2.3.9.4 Removing and installing fuel filler pipe
assembly
Removal procedure
Warning:
When removing or installing the fuel filler pipe, it is
strictly forbidden to use power tools. Power tools
are prone to sparks.
1 Release the fuel system pressure. Refer to
2.3.9.1 Releasing fuel system pressure
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Maintenance Manual of 1.5GDI Engine 2-41Fuel system

2 Turn off all electrical consumers and set the

ENGINE START/STOP button to “OFF” position.
3 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery
4 Remove the right rear wheel assembly. Refer
to 5.2.7.1 Removing and installing wheel
assembly
5 Remove the right rear wheel mudguard
assembly. Refer to 11.4.1.5 Removing and
installing rear wheel mudguard
6 Remove the fuel filler pipe assembly
a. Open the fuel filler flap.
b. Unscrew the fuel filler cap assembly ① as
arrowed.
Tip: After the fuel filler cap assembly is
unscrewed, seal the fuel filler to prevent debris
from entering the fuel filler pipe assembly.

c. Unscrew the fixing bolts of fuel filler pipe

assembly ① as arrowed.
• Tightening torque of bolt: 8±2Nm

c. Press the quick connector (arrow A) to

disconnect the fuel bleeding hose ① from the fuel
filler pipe assembly. If the fuel level in fuel tank is
higher than 3/4 of the max. fuel level, the fuel may
flow out from the fuel bleeding hose when it is
removed
d. Undo the fixing clip (arrow B) of fuel bleeding
hose ①.

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Fuel system 2-42 Maintenance Manual of 1.5GDI Engine

e. Loosen the clamp (arrow A), and disconnect the

fuel filler hose from the fuel filler pipe assembly.
f. Unscrew the fixing bolt (arrow B), and remove
the fuel filler pipe assembly ① . • Tightening
torque of bolt (arrow B): 8±2Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.3.9.5 Removing and installing fuel rail injector
assembly
Removal procedure
1 Release the fuel system pressure. Refer to
2.3.9.1 Releasing fuel system pressure
2 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
3 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery
4 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly
5 Remove the intake manifold. Refer to 2.6.7.5
Removing and installing intake manifold
6 Remove the fuel rail assembly
a.Unscrew the fixing bolts (arrow A) to allow the
water inlet pipe ① to move slightly. b. Unscrew
the engine harness fixing bolt (arrow B).
• Tightening torque of bolt (arrow A): 25±2.5Nm
• Tightening torque of bolt (arrow B): 22±2Nm

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Maintenance Manual of 1.5GDI Engine 2-43Fuel system

c. Unscrew the lock nuts (arrow A) of high-

pressure fuel pipe.
d. Unscrew the fixing bolt (arrow B) and remove
the high-pressure fuel pipe ①.
• Tightening torque of nut (arrow A): 22.5±2.5Nm
• Tightening torque of bolt (arrow B): 8±2Nm
Tip:
Before removing the high-pressure fuel pipe
connector, place a clean shop towel under the
connector to prevent the residual gasoline from
dripping on other accessories.
After removing the high-pressure fuel pipe, seal
the fuel rail port to prevent debris from entering
the fuel rail.
The high-pressure fuel pipe can only be used
once, and must be replaced with a new one after
removal.
e. Unscrew the bolts as arrowed, and remove the
fuel rail injector assembly with noise absorbent
①.
• Tightening torque of bolt: 25±2.5Nm

f. Disconnect the connectors as arrowed, and

remove the fuel rail injector assembly ①.

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Fuel system 2-44 Maintenance Manual of 1.5GDI Engine

g. Remove the injector ① as arrowed.

h. Remove the injector O-rings ①, ② and the

injector clamp ③.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
– As shown in the figure, install the new seal ring
① onto the tapered surface of the tool ②
(8910001ADE0000/2).
– Use tool ③ (8910001ADE0000/3) to push the
new seal ring ① on the tapered surface of tool ②
(8910001ADE0000/2) in the direction indicated by
arrow A to the position as indicated by arrow B in
the horizontal plane.

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Maintenance Manual of 1.5GDI Engine 2-45Fuel system

– As shown in the figure, install the tool ①

(8910001ADE0000/2) with the seal ring ② into
the injector.

– As shown in the figure, use tool ①

(8910001ADE0000/1) to push the seal ring ② in
the direction indicated by arrow A to the position
as indicated by arrow B
– Replace the O-ring ③.
– Replace the injector clamp ④ with a new one.
– Ensure that the fuel rail injector assembly has no
appearance defects.

2.3.9.6 Removing and installing fuel tank

assembly
Removal procedure
Tip:
When removing or installing the fuel tank
assembly, it is strictly forbidden to use power tools
which are prone to sparks.
1 Release the fuel system pressure. Refer to
2.3.9.1 Releasing fuel system pressure
2 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
3 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery

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Fuel system 2-46 Maintenance Manual of 1.5GDI Engine

4 Remove the fuel pump. Refer to 2.3.9.2

Removing and installing fuel pump
5 Pump the fuel from the fuel tank at the fuel
pump mounting port.
6 Lift the vehicle
7 Remove the fuel tank assembly
a. Press the quick connector as arrowed to
disconnect the fuel pipe ①.
Note: After the fuel pipe is disconnected, the
exposed pipe must be sealed to prevent impurities
from entering the fuel system.

b. Loosen the clamp bolts (arrow A), and remove

the fuel filler pipe ①.
c. Disconnect the pipe fittings (arrow B).
d. Disconnect the fuel tank isolation valve
connector (arrow C).
Note: After removing the pipe connecting the fuel
filler pipe assembly and the fuel tank assembly,
use a clean shop towel to block the fuel tank port
to prevent debris from falling into the fuel tank.

e. Use a lifting device to support the fuel tank

assembly ②.
f. Unscrew the fixing bolts of fuel tank assembly as
arrowed, and remove the fuel tank
mounting strap ①.
g. One technician slowly lowers the jack while the
other technician observes whether the fuel tank
interferes with other components of the body.
h. Lower the fuel tank slowly. Tightening torque of
bolt: 25±3Nm

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Maintenance Manual of 1.5GDI Engine 2-47Fuel system

i. Unscrew the fixing bolts of fuel tank heat shield

as arrowed, and remove the fuel tank heat shield
①.
Tightening torque of bolt: 8±2Nm

j. Unscrew the fixing bolts (arrow A) of fuel tank

isolation valve, disconnect the pipe fitting (arrow
B), and remove the fuel tank isolation valve ①.
Tightening torque of bolt: 8±2Nm

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Fuel system 2-48 Maintenance Manual of 1.5GDI Engine

k. Undo the fixing clips of fuel tank pipe as

arrowed, and disconnect the pipe from the fuel
tank assembly ①.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- Each fuel pipe of the fuel tank must be restored
to its original position. Otherwise, the fuel pipes
will be rubbed and damaged under the vibration of
the body, resulting in fuel leakage.
- Do not mix up the fittings of each pipe when
installing fuel pipe fittings.
– After installing the fuel tank assembly, check
whether the pipes are firmly fixed. - Ensure that
there is sufficient distance between the fuel tank
and the exhaust pipe heat shield to prevent the
fuel pipes from overheating.

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Maintenance Manual of 1.5GDI Engine 2-49Auxiliary emission control equipment

2.4 Auxiliary emission control equipment

2.4.1 Specifications
2.4.1.1 Fastener specifications

Location Specification Tightening torque (N.m)

Upstream oxygen sensor Upstream oxygen sensor 50±5
Downstream oxygen sensor Downstream oxygen sensor 50±5
Canister desorption pressure
Hexagon flange bolt M6×16 8±2
sensor
Hexagon flange nut M6 8±2
Canister assembly
Hexagon flange bolt M6×16 8±2
Hexagon socket head cap bolt
Crankcase vent pipe pressure
and conical spring washer 9±0.9
sensor bracket assembly
assembly M6×18
Oil-gas separator Hexagon flange bolt M6X25 9±0.9
PCV pipeline pressure sensor Hexagon flange bolt M5×16 5±0.5

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Auxiliary emission control equipment 2-50 Maintenance Manual of 1.5GDI Engine

2.4.2 Description and operation

2.4.2.1 Overview
Overview
The EVAP system is used to prevent the fuel vapors in the fuel system from escaping into the
atmosphere and polluting the environment. When the engine is not running or the fuel tank is refueled,
the fuel vapors from the sealed fuel tank are directed to the canister with activated carbon and stored.
When the engine is running, the fuel vapors in the canister are directed to the intake manifold through
the pipeline. The canister control valve is controlled by the ECM. When the engine is running, the vapor
flow controlled by the canister control valve is adjusted proportionally with the air flow. During
deceleration and idling, the canister control valve will close the vapor pipeline.
Positive crankcase ventilation system
The function of the positive crankcase ventilation system is to direct the crankcase gases back to the
intake manifold.
The positive crankcase ventilation (PCV) valve directs the crankcase gases back to the intake manifold.
When the electronic throttle is partially opened, the crankcase gases flow into the intake manifold
through the PCV valve. Under normal circumstances, the ventilation capacity of the PCV valve is
sufficient for the crankcase gases and a small amount of vent air to flow through it. The vent air flows
into the crankcase from the intake pipe. The fresh air flows from the rear end of air cleaner to the
crankcase through the vent hose. During this process, the pressure in the crankcase is maintained
within a specified range. When the electronic throttle is fully opened, the vacuum in the intake manifold
is not enough to open the PCV valve, and the air will flow through the connecting hose in the opposite
direction. On vehicles with particularly severe blow-by in the crankcase, the PCV valve cannot meet the
requirements. This is because in any case, part of the gases will flow into the intake pipe through the
hose.

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Maintenance Manual of 1.5GDI Engine 2-51Auxiliary emission control equipment

2.4.3 System working principles

2.4.3.1 System working principles
Working principle of upstream oxygen sensor
The upstream oxygen sensor is located on the catalytic converter assembly. By detecting the oxygen
content in the exhaust gases, it provides an indirect signal for the gas mixture concentration to the ECM
which will correct the fuel injection pulse width, so that the gas mixture concentration is guaranteed to
be at a theoretical value of 14.7 about.
The sensing element of oxygen sensor is a ceramic tube with pores. The outside of the tube wall is
surrounded by engine exhaust gases, and the inside is exposed to the atmosphere. The sensing
ceramic tube wall is made of solid electrolyte and includes an electric heating tube inside. When the
sensing ceramic tube reaches 350 ℃, it has the characteristics of solid electrolyte. The oxygen sensor
converts the concentration difference between oxygen ions inside and outside the sensing ceramic tube
into voltage signal for output. The output voltage is high or low due to the movement of electrons inside
the ceramic tube. If the gas mixture is rich, there will be a big concentration difference between oxygen
ions inside and outside the ceramic tube and a big potential difference, and a large amount of oxygen
ions will move from the inside to the outside, resulting in high output voltage. If the gas mixture is lean,
there will be a minor concentration difference between oxygen ions inside and outside the ceramic tube
and a minor potential difference, and only a small amount of oxygen ions will move from the inside to
the outside, resulting in low output voltage. The signal voltage changes abruptly near the theoretical
equivalent air-fuel ratio (λ=1).
Working principle of downstream oxygen sensor
The downstream oxygen sensor is located on the catalytic converter assembly Ⅱ, with the same
working principle as that of the upstream oxygen sensor. If the catalytic converter is working normally
and the fuel control system is in closed-loop control, the sensor voltage will be output stably at 0.45V.
Working principle of canister control valve
The canister control valve is composed of solenoid coil, armature and valve. There is a filter screen at
the inlet. The air flow through the canister control valve is related to the duty cycle of the electrical pulse
output from the ECM to the canister control valve, and also to the pressure difference between the
canister control valve inlet and outlet. When there is no electrical pulse, the canister control valve will be
closed.

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Auxiliary emission control equipment 2-52 Maintenance Manual of 1.5GDI Engine

2.4.4 Location of components

2.4.4.1 Location of components

Canister filter

Canister vent pipe

Canister assembly

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Maintenance Manual of 1.5GDI Engine 2-53Auxiliary emission control equipment

Upstream oxygen
sensor PCV pipeline pressure
sensor

Canister desorption
pressure sensor

Fuel vapor pipe

assembly

Oil-gas separator

Canister control
valve

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Auxiliary emission control equipment 2-54 Maintenance Manual of 1.5GDI Engine

2.4.5 Exploded view

2.4.5.1 Exploded view

Crankcase vent pipe

PCV pipeline pressure sensor

(6 pcs in total) (2 pcs in total)

Crankcase vent pipe

pressure sensor bracket
assembly

Oil-gas separator

Crankcase vent pipe

Tightening torque is measured in N•m

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Maintenance Manual of 1.5GDI Engine 2-55Auxiliary emission control equipment

2.4.6 Schematic diagram

2.4.6.1 Schematic diagram

Air cleaner
assembly

Turbocharger Absorption
Purge

Electronic
throttle body Canister
Produce fuel
Canister assembly
vapors
control valve
Engine

Fuel tank assembly

Canister filter

Atmosphere
Canister vent valve

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Auxiliary emission control equipment 2-56 Maintenance Manual of 1.5GDI Engine

2.4.7 Diagnostic information and procedure

2.4.7.1 Diagnostic instructions
Familiarize yourself with the system functions and operations before starting the system diagnosis,
which will help you correctly determine the fault cause when a fault occurs, and more importantly, help
determine whether the situation described by the customer is normal.
2.4.7.2 Visual inspection
• Check the aftermarket parts that may affect the operation of the auxiliary emission control equipment.
• Check the accessible or visible system components for obvious damage or external leakage.
• Check whether the fuel in the fuel tank is of the recommended grade and enough.
2.4.7.3 Inoperative canister control valve
1. Circuit diagram

(Main relay)

Engine
compartment
PDU

Caniste
r
control
valve

ECM

2. Diagnostic procedure

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Maintenance Manual of 1.5GDI Engine 2-57Auxiliary emission control equipment

Step 1 Check the canister control valve.

Canister control valve A Set the ENGINE START/STOP button to “OFF”

position.
B Remove the canister control valve.
C Measure whether the resistance across the
carbon canister control valve is the standard
resistance: 17Ω
N Replace the canister control valve

Step 2 Check the fuse EF30 of canister control valve.

A Check whether the fuse EF30 is blown.

N Go to step 5.

Step 3 Check and repair the fuse EF30 circuit.

A Check whether the fuse EF30 circuit is shorted.

B Repair the circuit and check that there is no
short circuit.
C Replace the fuse with one with rated current.
The fuse is rated at EF30 10A
D Verify if the canister control valve works
normally.
Y The system is working normally.

Step 4 Check the power supply circuit of the canister control valve.

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Auxiliary emission control equipment 2-58 Maintenance Manual of 1.5GDI Engine

Canister control valve harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the canister control valve harness
connector EN17.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
2 of the canister control valve harness connector
EN17 and the body ground.
Power Standard voltage: 11~14V
E Verify if the voltage is consistent with the
standard value.

N Replace or repair the harness or

connector.
Y

Step 5 Check whether the circuit between the canister control valve and the ECM is open.

Canister control valve harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the canister control valve harness
connector EN17 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of the canister control valve harness
connector EN17 and terminal 18 of the ECM
harness connector EN01.
Signal Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
N Replace or repair the harness or
connector.

ECM harness connector

Canister control valve

control

Step 6 Check whether the control circuit of canister control valve is shorted to ground.
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Canister control valve harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the canister control valve harness
connector EN17.
C Measure the resistance of circuit between
terminal 1 of the canister control valve harness
connector EN17 and the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
Signal standard value.
N Replace or repair the harness or
connector.

Step 7 Check whether the control circuit of canister control valve is shorted to power supply.

Canister control valve harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the canister control valve harness
connector EN17.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the canister control valve harness connector
EN17 and the body ground.
Signal Standard voltage: 0V
E Verify if the voltage is consistent with the
standard value.
N Replace or repair the harness or
connector.

Step 8 Replace the canister control valve.

A Replace the canister control valve.

B Verify if the fault is eliminated after the canister
control valve is replaced.
Y The system is working normally.

Step 9 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

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Next step

Step 10 End.

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Maintenance Manual of 1.5GDI Engine 2-61Auxiliary emission control equipment

2.4.8 Special tools

2.4.8.1 List of special tools

No. Legend Tool No. Name

Oxygen sensor
1 8910215BAC0000
disassembling tool

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Auxiliary emission control equipment 2-62 Maintenance Manual of 1.5GDI Engine

2.4.9 Removal and installation

2.4.9.1 Removing and installing upstream oxygen
sensor
Removal procedure
Tip:
If the engine is hot, wait until it cools down
naturally before operation.
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery
3. Remove the upstream oxygen sensor.
a. Remove the engine upper guard plate assembly
①.

b. Disconnect the upstream oxygen sensor

connector (arrow A).
c. Undo the fixing clip (arrow B) of upstream
oxygen sensor connector.

d. Use the oxygen sensor disassembling tool ①

(8910215BAC0000) to unscrew the upstream
oxygen sensor ② counterclockwise.
• Tightening torque of upstream oxygen sensor:
50±5Nm

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Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
– Do not knock the upstream oxygen sensor with
a wrench or any other hard object to avoid
damage.
– Do not use a upstream oxygen sensor that has
been impacted.
2.4.9.2 Removing and installing downstream
oxygen sensor
Removal procedure
Tip:
If the engine is hot, wait until it cools down
naturally before operation.
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery
3 Remove the downstream oxygen sensor.
a. Pull out the connector detent (arrow A), and
disconnect the downstream oxygen sensor
connector (arrow B).

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Auxiliary emission control equipment 2-64 Maintenance Manual of 1.5GDI Engine

b. Use a slotted screwdriver ① to push the

connector clip, and disconnect the downstream
oxygen sensor connector ②.

c. Use the oxygen sensor disassembling tool ①

(8910215BAC0000) to remove the downstream
oxygen sensor ②.
• Tightening torque of downstream oxygen sensor:
50±5Nm

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
– Do not knock the downstream oxygen sensor
with a wrench or any other hard object to avoid
damage.
– Do not use a downstream oxygen sensor that
has been impacted.
2.4.9.3 Removing and installing canister control
valve
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery

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3 Remove the canister control valve
a. Remove the engine upper guard plate assembly
①.

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Auxiliary emission control equipment 2-66 Maintenance Manual of 1.5GDI Engine

b. Disconnect the canister control valve connector

as arrowed.

c. Disconnect the canister control valve ① from

the bracket as arrowed.

d. Press the quick connector as arrowed to

remove the canister control valve ①.

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.4.9.4 Removing and installing canister
desorption pressure sensor
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery

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3 Remove the canister desorption pressure

sensor
a. Remove the engine upper guard plate assembly
①.

b. Disconnect the canister desorption pressure

sensor connector as arrowed.

c. Unscrew the fixing bolt as arrowed and remove

the canister desorption pressure sensor ①.
• Tightening torque of bolt: 8±2Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.4.9.5 Removing and installing canister assembly
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery
3 Remove the right rear wheel assembly. Refer
to 5.2.7.1 Removing and installing wheel
assembly
4 Remove the right rear wheel mudguard
assembly. Refer to 11.4.1.5 Removing and
installing rear wheel mudguard

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Auxiliary emission control equipment 2-68 Maintenance Manual of 1.5GDI Engine

5 Lift the vehicle

6 Remove the canister assembly
a. Undo the fixing clip (arrow A) of canister
assembly ①, press the movable clip (arrow B) on
the canister assembly, and disconnect the pipeline
connection.

b. Unscrew the fixing nut (arrow A) and bolts

(arrow B), and remove the canister assembly ①.
Tightening torque of nut (arrow A): 8±2Nm
• Tightening torque of bolt (arrow B): 8±2Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.

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2.4.9.6 Removing and installing canister filter

Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Remove the right rear wheel assembly. Refer
to 5.2.7.1 Removing and installing wheel
assembly
3 Remove the right rear wheel mudguard
assembly. Refer to 11.4.1.5 Removing and
installing rear wheel mudguard
4 Remove the canister filter
a. Undo the canister vent pipe to canister filter
fixing clip (arrow A), and remove the canister filter
①.

Installation procedure
The installation procedure is in reverse of removal
procedure.

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Auxiliary emission control equipment 2-70 Maintenance Manual of 1.5GDI Engine

2.4.9.7 Removing and installing oil-gas separator

Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery
3 Remove the oil-gas separator
a. Remove the engine upper guard plate assembly
①.

b. Loosen the clamp (arrow A), and disconnect the

crankcase vent pipe ①.
c. Loosen the clamp (arrow B), and disconnect the
crankcase vent pipe ②.

d. Unscrew the fixing bolts (arrow A).

e. Loosen the clamp (arrow B), and disconnect the
crankcase vent pipe pressure sensor bracket
assembly ① from the oil-gas separator.
• Tightening torque of bolt: 9±0.9Nm

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f. Unscrew the fixing bolts as arrowed, and

remove the oil-gas separator ①.
• Tightening torque of bolt: 9±0.9Nm

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
– Replace the seal washer ①.
– After taking out the used sealing strip from the
oil-gas separator, it is necessary to clean the
groove for the sealing strip, and then install the
new sealing strip in the groove, otherwise it will
cause the illusion of oil leakage.

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2.4.9.8 Removing and installing PCV pipeline

pressure sensor
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery
3 Remove the PCV pipeline pressure sensor
a. Remove the engine upper guard plate assembly
①.

b. Loosen the clamp as arrowed, and disconnect

the crankcase vent pipe ①.

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c. Unscrew the fixing bolt as arrowed, and remove

the PCV pipeline pressure sensor with harness
①.
• Tightening torque of bolt: 5±0.5Nm

d. Disconnect the PCV pipeline pressure sensor

connector as arrowed, and remove the PCV
pipeline pressure sensor ①.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
– Replace the O-ring as arrowed when installing.
– Check whether the new O-ring is in good
condition.

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Exhaust system 2-74 Maintenance Manual of 1.5GDI Engine

2.5 Exhaust system

2.5.1 Specifications
2.5.1.1 Fastener specifications

Location Specification Tightening torque (N.m)

Exhaust manifold Heat-resistant self-locking nut M8 40±2
Catalytic converter heat shield Hexagon flange bolt M6×12 9±1
Catalytic converter Hexagon flange bolt M10×1.25×25 50±5
Hexagon head bolt, spring washer
Exhaust manifold heat shield and plain washer assembly 9±1
M6×25
Cylinder head heat shield Hexagon flange bolt M6×12 9±1
Font exhaust pipeline assembly
Hexagon flange nut M10×1.25 45±5
and catalytic converter assembly
Front exhaust pipeline assembly
and middle exhaust pipeline Hexagon flange nut M10×1.25 45±5
assembly
Connection between middle
exhaust pipeline assembly and
Hexagon flange nut M10×1.25 45±5
rear exhaust pipeline with muffler
assembly

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2.5.2 Specifications
2.5.2.1 Description and operation
Overview
The main function of the exhaust system is to discharge the exhaust gases produced by combustion in
the cylinder, and to deal with harmful emissions as much as possible, while reducing noise. The
exhaust gases flow through the three-way catalytic converter assembly in which most of the harmful
gases are converted into harmless gases, and then pass through the muffler to reduce noise, and
finally are discharged into the atmosphere. After the conversion and noise reduction by exhaust system,
the emissions can meet the national standards.

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2.5.3 Location of components

2.5.3.1 Location of components

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2.5.4 Exploded view

2.5.4.1 Exploded view

Front exhaust pipe heat shield

Ⅱ

Front exhaust pipe heat shield I

Rear muffler heat shield

Middle exhaust pipe

Rear exhaust pipe with muffler assembly
assembly

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Exhaust system 2-78 Maintenance Manual of 1.5GDI Engine

2.5.5 Diagnostic information and procedure

2.5.5.1 Diagnostic instructions
Familiarize yourself with the system functions and operations before starting the system diagnosis,
which will help you correctly determine the diagnostic procedure when a fault occurs, and more
importantly, help determine whether the situation described by the customer is normal.
2.5.5.2 Visual inspection
– Check the aftermarket parts that may affect the operation of the exhaust system.
– Check the accessible or visible system components for obvious breakage or deformation.
– Check whether the exhaust is in normal color.
2.5.5.3 Clogged exhaust system
If the engine suffers from power loss, deterioration in fuel economy or poor acceleration, check for
“Clogged exhaust system” as follows: Diagnostic procedure
Step 1 Tap the rear exhaust pipeline with muffler assembly using a rubber hammer to check
whether there is a "clatter" sound.

Y The noise absorbent in the rear

exhaust pipeline with muffler
assembly is rusted and falls off
which clogs the muffler hole.
Replace the rear exhaust pipeline
with muffler assembly.
N

Step 2 Tap the middle exhaust pipe assembly using a rubber hammer to check whether there is a
"clatter" sound.

Y The noise absorbent in the middle

exhaust pipe assembly is rusted and
falls off which clogs the middle
exhaust pipe assembly. Replace the
middle exhaust pipe assembly.
N

Step 3 Tap the catalytic converter assembly Ⅱ using a rubber hammer to check whether there is
a "clatter" sound.

Y The catalysts in the catalytic

converter assembly Ⅱ are rusted
and fall off which clog the catalytic
converter assembly Ⅱ. Replace the
catalytic converter assembly Ⅱ.
N

Step 4 Remove the catalytic converter assembly and shake it to check whether there is a "clatter"
sound.

Y The catalysts in the catalytic

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converter assembly are rusted and
fall off which clog the catalytic
converter assembly. Replace the
catalytic converter assembly.

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Next step

Step 5 End.
2.5.5.4 Leaking exhaust system
If a "hissing" or crackle sound is heard from the engine when it is running, check for “Leaking exhaust
system” as follows: Diagnostic procedure
Step 1 Check whether there is any exhaust system component which is out of position or installed
incorrectly.

Y a. Ensure that the exhaust pipe

suspension cushion is in the correct
position and is not loose.
b. Tighten the exhaust system
components to the specified torque.
N

Step 2 Check whether the connection between the middle exhaust pipe assembly and the rear
exhaust pipeline with muffler assembly is leaking.

Y a. Check the gasket between the

middle exhaust pipe assembly and
the rear exhaust pipeline with muffler
assembly, and replace it with a new
one if necessary.
b. Tighten the nut connecting the
middle exhaust pipe assembly and
the rear exhaust pipeline with muffler
assembly to the specified torque.
N

Step 3 Check whether the connection between the catalytic converter assembly II and the middle
exhaust pipe assembly is leaking.

Y a. Check the gasket between the

catalytic converter assembly II and
the middle exhaust pipe assembly,
and replace it with a new one if
necessary.
b. Tighten the nut connecting the
catalytic converter assembly II and
the middle exhaust pipe assembly to
the specified torque.
N

Step 4 Check whether the connection between the catalytic converter assembly II and the catalytic
converter assembly is leaking.

Y a. Check the gasket between the

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Maintenance Manual of 1.5GDI Engine 2-81Exhaust system
catalytic converter assembly II and
the catalytic converter assembly,
and replace it with a new one if
necessary.
b. Tighten the nut connecting the
catalytic converter assembly II and
the catalytic converter assembly to
the specified torque.

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Exhaust system 2-82 Maintenance Manual of 1.5GDI Engine

Step 5 Check whether the connection between the catalytic converter assembly II and the
turbocharger assembly is leaking.

Y a. Check the turbine inlet gasket

between the catalytic converter
assembly II and the turbocharger
assembly, and replace it with a new
one if necessary.
b. Tighten the nut connecting the
catalytic converter assembly II and
the turbocharger assembly to the
specified torque.
N

Step 6 Check whether the connection between the cast exhaust manifold and the turbocharger
assembly is leaking.

Y a. Check the turbine outlet gasket

between the cast exhaust manifold
and the turbocharger assembly, and
replace it with a new one if
necessary.
b. Tighten the nut connecting the
cast exhaust manifold and the
turbocharger assembly to the
specified torque.
N

Step 7 Check whether the connection between the cast exhaust manifold and the cylinder head is
leaking.

Y a. Check the exhaust manifold

gasket between the cast exhaust
manifold and the cylinder head, and
replace it with a new one if
necessary.
b. Tighten the nut connecting the
cast exhaust manifold and the
cylinder head to the specified torque.
Next step

Step 8 End.
2.5.5.5 Noisy exhaust system
If the exhaust noise is loud or abnormal when the engine is running, check for “Noisy exhaust system”
as follows:
1. Diagnostic procedure

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Maintenance Manual of 1.5GDI Engine 2-83Exhaust system

Step 1 Check whether there is a crackle or "hissing” sound.

Y The exhaust system is leaking.

Check and repair the leaking parts.
N

Step 2 Check whether the rear exhaust pipeline with muffler assembly is cracked or damaged.

Y Replace the rear exhaust pipeline

with muffler assembly and gasket.
N

Step 3 Check whether the middle exhaust pipe assembly is cracked or damaged.

Y Replace the middle exhaust pipe

assembly and gasket.
N

Step 4 Check whether the catalytic converter assembly Ⅱ is cracked or damaged.

Y Replace the catalytic converter

assembly Ⅱ and gasket.
N

Step 5 Check whether the catalytic converter assembly is cracked or damaged.

Y Replace the catalytic converter

assembly.
N

Step 6 Check whether the cast exhaust manifold is cracked or damaged.

Y Replace the cast exhaust manifold.

Next step

Step 7 End.

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Exhaust system 2-84 Maintenance Manual of 1.5GDI Engine

2.5.6 Removal and installation

2.5.6.1 Removing and installing cast exhaust
manifold
Removal procedure
1 Turn off all electrical consumers and set the
ignition switch or ENGINE START/STOP button to
“OFF” position.
2 Disconnect the negative battery terminal. Refer
to 1.8.6.1 Maintaining and inspecting battery
3 If the engine is hot, wait until it cools down
naturally.
4 Remove the catalytic converter assembly
5 Remove the turbocharger assembly
6 Remove the cast exhaust manifold
a. Unscrew the fixing bolts of exhaust manifold
heat shield as arrowed, and remove the exhaust
manifold heat shield ①.
Tightening torque of bolt: 9±1Nm

b. Unscrew the fixing nuts of cast exhaust

manifold as arrowed, and remove the cast exhaust
manifold ①.
Tightening torque of nut: 40±2Nm

Installation procedure

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The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following: Before installing the cast exhaust
manifold, check the plane warpage of cast
exhaust manifold and replace it if necessary.
Remove the carbon deposits on the contact
surface of the cast exhaust manifold with the
cylinder head. When installing the exhaust
manifold gasket, make sure that the side with the
text marks as arrowed on the exhaust manifold
gasket ① faces outward.

2.5.6.2 Removing and installing catalytic converter

assembly
Removal procedure
1 Turn off all electrical consumers and set the
ignition switch or ENGINE START/STOP button to
“OFF” position.
2 Disconnect the negative battery terminal. Refer
to 1.8.6.1 Maintaining and inspecting battery
3 If the engine is hot, wait until it cools down
naturally.
4 Remove the upstream oxygen sensor
5 Remove the catalytic converter assembly
a. Unscrew the bolts (arrows A and B), and
remove the turbocharger heat shield ①.
Tightening torque of bolt (arrow A): 9±1Nm
• Tightening torque of bolt (arrow B): 9±1Nm

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b. Unscrew the fixing nuts of catalytic converter

assembly ① as arrowed.
Tightening torque of nut: 25±2Nm

c. Unscrew the nuts as arrowed, disconnect the

catalytic converter assembly Ⅱ ② from the
catalytic converter assembly ①, and remove the
gasket.
Tightening torque of nut: 45±5Nm

d. Unscrew the bolts (arrow A), and remove the

catalytic converter assembly fixing bracket ①.
e. Unscrew the bolts (arrow B), and remove the
catalytic converter assembly fixing bracket ②.
Tightening torque of bolt (arrow A): 50±5Nm
• Tightening torque of bolt (arrow B): 50±5Nm
Tip:
Prevent the catalytic converter assembly from
falling during removal.

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f. Remove the catalytic converter assembly ①.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
Replace the gasket.
The catalytic converter shall be handled with care
during disassembling, handling and assembling. It
is prohibited to bump the catalytic converter
assembly. Otherwise, it is likely to damage the
internal carrier assembly.
– After the catalytic converter is removed, it shall
be properly protected to prevent foreign materials,
liquids, etc. from entering the interior, for fear of
causing the catalytic converter to fail and resulting
in emission failure.
– After the catalytic converter assembly is
installed, check whether the pipe connections are
sealed properly. If there is exhaust gas leakage,
check the tightening torque of the exhaust pipe
bolts and nuts of connections, and replace the
damaged parts if necessary.
2.5.6.3 Removing and installing GPF differential
pressure sensor and connecting pipe
Removal procedure
1 If the engine is hot, wait until it cools down
naturally.
2 Disconnect the negative battery terminal. Refer
to 1.8.6.1 Maintaining and inspecting battery
3 Remove the GPF differential pressure sensor
and connecting pipe
a. Disconnect the GPF differential pressure sensor
connector (arrow A), unscrew the fixing nut (arrow
B) of differential pressure sensor, and detach the
connection; unscrew the nuts (arrow C) fixing the
differential pressure sensor connecting pipe to the
body, and disconnect the differential pressure
sensor connecting pipe ② from the particulate
filter.
Tightening torque of nut (arrow B): 8±2Nm
Tightening torque of nut (arrow C): 8±2Nm
b. Disconnect the connecting pipe ② from the
GPF differential pressure sensor ①.

Installation procedure
The installation is in reverse of removal procedure.
2.5.6.4 Removing and installing particulate filter
assembly

Removal procedure
1 If the engine is hot, wait until it cools down

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naturally.
2 Disconnect the negative battery terminal. Refer
to 1.8.6.1 Maintaining and inspecting battery
3 Remove the downstream oxygen sensor. Refer
to 2.4.9.2 Removing and installing downstream
oxygen sensor
4 Remove the exhaust temperature sensor. Refer
to 2.5.6.7 Removing and installing exhaust
temperature sensor
5 Remove the GPF differential pressure sensor
and connecting pipe. Refer to2.5.6.3 Removing
and installing GPF differential pressure sensor
and connecting pipe
6 Remove the particulate filter assembly

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a. Unscrew the nuts as arrowed.

b. Disconnect the particulate filter assembly ②
from the catalytic converter assembly ① , and
remove the gasket.
Tightening torque of nut: 45±5Nm

c. Unscrew the nuts (arrow A), disconnect the

middle exhaust pipeline assembly ① from the
particulate filter assembly ② , and remove the
gasket.
d. Detach the exhaust pipe suspension cushion I
(arrow B), and remove the particulate filter
assembly ②.
Tightening torque of nut (arrow A): 45±5Nm

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
Replace the gasket.
After the particulate filter assembly is installed,
check whether the pipe connections are sealed
properly. If there is exhaust gas leakage, check
the tightening torque of the exhaust pipe nuts of
connections, and replace the damaged parts if
necessary.
2.5.6.5 Removing and installing middle exhaust
pipe assembly
Removal procedure
1 Turn off all electrical consumers and set the
ignition switch or ENGINE START/STOP button to
“OFF” position.
2 If the engine is hot, wait until it cools down
naturally.
3 Remove the middle exhaust pipeline assembly
a. Unscrew the nuts as arrowed, and disconnect
the middle exhaust pipeline assembly ① from the
catalytic converter assembly Ⅱ ②.
b. Remove the gasket.
Tightening torque of nut: 45±5Nm

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c. Unscrew the nuts as arrowed, and disconnect

the middle exhaust pipeline assembly ① from the
rear exhaust pipeline with rear muffler assembly
②.
d. Remove the gasket. Tightening torque of nut:
45±5Nm

e. Detach the middle exhaust pipe suspension

cushion I as arrowed, and remove the middle
exhaust pipeline assembly ①.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
Replace the gasket.
- When removing and installing the exhaust pipe
suspension cushion, first lubricate the connection
between the suspension cushion and the rigid
bracket for smooth removal and installing.

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2.5.6.6 Removing and installing rear exhaust

pipeline with muffler assembly
Removal procedure
1 Turn off all electrical consumers and set the
ignition switch or ENGINE START/STOP button to
“OFF” position.
2 If the engine is hot, wait until it cools down
naturally.
3 Remove the rear exhaust pipeline with rear
muffler assembly
a. Unscrew the nuts as arrowed, disconnect the
middle exhaust pipeline assembly ① from the
rear exhaust pipeline with rear muffler assembly
②, and remove the gasket.
Tightening torque of nut: 45±5Nm

b. Detach the exhaust pipe suspension cushion II

as arrowed, and remove the rear exhaust pipeline
with rear muffler assembly ①.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
Replace the gasket.
- When removing and installing the exhaust pipe
suspension cushion, first lubricate the connection
between the suspension cushion and the rigid
bracket for smooth removal and installing.
After the rear exhaust pipeline with rear muffler
assembly is installed, check whether the pipe
connections are sealed properly. If there is
exhaust gas leakage, check the tightening torque
of nuts of connections, and replace the damaged
parts if necessary.

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Intake system 2-92 Maintenance Manual of 1.5GDI Engine

2.5.6.7 Removing and installing exhaust

temperature sensor
Removal procedure
1 Turn off all electrical consumers and set the
ignition switch or ENGINE START/STOP button to
“OFF” position.
2 If the engine is hot, wait until it cools down
naturally.
3 Lift the vehicle.
4 Remove the exhaust temperature sensor.
a. Disconnect the exhaust temperature sensor
connector (arrow A), unscrew the nut (arrow)
fixing the exhaust temperature sensor on the
particulate filter assembly, and remove the
exhaust temperature sensor ①.
Tightening torque of nut (arrow B): 45±5Nm

Installation procedure
The installation is in reverse of removal procedure.

2.6 Intake system

2.6.1 Specifications
2.6.1.1 Fastener specifications

Location Specification Tightening torque (N.m)

Air cleaner assembly Hexagon flange bolt M6×30 8±2
Engine harness grounding point Hexagon flange bolt M6×12 8±2
Intake manifold bracket Hexagon flange bolt M6×12 25±2.5
Intercooler air outlet tube fixed
on fixing bracket of intercooler Hexagon flange bolt M6×25 8±2
air outlet tube
Electronic throttle body Bolt M6×51 9±0.9
All-metal hexagon flange lock
20±2.5
Intake manifold nut M8
Hexagon flange bolt M6×35 20±2.5

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2.6.2 Description and operation

2.6.2.1 Description and operation
Overview
The main function of the intake system is to provide enough clean air to ensure the quality of the
combustible mixture. The air enters the air cleaner assembly in the engine compartment, in which the
impurities in the air are filtered out through the air cleaner element. The clean air enters the
turbocharger assembly for supercharging, then passes through the intercooler assembly for cooling,
and then enters the intake manifold through the electronic throttle body, and finally enters the cylinder
when the intake valve is open.
2.6.2.2 Electronic throttle body self-learning
1. Self-learning conditions:
a. The road speed is 0.
b. The engine speed is 0.
c. The engine water temperature is 5℃-100℃.
d. The intake temperature is not less than 5℃.
e. The electronic throttle opening is set to 0.
f. The battery voltage is greater than 10V.
g. The harness connection is normal and the throttle body and ECU are working normally.
2. Self-learning operation method:
a. Set the ENGINE START/STOP button in "ON” position and wait for 30 seconds. At this time, do not
perform any other operations until the learning is complete.
3. Situations that require self-learning:
a. After ECU flash or replacement.
b. The positive and negative connections of the battery are disconnected.
c. After reconnecting the ECU.
d. After replacing the throttle body.

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Intake system 2-94 Maintenance Manual of 1.5GDI Engine

2.6.3 System working principles

2.6.3.1 System working principles
1. Working principle of intake system
The electronic throttle body is a key component of the engine intake system, and mainly used to adjust
the intake passage area based on the driver’s intention, so as to control the intake capacity, meet the
intake demand of engine under different working conditions, and feed back the throttle valve plate
position signal to the ECM to realize accurate control.
The electronic throttle body consists of four parts: drive module, transmission module, execution
module and feedback module. All parts are integrated inside a throttle housing; The throttle feedback
module adopts a two-way redundant structure. In the event of a failure, the throttle valve plate stops at
the mechanically determined limp home position (NLP), which is above the mechanical bottom dead
center.
The electronic throttle body can only be controlled by the corresponding ECU or electronic test circuit to
ensure that the throttle valve plate will not dynamically run to the mechanical dead center position.
2. Throttle position sensor
The throttle position sensor converts the throttle opening (i.e. engine load) into an electrical signal and
inputs it to the ECM which judges the engine operating condition (such as idling, heavy load, etc.)
based on the signal voltage and controls the fuel injection volume according to the operating condition;
on models equipped with an AT, the throttle opening signal is also used as one of the main signals for
the transmission to determine the timing of gear shifting and for the torque converter to determine the
timing of lock-up.
3. Throttle drive motor
The ECM calculates the amount of intake air required by the engine based on the accelerator pedal
position signal, gear position signal, engine speed signal, etc., combined with various signals for
operating conditions, and then controls the throttle opening and timing.
4. MAP/IAT sensor
The amount of air entering the engine cylinder is related to the intake temperature and intake pressure.
For the same volume of air, the air mass is larger in a low temperature than that in a high temperature.
The IAT sensor feeds back signals to the ECM according to changes in intake temperature and mass to
correct the fuel injection volume.
The MAP/IAT sensor is a resistor with a negative temperature coefficient (NTC). The resistance
changes with the intake temperature. The sensor sends a voltage indicating the change in intake
temperature to the ECM.

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Maintenance Manual of 1.5GDI Engine 2-95Intake system

2.6.4 Location of components

2.6.4.1 Location of components

Intake manifold
assembly

Air pipe assembly

Air cleaner upper

Air cleaner fixing bracket housing
II
Air cleaner lower
housing
Air cleaner fixing
bracket I

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Intake system 2-96 Maintenance Manual of 1.5GDI Engine

2.6.5 Exploded view

2.6.5.1 Exploded view

Air pipe assembly

(2 pcs in total)

Air cleaner fixing bracket

II
Relief pipe

Air cleaner upper housing

Intake manifold Air cleaner element

assembly

Air cleaner lower

housing

Air cleaner fixing bracket

I

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Intake manifold

MAP / IAT sensor

(3 pcs in total)

Self-tapping screw
(2 pcs in total)

Canister control valve

bracket

Canister control valve

Intake manifold
bracket

Electronic throttle body

(2 pcs in total)

(4 pcs in total)

Tightening torque is measured in N•m

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Intake system 2-98 Maintenance Manual of 1.5GDI Engine

2.6.6 Diagnostic information and procedure

2.6.6.1 Diagnostic instructions
Familiarize yourself with the system functions and operations before starting the system diagnosis,
which will help you correctly determine the fault cause when a fault occurs, and more importantly, help
determine whether the situation described by the customer is normal.
2.6.6.2 Visual inspection
– Check the aftermarket parts that may affect the operation of the intake system.
– Check the accessible or visible system components for obvious blockage or leakage.
2.6.6.3 Clogged intake system
If the engine suffers from power loss, deterioration in fuel economy or poor acceleration, check for
“Clogged intake system” as follows: Diagnostic procedure

Step 1 Check whether the air cleaner element is clogged.

Y Replace the air cleaner element.

N

Step 2 Check whether the electronic throttle body has excessive carbon deposits.

Y Clean the electronic throttle body.

Step 3 Check whether there are excessive carbon deposits in the intake manifold or cylinder head
intake port.

Y Clean off the carbon deposits in the

intake manifold and cylinder head
intake port.

Next step

Step 4 End.
2.6.6.4 Leaking intake system
If a "hissing" sound is heard from the engine when it is running, check for “Leaking intake system” as
follows: Diagnostic procedure
Step 1 Check whether the connections of the intake system components are loose.

Y Tighten the intake system

components to the specified torque.
N

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Maintenance Manual of 1.5GDI Engine 2-99Intake system

Step 2 Check whether the vacuum brake hose assembly is aged or damaged.

Y Replace the damaged vacuum brake

hose assembly.
N

Step 3 Check whether the crankcase vent pipe is aged or damaged.

Y Replace the aged and damaged

crankcase vent pipe.
N

Step 4 Check whether the MAP/IAT sensor is leaking.

Y Tighten the MAP/IAT sensor to the

specified torque, and replace the
seal ring if necessary.
N

Step 5 Check whether the electronic throttle body is leaking.

Y Tighten the electronic throttle body

to the specified torque, and replace
the seal ring if necessary.
N

Step 6 Check whether the intake manifold is leaking or damaged.

Y Replace the damaged intake

manifold and seal ring.
Next step

Step 7 End.

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Intake system 2-100 Maintenance Manual of 1.5GDI Engine

2.6.7 Removal and installation

2.6.7.1 Removing and installing air cleaner
assembly
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Remove the air cleaner assembly
a. Remove the engine upper guard plate assembly
①.

b. Unscrew the fixing screws of intake pipe

assembly ① as arrowed.

c. Undo the fixing clips as arrowed, and remove

the intake pipe assembly ①.

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d. Loosen the fixing clamp as arrowed, and

disconnect the air pipe assembly ① from the air
cleaner assembly.

e. Pry up the detent (arrow A), and disconnect the

relief pipe ② from the air cleaner assembly ①.
f. Unscrew the fixing bolts (arrow B), and remove
the air cleaner assembly ①.
• Tightening torque of bolt (arrow B): 8±2Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.6.7.2 Removing and installing air cleaner
element
Removal procedure

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Intake system 2-102 Maintenance Manual of 1.5GDI Engine

1 Turn off all electrical consumers and set the

ENGINE START/STOP button to “OFF” position.
2 Remove the air cleaner element
a. Unscrew the fixing bolt (arrow A) and screws
(Arrow B).
b. Detach the air cleaner upper housing ①.
• Tightening torque of bolt (arrow A): 8±2Nm

c. Remove the air cleaner element ①.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
– To replace the air cleaner element, use the
original product.
–Clean off the debris in the air cleaner housing.
2.6.7.3 Removing and installing intake pipe
assembly
Removal procedure

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Maintenance Manual of 1.5GDI Engine 2-103Intake system

1 Turn off all electrical consumers and set the

ENGINE START/STOP button to “OFF” position.
2 Remove the intake pipe assembly
a. Unscrew the fixing screws of intake pipe
assembly ① as arrowed.

b. Undo the fixing clips as arrowed, and remove

the intake pipe assembly ①.

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.6.7.4 Removing and installing air pipe assembly
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Remove the air pipe assembly
a. Remove the engine upper guard plate assembly
①.

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Intake system 2-104 Maintenance Manual of 1.5GDI Engine

b. Loosen the fixing clamp (arrow A), and

disconnect the crankcase vent pipe ① from the
air pipe assembly.
c. Press the quick connector (arrow B) to
disconnect the fuel vapor pipe assembly ② from
the air pipe assembly.
d. Press the quick connector (arrow C) to
disconnect the fuel vapor pipe assembly Ⅰ ③
from the air pipe assembly.

e. Loosen the fixing clamps as arrowed, and

remove the air pipe assembly ①.

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.6.7.5 Removing and installing intake manifold
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery
3 Remove the dipstick tube. Refer to 2.14.8.6
Removing and installing dipstick tube
4 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly
5 Remove the electronic throttle body. Refer to
2.6.7.6 Removing and installing electronic throttle
body

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6 Remove the intake manifold

a. Disconnect the engine harness connectors
(arrows A and B).
b. Undo the fixing clip (arrow C).

c. Unscrew the fixing screws (arrow A) and bolts

(arrow B) of fuel vapor pipe assembly ①.
• Tightening torque of bolt (arrow B): 8±2Nm

d. Press the quick connectors as arrowed, and

disconnect the fuel vapor pipe assembly ①.

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e. Disconnect the engine harness connectors

(arrow A).
f. Unscrew the fixing bolts (arrow B) and screws
(Arrow C).
g. Undo the fixing clip (arrow D), and disconnect
the engine harness ①.
• Tightening torque of bolt (arrow B): 8±2Nm

h. Loosen the fixing clamps (arrow A), and remove

the crankcase vent pipe ①.
i. Undo the fixing clips (arrow B), and remove the
engine fuel inlet hose ②.

j. Remove the intake manifold noise shield ①.

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k. Undo the fixing clip (arrow A).

l. Unscrew the fixing bolts (arrow B), and remove
the intake manifold bracket ①.
• Tightening torque of bolt (arrow B): 25±2.5Nm

m. Loosen the fixing clamp (arrow A), disconnect

the vacuum brake hose assembly ① from the
intake manifold ②.
n. Disconnect the knock sensor connector from
the bracket (arrow B). o. Unscrew the nuts (arrow
C) and bolts (arrow D), and remove the intake
manifold ②.
• Tightening torque of nut (arrow C): 20±2.5Nm
• Tightening torque of bolt (arrow D): 20±2.5Nm

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
– Check whether there are carbon deposits in the
intake manifold and intake port, and clean off the
carbon deposits if any.
– Replace the intake manifold seal ring ① and
the electronic throttle body O-ring ②.

2.6.7.6 Removing and installing electronic throttle

body
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery
3 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly

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4 Remove the electronic throttle body

a. Press the quick connector (arrow A), and
disconnect the fuel vapor pipe assembly I ① from
the intercooler air outlet tube.
b. Loosen the clamp (arrow B), unscrew the fixing
bolt (arrow C), and disconnect the intercooler air
outlet tube ② from the electronic throttle body.
• Tightening torque of bolt (arrow C): 8±2Nm

c. Disconnect the electronic throttle body

connector (arrow A).
d. Undo the harness fixing clip (arrow B).

e. Unscrew the fixing bolts as arrowed, and

remove the electronic throttle body ①.
• Tightening torque of bolt: 9±0.9Nm

Installation procedure

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Maintenance Manual of 1.5GDI Engine 2-109Intake system

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
– Open the throttle by hand and use a soft object
① of suitable size to lock the throttle in the fully
open position.

– Use acetone and a clean brush to carefully

clean the throttle housing, especially the area
where the throttle is closed as arrowed.
– Use a lint-free shop towel to dry the throttle
housing.
– After the acetone has completely evaporated,
the electronic throttle body can be installed.
Tip:
Acetone is flammable and corrosive. When using
it, please follow its instructions.
Do not use compressed air to clean the throttle.

– Replace the O-ring ①.

– After the electronic throttle body is installed,
perform the electronic throttle body self-learning.
Refer to 2.6.2.2 Electronic throttle body self-
learning.

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Ignition system 2-110 Maintenance Manual of 1.5GDI Engine

2.7 Ignition system

2.7.1 Specifications
2.7.1.1 Fastener specifications

Location Specification Tightening torque (N.m)

Expansion tank water return
Hexagon flange bolt M6×12 8±2
tube
Ignition coil Shoulder stud M6×16×M6×30 9±0.9
Spark plug Spark plug 20±2
Knock sensor Hexagon flange bolt M6×30 25±2.5
Hexagon socket head cap bolt
Speed sensor and conical spring washer 9±0.9
assembly M6×18
Hexagon socket head cap bolt
and conical spring washer
Phase sensor assembly M6×18 9±0.9

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Maintenance Manual of 1.5GDI Engine 2-111Ignition system

2.7.2 Description and operation

2.7.2.1 Overview
Overview
The ignition system converts the low voltage supplied by the battery into high voltage, and according to
the established ignition timing sequence, timely and accurately distributes the voltage to the spark plug
of each cylinder to generate electric sparks in the spark plug gap and ignite the combustible mixture in
the cylinder, pushing the piston to run the engine normally.
This vehicle adopts an independent ignition mode, that is, each cylinder is equipped with an ignition coil,
and the ignition in the cylinders is independent of each other. At the same time, the ignition in each
cylinder can be controlled more accurately, so that the mixture in the cylinder is combusted more
completely, and the stability of the ignition system is improved.
The ignition system is mainly composed of the following components:
– Knock sensor
– MAP/IAT sensor
– Speed sensor
– Ignition coil
– Coolant temperature sensor
– Spark plug
– Battery
– ECM
– ENGINE START/STOP button

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Ignition system 2-112 Maintenance Manual of 1.5GDI Engine

2.7.3 System working principles

2.7.3.1 System working principles
Ignition coil
The ignition coil is composed of the primary winding, secondary winding, iron core, and housing.
The ground circuit of the primary winding is closed via the ECM. At this time, the primary winding will be
energized and store energy, inducing a high voltage in the secondary winding, and the spark plug
connected to the ignition coil will discharge. When the ECM opens the primary winding circuit, the
ignition will be stopped.
Spark plug
The spark plug directs the high voltage generated by the ignition coil into the combustion chamber, and
uses the electric sparks generated by the electrodes to ignite the mixture.
Knock sensor
The knock sensor is an vibration acceleration sensor, which is installed in the area of engine block most
sensitive to knocks. The ECM uses the knock sensor to detect the knock intensity, and then corrects
the ignition advance angle, effectively controls the knocks, and optimizes the engine power
performance, fuel economy and emission level. If the engine knocks, the ECM will receive this signal,
filter signals other than knocks and calculate. The ECM will judge the position of the engine in the
working cycle through the signals from the camshaft and crankshaft position sensors, determine which
cylinder is knocking by calculation, and decrease the ignition advance angle of this cylinder until the
knocks disappear. The ECM will then increase the ignition advance angle until it is at the best position
under the current working conditions. Because the sensor signal is weak, the sensor lead is shielded.
Speed sensor
The speed sensor is installed next to the engine speed ring gear to detect the speed and position of the
crankshaft. The speed sensor uses the principle of the Hall effect to generate a voltage pulse signal
corresponding to the crankshaft angle. It uses teeth to change the intensity of the magnetic field
passing through the Hall element, so that the Hall element generates a pulsed Hall voltage signal. After
being amplified and regulated, the signal is output from the crankshaft position sensor. This output
signal represents the speed and position of the crankshaft.
Phase sensor
The phase sensor is a Hall effect sensor, which is installed near the intake/exhaust camshaft, works
with the signal wheel on the camshaft. The signal wheel corresponds to a specific position of the engine
in the working cycle. The ECM detects the digital voltage signal through the phase sensor to determine
which cylinder is working, and implements one-to-one control. The ECM can then calculate the actual
fuel injection sequence. If the camshaft position sensor signal is lost while the engine is running, the
fuel injection system will switch to calculating the fuel injection sequence based on the last fuel injection
pulse to keep the engine running. If the engine is shut down and restarted, the fuel injection sequence
will be changed from sequence to group. Even if the fault exists, the engine can be restarted.

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Maintenance Manual of 1.5GDI Engine 2-113Ignition system

2.7.4 Location of components

2.7.4.1 Location of components

Ignition coil 4

Ignition coil 3 Exhaust phase sensor

Ignition coil 2

Ignition coil 1

Intake phase sensor

Speed sensor

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Ignition system 2-114 Maintenance Manual of 1.5GDI Engine

2.7.5 Exploded view

2.7.5.1 Exploded view

(2 pcs in total)
Phase sensor (intake
Phase sensor (exhaust side)
side)

(4 pcs in total)

Ignition coil

Spark plug

(4 pcs in total)

Knock sensor

Speed sensor

Tightening torque is in N•m

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Maintenance Manual of 1.5GDI Engine 2-115Ignition system

2.7.6 Electrical schematic diagram

2.7.6.1 Electrical schematic diagram

Speed sensor

ECM Ignition coil

Intake/exhaust phase sensor

Knock sensor

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Ignition system 2-116 Maintenance Manual of 1.5GDI Engine

Main
relay Engine
compartment
relay box

Ignition coil 1 Ignition coil 2 Ignition coil 3 Ignition coil 4

ECM

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Maintenance Manual of 1.5GDI Engine 2-117Ignition system

2.7.7 Diagnostic information and procedure

2.7.7.1 Diagnostic instructions
Familiarize yourself with the system functions and operations before starting the system diagnosis,
which will help you correctly determine the fault cause when a fault occurs, and more importantly, help
determine whether the situation described by the customer is normal.
2.7.7.2 Visual inspection
• Check the aftermarket parts that may affect the performance of the ignition system.
• Check the accessible or visible system components for obvious damage or conditions which may
cause faults.
2.7.7.3 No power output from main relay
Diagnostic procedure
Step 1 Check whether the main relay is normal.

Y Replace the main relay.

Y

Step 2 Check whether the main relay control output circuit is normal.

N Check and repair the main relay

control output circuit.
Y

Step 3 Check whether the main relay power output circuit is normal.

N Check and repair the main relay

power output circuit.
Y

Step 4 Check whether the ECM works normally.

N Replace and program the ECM.

Next step

Step 5 End.

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Ignition system 2-118 Maintenance Manual of 1.5GDI Engine

2.7.7.4 Spark plug not sparking

Diagnostic procedure

Step 1 Check whether the engine immobilizer system works normally.

N Check and repair the engine

immobilizer system.
Y

Step 2 Check whether the spark plug model is correct.

N Replace the spark plug with the

correct model.
Y

Step 3 Check whether the gap between the spark plug electrodes is normal.

N Replace the spark plug.

Y

Step 4 Check whether the ignition coil control circuit is normal.

N Check and repair the ignition coil

control circuit.
Y

Step 5 Check whether the resistance of the ignition coil is normal.

N Replace the ignition coil.

Y

Step 6 Check whether the ECM works normally.

N Replace and program the ECM.

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Maintenance Manual of 1.5GDI Engine 2-119Ignition system

Next step

Step 7 End.

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Ignition system 2-120 Maintenance Manual of 1.5GDI Engine

2.7.8 Removal and installation

2.7.8.1 Removing and installing ignition coil
Removal procedure
Tip:
Before removing the ignition coil, blow off the
debris around the ignition coil to prevent the debris
from falling into the combustion chamber after the
spark plug is unscrewed.
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery
3 Remove the ignition coil
a. Remove the engine upper guard plate assembly
①.

b. Disconnect the ignition coil connectors (arrow

A).
c. Undo the harness fixing clips (arrows B and C).

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d. Unscrew the fixing bolts of expansion tank

water return tube ① as arrowed.
• Tightening torque of bolt: 8±2Nm

e. Unscrew the shoulder studs as arrowed, and

remove the ignition coil ①.
• Tightening torque of nut: 9±0.9Nm

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
– Ensure that there is no crack on the surface of
the ignition coil.
– When installing the ignition coil, press the
ignition coil to the bottom, with its top in full
contact with the cylinder head cover. It is
forbidden to install it when it is not fully
compressed.
2.7.8.2 Removing and installing spark plug
Removal procedure
Tip:
It is forbidden to remove the spark plug when the
engine is hot, for fear of damage to the spark plug
thread on the cylinder head.
After removing the spark plug, plug the spark plug
hole with a cloth to prevent debris from falling into
the cylinder.
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery

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3 Remove the spark plug

a. Remove the engine upper guard plate assembly
①.

b. Disconnect the ignition coil connectors (arrow

A).
c. Undo the harness fixing clips (arrows B and C).

d. Unscrew the fixing bolts of expansion tank

water return tube ① as arrowed.
• Tightening torque of bolt: 8±2Nm

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Maintenance Manual of 1.5GDI Engine 2-123Ignition system

e. Unscrew the shoulder studs as arrowed, and

remove the ignition coil ①.
• Tightening torque of nut: 9±0.9Nm

f. Use the spark plug removal tool ① to unscrew

the spark plug as arrowed.
• Tightening torque of spark plug: 20±2Nm

Installation procedure

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Ignition system 2-124 Maintenance Manual of 1.5GDI Engine

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
– When installing the spark plug, check whether
the spark plug model is correct.
– Check the spark plug as arrowed for residual oil
and carbon deposits, and clean it if necessary.

– Check the gap (a) between the spark plug

electrodes.
• Standard value: 0.7～0.8mm

2.7.8.3 Removing and installing knock sensor

Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery
3 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly
4 Remove the electronic throttle body. Refer to
2.6.7.6 Removing and installing electronic throttle
body

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Maintenance Manual of 1.5GDI Engine 2-125Ignition system

5 Remove the knock sensor

a. Disconnect the knock sensor connector from
the bracket (arrow A).
b. Disconnect the knock sensor connector (arrow
B).

c. Unscrew the fixing bolt as arrowed, and remove

the knock sensor ①.
• Tightening torque of bolt: 25±2.5Nm
• Note:
Before removal, note the location of the knock
sensor.

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.7.8.4 Removing and installing speed sensor
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery
3 Lift the vehicle.
4 Remove the speed sensor
a. Unscrew the fixing screws (arrow A) and bolts
(arrow B), and remove the engine compartment
lower guard plate ①.
• Tightening torque of bolt (arrow B): 6±2Nm

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Ignition system 2-126 Maintenance Manual of 1.5GDI Engine

b. Disconnect the speed sensor connector as

arrowed.

c. Unscrew the fixing bolt as arrowed, and remove

the speed sensor ①.
• Tightening torque of bolt: 9±0.9Nm
Tip:
Plug the sensor mounting hole after removing the
speed sensor to prevent debris from entering the
hole.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
– Clean the oil dirt and impurities off the surface of
speed sensor and the detection terminals.
– Replace the O-ring ① during installation.

2.7.8.5 Removing and installing phase sensor

Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery

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3 Remove the phase sensor

a. Remove the engine upper guard plate assembly
①.

b. Disconnect the intake phase sensor connector

as arrowed.

c. Disconnect the engine fuel inlet hose ① as

arrowed.

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Ignition system 2-128 Maintenance Manual of 1.5GDI Engine

d. Unscrew the fixing bolt as arrowed, and remove

the intake phase sensor ①.
• Tightening torque of bolt: 9±0.9Nm

e. Disconnect the exhaust phase sensor

connector as arrowed.

f. Unscrew the fixing bolt as arrowed, and remove

the exhaust phase sensor ①.
• Tightening torque of bolt: 9±0.9Nm

Installation procedure

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Maintenance Manual of 1.5GDI Engine 2-129Ignition system

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
– Replace the O-ring ① during installation.

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Control system 2-130 Maintenance Manual of 1.5GDI Engine

2.8 Control system

2.8.1 Specifications
2.8.1.1 Fastener specifications

Location Specification Tightening torque (N.m)

MAP/IAT sensor (intake
Hexagon flange bolt M5×16 5±0.5
manifold)
Water temperature sensor Water temperature sensor 15±1.5
Oil control valve Hexagon flange bolt M5×12 6±0.9
Electronic accelerator pedal All-metal hexagon flange lock
8±1
assembly nut M6
ECU bracket Hexagon flange bolt M6×12 8±2
ECM Hexagon flange nut M6 8±2

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Maintenance Manual of 1.5GDI Engine 2-131Control system

2.8.2 Description and operation

2.8.2.1 Overview
Overview
The functions of the engine control system include: electronic fuel injection control, electronic spark
control, idle speed control, charge air pressure control, exhaust emission control, cruise system control,
fail-safe protection and backup system, self-diagnosis system, data communication system, anti-theft
system etc.
The core of the electronic fuel injection system is the ECM, which calculates the fuel injection volume
(injection pulse width) required for combustion in the cylinder based on the signals fed back from the
sensors and signals for various operating conditions, and opens the injector at the appropriate injection
timing to inject an appropriate amount of fuel into the cylinder to provide a combustible mixture with the
best air-fuel ratio. A series of actuators such as injector and ignition coil work together to keep the
engine in good working status. The electronic fuel injection system has the following advantages:
– A combustible mixture with the best air-fuel ratio allows the engine to maintain the best power,
economy and emission performance under various operating conditions.
– The electronic fuel injection system works in conjunction with the emission control system, which can
greatly reduce the emissions of three harmful gases: HC, CO, and NOx.
– The fuel injection pressure is increased and the spray pattern improved; because each cylinder is
equipped with an injector (multi-point injection), the fuel distribution is more even, which improves the
stability of engine operation.
– The ECM adjusts and optimizes the timing of fuel injection and ignition based on changes in air
density caused by changes in atmospheric pressure, ambient temperature, charge air pressure and
temperature.
– During the transition to acceleration and deceleration, the fuel control system can respond quickly to
provide good acceleration and deceleration performance.
– The deceleration fuel cutoff function reduces emissions and saves fuel.
– When the engine starts at idle speed, the fuel supply is automatically controlled, which makes the
engine easy to start and improves the warm-up performance.
Introduction to GDI engine control system
Upstream oxygen
Air cleaner Turbocharger Electronic sensor
assembly assembly throttle body MAP / IATPhase Oil control Ignition Phase Downstream oxygen
sensor sensor valve coil sensor sensor

Electronic intake air

recirculation valve

Catalytic converter
assembly

Turbocharger
assembly

Canister control
valve

Canister
assembly
Charge air pressure
control solenoid valve

Fuel pump High- Fuel rail injector High-pressure High- Speed Oil pump Knock sensor Water temperature
pressure assembly fuel rail pressure pressure sensor solenoid sensor
sensor
fuel pump injector valve

This is a GDI engine. Its main difference from the PFI engine is that the fuel is directly injected into the
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cylinder without mixing with air in the port. To achieve this function, the high-pressure fuel injection
system is used, including the high-pressure fuel pump, high-pressure fuel rail, high-pressure fuel rail
pressure sensor, and high-pressure injector.
Technical characteristics of 1.5T GDI engine
GDI technology, 3 injections per cycle. Low-inertia exhaust gas turbocharger, taking into account both
high-speed power and low-speed torque. Intake/exhaust DVVT, new generation of silent chain
technology, roller rocker arm, hydraulic tappet, MAHLE sodium-filled hollow exhaust valve. Patented
GCCS, high-energy ignition coil, NGK high-performance spark plug. The electronically controlled
variable displacement oil pump, improving fuel economy under the premise of satisfying lubrication
requirement. Lightweight thin-walled cylinder block, offset crankshaft technology, gantry cast iron
cylinder block + aluminum alloy oil pan, improving NVH performance.
2.8.3 System working principles
2.8.3.1 System working principles
MAP / IAT sensor
The MAP/IAT sensor is used to detect and sense the actual air intake status of the engine when the
engine is running. For the EMS that adopts the speed-density air intake metering method, the ECM will
quickly calculate the engine instantaneous air intake based on the data provided by the sensor and
referring to the input parameters of other sensors of the EMS. Therefore, the MAP/IAT sensor is one of
the main components that indicate the actual operating conditions and load status of the engine.
The MAP/IAT sensor is a resistor with a negative temperature coefficient (NTC). The resistance
changes with the intake temperature. The sensor sends a voltage indicating the change in intake
temperature the ECM.
The MAP/IAT sensor is composed of a silicon chip with an etched pressure diaphragm. There are 4
piezoelectric resistors and a signal processing circuit on the pressure diaphragm.
The water temperature sensor is located on the main water passage of the water pump bracket housing
assembly. The EMS will calculate the best control scheme based on the signal provided by the water
temperature sensor. At the same time, the temperature information is also transmitted to the instrument
panel to display the current engine operating temperature.
Oil control valve
The oil control valve is located on the cylinder head cover, near the front end of the engine. The
working power of the oil control valve is provided by the main relay controlled by the ECM. The ECM
controls the grounding of the oil control valve with a pulse width modulation signal, which can
continuously change the timing relationship between the crankshaft and the camshaft, so that the
engine can obtain the best valve timing required under different operating conditions, and thus realize
the control of the valve timing. It will help improve engine efficiency and idle speed stability and provide
greater torque and power, while helping to improve fuel economy and reduce hydrocarbon and nitrogen
oxide emissions.
ECM
The ECM of this vehicle is a microprocessor with a SCM as its core. It tests and calculates the required
air-fuel ratio and the ignition advance angle of the engine according to the input data from each sensor,
and directly controls the intake flow and the corresponding fuel supply, fuel injection timing, high-
pressure ignition timing, ignition close angle, engine idle speed in various engine operating conditions,
and working status of other accessory systems (such as A/C compressor, cooling fan, etc.). It
processes sensor data from different parts of the vehicle, judges the working status of the engine, and
then accurately controls the engine through the actuators.
The ECM has the function of continuously monitoring and controlling the normal operation of the engine.

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Maintenance Manual of 1.5GDI Engine 2-133Control system

2.8.4 Location of components

2.8.4.1 Location of components

ECM

Electronic accelerator
pedal assembly

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Oil control
valve

MAP / IAT sensor

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Maintenance Manual of 1.5GDI Engine 2-135Control system

2.8.5 Electrical schematic diagram

2.8.5.1 Electrical schematic diagram

Electronic accelerator pedal ECM Electronic throttle body

assembly

The throttle opening of the electronic throttle body is controlled as follows: the ECM analyzes the
driver’s real-time driving intention in advance according to control input signals of driver depressing the
electronic accelerator pedal assembly and other sensor input signals from the engine and vehicle,
calculates the engine output power required by the vehicle at this moment and in this status, and
controls the throttle opening of engine and adjusts the corresponding air supply accordingly; at the
same time, the throttle position sensor on the electronic throttle body can detect the actual opening of
the throttle timely and feed it back to the ECM; then the ECM optimizes and corrects the control
parameters of the vehicle again based on the feedback signal. This control process can ensure that the
engine and the vehicle work in the best control status.

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2.8.6 Diagnostic information and procedure

2.8.6.1 Diagnostic instructions
The diagnostic scan tool may be used to read the switch and sensor values by reading the DTC via the
OBD DLC of the vehicle and reading the data table displayed on the scan tool based on the data table
of EMS without removing any part. Reading the data table is the first step in troubleshooting and one of
the ways to reduce diagnosis time.
Description of MIL lighting up and fault confirmation pattern for UAES fault class
Description of MIL lighting up and fault confirmation pattern for UAES fault class
No. Fault class Description
The fault class of misfire-related fault diagnosis path is generally defined as 2. For the misfire
that causes active catalytic converter, the MIL flashes immediately to remind the driver; for the
1 2 misfire that causes the deterioration of emissions, the MIL will light up if the corresponding
level of misfire is detected in 2 consecutive driving cycles; after 40 consecutive trouble-free
warm-up cycles, the fault will be eliminated.
When the fault is detected for 2 consecutive driving cycles, the fault will be confirmed, and the
2 3 MIL will light up; when the fault is detected as rectified for 3 consecutive driving cycles, the
MIL will go out; after 40 consecutive trouble-free warm-up cycles, the fault will be eliminated.
In five seconds after the fault is detected, the fault will be confirmed, and the MIL will light up;
3 4 when the fault is detected as rectified for 3 consecutive driving cycles, the MIL will go out; after
40 consecutive trouble-free warm-up cycles, the fault will be eliminated.
When the fault is detected for 2 consecutive driving cycles, the fault will be confirmed, and the
MIL will not light up; if the fault is detected as rectified for 3 consecutive driving cycles, it
4 5
indicates that the fault is rectified; after 40 consecutive trouble-free warm-up cycles, the fault
will be eliminated.
After the fault is reported, it will not be confirmed and the MIL will not light up; after 40
consecutive trouble-free warm-up cycles, the fault will be eliminated; the fault cannot be read
5 6
with a general scan tool. Relevant information can be read through a customized diagnostic
scan tool.
After the fault is reported, it will not be confirmed and the MIL will not light up; after 5
6 7 consecutive trouble-free warm-up cycles, the fault will be eliminated; the fault cannot be read
with a general scan tool.
In 200ms after the fault is detected, the fault will be confirmed, and the MIL will not light up; in
200ms after the fault is rectified, the fault will be deleted; the fault cannot be read with a
7 9 general scanning tool, and the relevant information can be read through a customized
diagnostic scan tool. The fault will be confirmed when detected, and the MIL will not light up;
the fault will be deleted after rectified.
When the fault is detected for 2 consecutive driving cycles, the fault will be confirmed, and the
8 11 MIL will light up; when the fault is detected as rectified for 3 consecutive driving cycles, the
MIL will go out; after 40 consecutive trouble-free warm-up cycles, the fault will be eliminated.
In 200ms after the fault is detected, the SVS lamp will light up; in 200ms after the fault is
rectified, the SVS lamp will go out; after 40 consecutive trouble-free warm-up cycles, the fault
9 12
will be eliminated; the fault cannot be read with a general scanning tool, and the relevant
information can be read through a customized diagnostic scan tool.
In 200ms after the fault is detected, the SVS lamp will light up; when the fault is detected for 2
consecutive driving cycles, the fault will be confirmed, and the MIL will light up; in 200ms after
10 13 the fault is rectified, the SVS lamp will go out; when the fault is detected as rectified for 2
consecutive driving cycles, the MIL will go out; after 40 consecutive trouble-free warm-up
cycles, the fault will be eliminated.
2.8.6.2 Visual inspection
• Verify the symptoms
No symptom present during troubleshooting is the most difficult case in which the fault described by the
user must be analyzed thoroughly. Then the same or similar conditions and environment when the
user’s vehicle fails can be simulated. No matter how experienced the maintenance personnel are and
how skilled their technique is, if they do not verify the symptoms before troubleshooting, they may
ignore some critical concerns and give incorrect conjecture during repair. This would lead to the failure
of troubleshooting.
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Maintenance Manual of 1.5GDI Engine 2-137Control system
• Check the accessible or visible system components for obvious damage or conditions which may
cause faults.
• The connectors and the support points of vibration are the main locations which must be inspected
thoroughly. The vibration method is recommended in case of fault due to vibration.
a Vibrate the possibly defective sensor part with fingers and check it for fault.
b Lightly shake the connector in the vertical and horizontal directions.
c Lightly shake the harness in the vertical and horizontal directions.

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2.8.6.3 ECU terminals

EMS harness connector (EN01)

ECM harness connector

Wire Reference value

Terminal No. Terminal definition Condition
diameter/color (approx.)
1 0.5/orange Electronic throttle motor DCP － －
2 0.5/green Electronic throttle motor DCM － －
High-pressure fuel pump fuel
3 1.5/black － －
control -
High-pressure fuel pump fuel
4 1.5/red － －
control +
5 0.5/brown VCT (exhaust) signal － －
6 0.5/blue MAP/IAT sensor ground － －
7 0.5/yellow Speedsensor power supply － －
Throttle position sensor power
8 0.5/purple － －
supply
9 0.5/purple Fuel rail pressure sensor ground － －
10 0.35/white Knock sensor - － －
MAP/IAT sensor temperature
11 0.5/brown － －
signal
12 0.5/green MAP/IAT sensor pressure signal － －
14 0.5/blue Fuel rail pressure sensor signal － －
Grounding of oil pump solenoid
16 0.5/green － －
valve
18 0.5/green Canister solenoid valve signal － －
19 0.5/white Relief valve - － －
20 0.5/white VCT (intake) signal － －
23 0.5/pink Speed sensor signal － －
24 0.5/yellow Throttle position sensor signal 1 － －
25 0.35/yellow Knock sensor + － －
26 0.5/gray Phase sensor ground － －
27 0.5/yellow Phase sensor power supply － －
28 0.5/blue Speed sensor ground － －

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31 0.5/pink Injector 1 + － －
32 0.5/brown Injector 4 + － －

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Wire Reference value

Terminal No. Terminal definition Condition
diameter/color (approx.)
33 0.5/green Injector 1 - － －
34 0.5/orange Injector 3 - － －
37 0.75/orange Ignition coil 1 control signal － －
38 0.75/yellow Ignition coil 3 control signal － －
39 0.75/orange Ignition coil 4 control signal － －
40 0.75/white Ignition coil 2 control signal － －
41 0.5/pink Throttle position sensor signal 2 － －
Coolant temperature sensor
43 0.5/black － －
ground
Rail pressure sensor / MAP/IAT
44 0.5/pink sensor － －
Power
46 0.5/green Injector 3 + － －
47 0.5/white Injector 2 + － －
48 0.5/purple Injector 4 - － －
49 0.5/black Injector 2 - － －
51 0.5/gray Throttle position sensor ground － －
53 0.5/white Phase sensor (intake) signal － －
54 0.5/blue Phase sensor (exhaust) signal － －
Coolant temperature sensor
57 0.5/green － －
signal
EMS harness connector (FB46)
ECM harness connector

Wire Reference value

Terminal No. Terminal definition Condition
diameter/color (approx.)
1 0.75/orange Power supply － －
2 0.75/orange Power supply － －
3 0.75/black Ground － －
4 0.75/orange Power supply － －

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5 0.75/black Ground － －
6 0.75/black Ground － －

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Wire Reference value

Terminal No. Terminal definition Condition
diameter/color (approx.)
14 0.35/purple IG1 power supply － －
Upstream oxygen sensor signal
17 0.5/purple － －
+
Accelerator pedal position
18 0.35/blue － －
sensor signal 1
Accelerator pedal position
19 0.35/pink － －
sensor 5V power supply 1
Accelerator pedal position
20 0.35/purple － －
sensor 5V power supply 2
Accelerator pedal position
21 0.35/gray － －
sensor ground 1
ENGINE START/STOP button
26 0.35/pink － －
signal
30 0.35/gray Sensor ground － －
31 0.35/green Start feedback signal － －
32 0.35/brown Main relay control signal － －
36 0.5/green LIN communication － －
Temperature signal of charge air
37 0.35/orange temperature and pressure － －
sensor
Pressure signal of charge air
38 0.35/yellow temperature and pressure － －
sensor
Downstream oxygen sensor
39 0.5/green － －
signal +
Accelerator pedal position
40 0.35/white － －
sensor signal 2
41 0.5/purple Anti-theft coil signal input － －
42 0.35/pink Sensor 5V power supply － －
PCV pipeline pressure sensor
43 0.35/pink － －
5V power supply
44 0.5/orange Waste gate control signal － －
Accelerator pedal position
49 0.35/green － －
sensor ground 2
51 0.35/gray Compressor relay control signal － －
52 0.5/yellow Electronic fan module PWM － －
PCV pipeline pressure sensor
53 0.35/brown － －
signal
54 0.35/pink Speed signal － －
56 0.35/blue PCAN-H － －
57 0.35/brown PCAN-L － －
PCV pipeline pressure sensor
58 0.35/white － －
ground
59 0.35/brown STT ON indicator lamp － －
Fuel tank evaporating pressure
64 0.35/blue － －
sensor signal

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Downstream oxygen sensor

67 0.5/gray － －
signal -
Upstream oxygen sensor signal
68 0.5/orange － －
-
70 0.35/white Starter relay control signal － －
71 0.35/red Power supply － －
Downstream oxygen sensor
72 0.5/blue － －
heater -
77 0.35/gray Brake switch N/C signal － －
82 0.35/green Brake switch N/O signal － －
84 0.35/pink Sensor 5V power supply － －

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Wire Reference value

Terminal No. Terminal definition Condition
diameter/color (approx.)
86 0.35/green Fuel pump relay control signal － －
88 0.35/green Vacuum sensor signal － －
89 0.35/yellow Cruise control signal － －
90 0.35/black Sensor ground － －
Canister desorption pressure
91 0.35/white － －
sensor signal
Canister vent valve control
93 0.35/green － －
signal
Upstream oxygen sensor heater
94 0.5/green － －
-
2.8.6.4 Data list
Diagnostic Range
Unit Remarks
display/measurement item Min. Max.
1=Default session
Current diagnostic session 2=Programming
1 3 —
mode session
3=Extended session
Battery voltage 7 18 V —
Engine coolant temperature
sensor voltage
0 5 V —

IAT sensor voltage 0 5 V —

MAP sensor voltage 0 5 V —
Accelerator pedal position
0 5 V —
sensor 1 voltage
Accelerator pedal position
0 5 V —
sensor 2 voltage
Throttle position sensor 1
0 5 V —
voltage
Throttle position sensor 2
0 5 V —
voltage
Upstream oxygen sensor
0 5 V —
voltage
Downstream oxygen
0 5 V —
sensor voltage
Knock sensor 1 signal 0 5 V —
Knock sensor 2 signal 0 5 V —
Knock sensor 3 signal 0 5 V —
Knock sensor 4 signal 0 5 V —

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Maintenance Manual of 1.5GDI Engine
2.8.6.5 List of diagnostic trouble codes (DTCs)
DTC DTC definition
Intake VVT Operation Fault
P000A00
(Slow Response)
Exhaust VVT Operation
P000B00
Fault (Slow Response)
Intake VVT Control
P001000 Solenoid Valve Circuit
Open
Intake Camshaft Locking
P001100 Position Operation
Implausible
Exhaust VVT Control
P001300 Solenoid Valve Circuit
Open
Exhaust Camshaft Locking
P001400 Position Operation
Implausible
Crankshaft-Exhaust
Camshaft Initial Installation
P001776
Position Implausible
(Bank1)
Excessive Relative Position
Deviation between
P001778
Crankshaft and Exhaust
Camshaft (Bank1)
Upstream Oxygen Sensor
P003000
Heater Control Circuit Open
2-145Control system
Possible causes Recommended action
1 Check whether the cam phase regulator
1 The OCV oil valve pressure is
works normally (blockage due to dirt, oil
insufficient
leakage, stuck)
2 The OCV oil valve is clogged
2 Check whether the OCV oil control valve
or leaking
works normally
1 Check whether the cam phase regulator
1 The OCV oil valve pressure is
works normally (blockage due to dirt, oil
insufficient
leakage, stuck)
2 The OCV oil valve is clogged
2 Check whether the OCV oil control valve
or leaking
works normally
1 The corresponding pin of
1 The corresponding pin of intake VVT
intake VVT control circuit is
control circuit is open-circuited
open-circuited
2 The connector is not connected properly
2 The connector has poor
or has poor contact
contact or is open-circuited
3 The intake VVT circuit is damaged
3 The actuator side circuit is
4 The VVT control pin at ECU side is faulty
damaged
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
1 The status of intake VVT lock
2 Read and save the fail-frost frame
pin is abnormal
information
2 There is interference in the
3 Check whether the lock pin is damaged
harness
4 Check the harness for external
interference
1 The corresponding pin of
1 The corresponding pin of exhaust VVT
exhaust VVT control circuit is
control circuit is open-circuited
open-circuited
2 The connector is not connected properly
2 The connector has poor
or has poor contact
contact or is open-circuited
3 The exhaust VVT circuit is damaged
3 The actuator side circuit is
4 The VVT control pin at ECU side is faulty
damaged
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
1 The status of exhaust VVT
2 Read and save the fail-frost frame
lock pin is abnormal
information
2 There is interference in the
3 Check whether the lock pin is damaged
harness
4 Check the harness for external
interference
Crankshaft-Exhaust Camshaft
Check whether the relative installation
Initial Installation Position
position of crankshaft-exhaust camshaft is
Implausible (Bank1)
correct
Check whether the position of exhaust
The exhaust camshaft is aging
camshaft deviates much from the initial
and twisted
installation position
1 The connector is not
connected properly or has poor
1 Check whether the connector is not
contact
connected properly or has poor contact
2 The pin of upstream oxygen
2 The pin of upstream oxygen sensor
sensor heater control circuit is
heater control circuit is open-circuited
open-circuited
3 The power supply terminal of upstream
3 The power supply terminal of
oxygen sensor heater control circuit is not
upstream oxygen sensor heater
connected to the main relay
control circuit is not connected
4 The sensor is damaged
to the main relay
5 The upstream oxygen sensor heater pin
4 The sensor is damaged
at ECU side is open-circuited or the ECU
5 The upstream oxygen sensor
internal circuit is damaged
heater pin at ECU side is open-
circuited or the ECU internal
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Control system 2-146
circuit is damaged
1 The pin of upstream oxygen
sensor heater control circuit is
shorted to ground
Upstream Oxygen Sensor 2 The power supply terminal of
P003100 Heater Control Circuit upstream oxygen sensor heater
Voltage Low control circuit is grounded
3 The upstream oxygen sensor
heater pin at ECU side is
shorted to ground
1 The pin of upstream oxygen
sensor heater control circuit is
Upstream Oxygen Sensor
shorted to power supply
P003200 Heater Control Circuit
2 The upstream oxygen sensor
Voltage High
heater pin at ECU side is
shorted to power supply
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Maintenance Manual of 1.5GDI Engine
1 Check whether the pin of upstream
oxygen sensor heater control circuit is
shorted to ground
2 Check whether the power supply
terminal of upstream oxygen sensor heater
control circuit is grounded
3 Check whether the upstream oxygen
sensor heater pin at ECU side is shorted to
ground
1 Check whether the pin of upstream
oxygen sensor heater control circuit is
shorted to power supply
2 Check whether the upstream oxygen
sensor heater pin at ECU side is shorted to
power supply
Maintenance Manual of 1.5GDI Engine
DTC DTC definition Possible causes
1 The connector is not
connected properly or has poor
contact
2 The pin of turbocharger relief
Turbocharger Relief Valve valve drive circuit is open-
P003300
Drive Circuit Open circuited
3 The pin of turbocharger relief
valve drive circuit at ECU side
is open-circuited or the ECU
internal circuit is damaged
1 The turbocharger relief valve
drive circuit is shorted to
Turbocharger Relief Valve ground
P003400
Drive Circuit Voltage Low 2 The drive circuit between
EMS and turbocharger relief
valve is shorted to ground
1 The turbocharger relief valve
drive circuit is shorted to power
supply
Turbocharger Relief Valve
P003500 2 The drive circuit between
Drive Circuit Voltage High
EMS and turbocharger relief
valve is shorted to power
supply
1 The connector is not
connected properly or has poor
contact
2 The downstream oxygen
sensor heater control pin is
open-circuited
Downstream Oxygen 3 The power supply terminal of
P003600 Sensor Heater Control downstream oxygen sensor
Circuit Open heater is not connected to the
main relay
4 The sensor is damaged
5 The downstream oxygen
sensor heater pin at ECU side
is open-circuited or the ECU
internal circuit is damaged
1 The pin of downstream
oxygen sensor heater control
circuit is shorted to ground
2 The power supply terminal of
Downstream Oxygen
downstream oxygen sensor
P003700 Sensor Heater Control
heater control circuit is
Circuit Voltage Low
grounded
3 The downstream oxygen
sensor heater pin at ECU side
is shorted to ground
1 The pin of downstream
oxygen sensor heater control
Downstream Oxygen circuit is shorted to power
P003800 Sensor Heater Control supply
Circuit Voltage High 2 The downstream oxygen
sensor heater pin at ECU side
is shorted to power supply
1 The OCV oil valve pressure is
Intake VVT Operation Fault insufficient
P003C00
(Stuck) 2 The OCV oil valve is clogged
or leaking
P005300 Upstream Oxygen Sensor 1 The heater circuit is faulty
2-147Control system
Recommended action
1 Check whether the connector is not
connected properly or has poor contact
2 Check whether the pin of turbocharger
relief valve drive circuit is open-circuited
3 Check whether the pin of turbocharger
relief valve drive circuit at ECU side is
open-circuited or the ECU internal circuit is
damaged
1 Check whether the pin of turbocharger
relief valve drive circuit is shorted to
ground
2 Check whether the pin of turbocharger
relief valve drive circuit at ECU side is
shorted to ground
1 Check whether the pin of turbocharger
relief valve drive circuit is shorted to power
supply
2 Check whether the pin of turbocharger
relief valve drive circuit at ECU side is
shorted to power supply
1 Check whether the connector is not
connected properly or has poor contact
2 Check whether the downstream oxygen
sensor heater control pin is open-circuited
3 Check whether the power supply
terminal of downstream oxygen sensor
heater circuit is not connected to the main
relay
4 Check whether the sensor is damaged
5 Check whether the downstream oxygen
sensor heater pin at ECU side is open-
circuited or the ECU internal circuit is
damaged
1 Check whether the pin of downstream
oxygen sensor heater control circuit is
shorted to ground
2 Check whether the power supply
terminal of downstream oxygen sensor
heater control circuit is grounded
3 Check whether the downstream oxygen
sensor heater pin at ECU side is shorted to
ground
1 Check whether the pin of downstream
oxygen sensor heater control circuit is
shorted to power supply
2 Check whether the downstream oxygen
sensor heater pin at ECU side is shorted to
power supply
1 Check whether the cam phase regulator
works normally (blockage due to dirt, oil
leakage, stuck)
2 Check whether the OCV oil control valve
works normally
1 Connect the diagnostic scan tool and set
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Heater Circuit Fault 2 The oxygen sensor resister is the ignition switch in the "ON" position
aged 2 Read and save the fail-frost frame
information
3 Measure whether the voltage of #1 wire
(white, positive pole of heater power
supply) at oxygen sensor side of the
upstream oxygen sensor harness is 12V
with the oxygen sensor connector
connected.
4 Measure whether the voltage of #2 wire
(white, ground of heater power supply) at
oxygen sensor side of the upstream
oxygen sensor harness is 12V with the
oxygen sensor connector connected.
5 Disconnect the upstream oxygen sensor
harness connector, remove the upstream
oxygen sensor, and allow the oxygen
sensor to cool down at room temperature.
When the oxygen sensor reaches the room
temperature ①, use a multimeter to
measure whether the resistance between
the #1 port (white, positive pole of heater
power supply) and #2 port (white, ground
of heater power supply) at the sensor side
is greater than 15Ω.

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Maintenance Manual of 1.5GDI Engine
DTC DTC definition
Upstream Oxygen Sensor
1 The oxygen sensor is faulty
P005326 Heater Circuit Fault
(Starting)
Downstream Oxygen
P005400 Sensor Heater Internal 2 The oxygen sensor resister is
Resistance Implausible
Ambient Pressure Sensor
P222900
Shorted to Power Supply
Ambient Pressure Sensor
P222800
Shorted to Ground
1 The OCV oil valve pressure is
Exhaust VVT Operation
P005A00
Fault (Stuck) 2 The OCV oil valve is clogged
Ambient Pressure Sensor
P223000
Signal Fault
Ambient Pressure Sensor
P222722
Pressure Implausibly High
Possible causes
2 The harness is faulty
1 The heater circuit is faulty
aged
The ECU built-in ambient
pressure sensor is faulty
The ECU built-in ambient
pressure sensor is faulty
insufficient
or leaking
The ECU built-in ambient
pressure sensor is faulty
The ECU built-in ambient
pressure sensor is faulty
2-149Control system
Recommended action
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check whether the status of oxygen
sensor connector is abnormal
4 Disconnect the upstream oxygen sensor
harness connector, remove the upstream
oxygen sensor, and allow the oxygen
sensor to cool down at room temperature.
When the oxygen sensor reaches the room
temperature ①, use a multimeter to
measure the resistance between the
positive pole and the ground of heater
power supply at the sensor side is greater
than 3Ω
5 Check for contact resistance in the
oxygen sensor heater harness
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Measure whether the voltage of #1 wire
(white, positive pole of heater power
supply) at oxygen sensor side of the
downstream oxygen sensor harness is 12V
with the oxygen sensor connector
connected
4 Measure whether the voltage of #2 wire
(white, ground of heater power supply) at
oxygen sensor side of the downstream
oxygen sensor harness is 12V with the
oxygen sensor connector connected
5 Disconnect the downstream oxygen
sensor harness connector, remove the
downstream oxygen sensor, and allow the
oxygen sensor to cool down at room
temperature. When the oxygen sensor
reaches the room temperature ①, use a
multimeter to measure whether the
resistance between the #1 port (white,
positive pole of heater power supply) and
#2 port (white, ground of heater power
supply) at the sensor side is greater than
15
The ECU built-in ambient pressure sensor
is faulty
Check whether the signal value of ambient
pressure sensor is too high or low
1 Check whether the cam phase regulator
works normally (blockage due to dirt, oil
leakage, stuck)
2 Check whether the OCV oil control valve
works normally
Check whether the deviation between the
signal value of ambient pressure sensor
and the current atmospheric pressure is
excessive
Check whether the deviation between the
signal value of ambient pressure sensor
GAC Motor 2019
Control system 2-150 Maintenance Manual of 1.5GDI Engine

and the current atmospheric pressure is

Ambient Pressure Sensor
P222721
Pressure Implausibly Low
Ambient Pressure Sensor
P120200
Pressure above Upper Limit
Ambient Pressure Sensor
Pressure below Lower Limit
P120300
Faulty
The ECU built-in ambient
pressure sensor is faulty
The ECU built-in ambient
pressure sensor is faulty
The ECU built-in ambient
pressure sensor is faulty
excessive
Check whether the deviation between the
signal value of ambient pressure sensor
and the current atmospheric pressure is
excessive
Check whether the deviation between the
signal value of ambient pressure sensor
and the current atmospheric pressure is
excessive
Check whether the deviation between the
signal value of ambient pressure sensor
and the current atmospheric pressure is
excessive

1. The fuel passage is leaking

1 Check for leaks in the fuel passage
2 The fuel is insufficient
2 Check whether the fuel is insufficient
High-Pressure Fuel Rail 3 The low-pressure fuel pump
P008700 3 Check whether the low-pressure fuel
Pressure Low is damaged
pump is damaged
4 The working capacity of the
4 Check whether the working capacity of
high-pressure fuel pump is
the high-pressure fuel pump is impaired
impaired
1 The high-pressure fuel pump 1 Check whether the high-pressure fuel
High-Pressure Fuel Rail control is faulty pump control is normal
P008800
Pressure High 2 The pressure relief valve is 2 Check whether the pressure relief valve
clogged is clogged or not working properly

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine
DTC DTC definition Possible causes
1 The high-pressure fuel pump
Too Small PID Control control is faulty
P008984 Deviation of High-pressure
Fuel Supply 2 The pressure relief valve is
clogged
1. The fuel passage is leaking
2 The fuel is insufficient
Too Large PID Control 3 The low-pressure fuel pump
P008985 Deviation of High-pressure
is damaged
Fuel Supply
4 The working capacity of the
high-pressure fuel pump is
impaired
Short Circuit between Flow
Short Circuit between Flow
Control Valve High Side
P009000 Control Valve High Side and
and Low Side Control
Low Side Control Circuits
Circuits
1 The signal terminal of charge
air temperature sensor is
IAT Sensor 2 Circuit shorted to ground
P009700
Voltage Low 2 The signal pin of charge air
temperature sensor at ECU
side is shorted to ground
1 The signal terminal of charge
air temperature sensor is
shorted to power supply or
open-circuited
2 The sensor reference ground
IAT Sensor 2 Circuit terminal is open-circuited
P009800
Voltage High 3 The signal pin of charge air
temperature sensor at ECU
side is shorted to power supply,
open-circuited or the ECU
internal circuit is damaged
4 The sensor is damaged
2-151Control system
Recommended action
1 Check whether the high-pressure fuel
pump control is normal
2 Check whether the pressure relief valve
is clogged or not working properly
1 Check for leaks in the fuel passage
2 Check whether the fuel is insufficient
3 Check whether the low-pressure fuel
pump is damaged
4 Check whether the working capacity of
the high-pressure fuel pump is impaired
Check for short circuit between flow control
valve high side and low side control circuits
1 Connect the diagnostic scan tool, set the
ignition switch in the "ON" position (do not
start the engine), and observe whether the
“value measured by IAT sensor” in the data
stream is lower than the lowest
temperature range of the intake manifold
that can be reached under normal
conditions. You can also use a multimeter
to measure whether the voltage between
the signal terminal of charge air
temperature sensor and the ground is
close to or equal to 5V
2 The ignition switch is set in the “OFF”
position, the connector is not connected
properly or has poor contact
3 Check whether the sensor signal terminal
is shorted to ground
4 Check whether the signal pin of charge
air temperature sensor at ECU side is
shorted to ground
1 Connect the diagnostic scan tool, set the
ignition switch in the "ON" position (do not
start the engine), and observe whether the
“value measured by IAT sensor” in the data
stream is lower than the lowest
temperature range of the intake manifold
that can be reached under normal
conditions. You can also use a multimeter
to measure whether the voltage between
the signal terminal of charge air
temperature sensor and the ground is
close to or equal to 5V
2 The ignition switch is set in the “OFF”
position, the connector is not connected
properly or has poor contact
3 Check whether the sensor signal terminal
is shorted to power supply or open-
circuited
4 Check whether the sensor reference
ground terminal is open-circuited
5 Check whether the sensor is damaged
6 Check whether the signal pin of charge
air temperature sensor at ECU side is
shorted to power supply, open-circuited or
the ECU internal circuit is damaged
GAC Motor 2019
Control system 2-152
1 The signal terminal of charge
air temperature sensor has
poor contact
IAT Sensor 2 Circuit 2 The connector has poor
P009900
Voltage Implausible contact
3 The signal pin of charge air
temperature sensor at ECU
side has poor contact
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
1 Connect the diagnostic scan tool, set the
ignition switch in the "ON" position (do not
start the engine), and observe whether the
“value measured by IAT sensor” in the data
stream is lower than the lowest charge air
temperature range that can be reached
under normal conditions. You can also use
a multimeter to measure whether the
voltage between the signal terminal of
charge air temperature sensor and the
ground is close to or equal to 5V
2 The ignition switch is set in the “OFF”
position, the connector is not connected
properly or has poor contact
3 Check whether the sensor signal terminal
has poor contact
4 Check whether the signal pin of charge
air temperature sensor at ECU side has
poor contact
Maintenance Manual of 1.5GDI Engine 2-153Control system

DTC DTC definition Possible causes Recommended action

1. The fuel passage is leaking
2 The fuel is insufficient
3 The low-pressure fuel pump
is damaged
4 The working capacity of the
high-pressure fuel pump is
Operation Failure after High impaired
P00C600
Pressure Start 5 The injector is damaged
6 The fuel pipe has been
replaced with a new one or the
vehicle has just rolled off the
assembly line, the fuel pressure
has not yet been built-up, and a
fault may be reported
1 The sensor is frozen or oily
High Pressure Value of 2 The sensor is aged
P00C722 MAP Sensor Signal during 3 The intake pipe is
Start disconnected or seriously
leaking
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check for leaks in the fuel passage
4 Check whether the fuel is insufficient
5 Check whether the low-pressure fuel
pump is damaged
6 Check whether the working capacity of
the high-pressure fuel pump is impaired
7 Check whether the injector is damaged
8 Check whether the fuel pipe has been
replaced with a new one or the vehicle has
just rolled off the assembly line
9 Clear the fault, drive the vehicle for 10
minutes to build up fuel pressure, then turn
off the engine and start it again, and check
whether the fault recurs
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Do not start the engine. Observe whether
the “intake pressure” item in the data
stream deviates from the ambient pressure
by about 101kpa (the specific value is
related to the current atmospheric
pressure)
3 Set the ignition switch in the "OFF"
position, and check the sensor probe for
ice, oil dirt, etc. that may affect the normal
measurement

4 Check whether the installation position of

1 The sensor is frozen or oily
MAP Sensor Pressure
P010622 Implausibly Higher Than
Model Pressure
1 The sensor is frozen or oily
MAP Sensor Pressure
P010621 Implausibly Lower Than
Model Pressure
1 The sensor is frozen or oily
MAP Sensor Pressure
P120000
above Upper Limit
2 The sensor is aged
3 The intake pipe is
disconnected or seriously
leaking
2 The sensor is aged
3 The intake pipe is
disconnected or seriously
leaking
2 The sensor is aged
3 The intake pipe is
disconnected or seriously
leaking
MAP sensor is correct or the intake pipe is
disconnected or seriously leaking, etc.
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Set the ignition switch in the "OFF"
position, and check the sensor probe for
ice, oil dirt, etc. that may affect the normal
measurement
3 Check whether the installation position of
charge air sensor is correct or the intake
pipe is disconnected or seriously leaking,
etc.
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Set the ignition switch in the "OFF"
position, and check the sensor probe for
ice, oil dirt, etc. that may affect the normal
measurement
3 Check whether the installation position of
charge air sensor is correct or the intake
pipe is disconnected or seriously leaking,
etc.
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Set the ignition switch in the "OFF"
position, and check the sensor probe for
ice, oil dirt, etc. that may affect the normal

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Control system 2-154
1 The sensor is frozen or oily
2 The sensor is aged
MAP Sensor Pressure
P120100 3 The intake pipe is
below Lower Limit
disconnected or seriously
leaking
1 The sensor is frozen or oily
2 The sensor is aged
Charge Air Pressure above
P120400 3 The intake pipe is
Upper Limit
disconnected or seriously
leaking
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
measurement
3 Check whether the installation position of
charge air sensor is correct or the intake
pipe is disconnected or seriously leaking,
etc.
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Set the ignition switch in the "OFF"
position, and check the sensor probe for
ice, oil dirt, etc. that may affect the normal
measurement
3 Check whether the installation position of
charge air sensor is correct or the intake
pipe is disconnected or seriously leaking,
etc.
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Set the ignition switch in the "OFF"
position, and check the sensor probe for
ice, oil dirt, etc. that may affect the normal
measurement
3 Check whether the installation position of
charge air sensor is correct or the intake
pipe is disconnected or seriously leaking,
etc.
Maintenance Manual of 1.5GDI Engine
DTC DTC definition Possible causes
1 The sensor is frozen or oily
Charge Air Pressure below 2 The sensor is aged
P120500
Lower Limit 3 The intake pipe is
disconnected or seriously
leaking
1 The sensor is frozen or oily
Charge Air Pressure 2 The sensor is aged
P023622
Implausibly High 3 The intake pipe is
disconnected or seriously
leaking
1 The sensor is frozen or oily
2 The sensor is aged
Charge Air Pressure
P023621 3 The intake pipe is
Implausibly High
disconnected or seriously
leaking
1 The sensor is frozen or oily
2 The sensor installation
Abnormal Signal Value
position is incorrect
P01062A without Fluctuation of MAP
3 The intake pipe is
sensor
disconnected or seriously
leaking
1 The MAP sensor signal
terminal is shorted to ground
2 The sensor 5V reference
MAP Sensor Shorted to
P010700 voltage terminal is open-
Ground
circuited
3 The MAP sensor signal pin at
ECU side is shorted to ground
1 The MAP sensor signal
MAP sensor Shorted to terminal is shorted to power
P010800
Power Supply supply or open-circuited
2 The sensor reference ground
2-155Control system
Recommended action
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Set the ignition switch in the "OFF"
position, and check the sensor probe for
ice, oil dirt, etc. that may affect the normal
measurement
3 Check whether the installation position of
charge air sensor is correct or the intake
pipe is disconnected or seriously leaking,
etc.
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Set the ignition switch in the "OFF"
position, and check the sensor probe for
ice, oil dirt, etc. that may affect the normal
measurement
3 Check whether the installation position of
charge air sensor is correct or the intake
pipe is disconnected or seriously leaking,
etc.
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Set the ignition switch in the "OFF"
position, and check the sensor probe for
ice, oil dirt, etc. that may affect the normal
measurement
3 Check whether the installation position of
charge air sensor is correct or the intake
pipe is disconnected or seriously leaking,
etc.
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Do not start the engine. Observe whether
the “intake pressure” item in the data
stream deviates from the ambient pressure
by about 101kpa (the specific value is
related to the current atmospheric
pressure)
3 Set the ignition switch in the "OFF"
position, and check the sensor probe for
ice, oil dirt, etc. that may affect the normal
measurement
4 Check whether the installation position of
MAP sensor is correct or the intake pipe is
disconnected or seriously leaking, etc.
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position Do
not start the engine. Use a multimeter to
measure whether the voltage of MAP
sensor signal terminal is close to or equal
to 0V
2 Set the ignition switch in the "OFF"
position, and check whether the pressure
sensor signal terminal is shorted to ground
3 Check whether the sensor 5V reference
voltage terminal is open-circuited
4 Check whether the MAP sensor signal
pin at ECU side is shorted to ground
1 Connect the diagnostic scan tool, set the
ignition switch in the "ON" position (do not
start the engine), and use a multimeter to
measure whether the voltage between the
GAC Motor 2019
Control system 2-156 Maintenance Manual of 1.5GDI Engine

terminal is open-circuited MAP sensor signal terminal and the

3 The MAP sensor signal pin at ground is close to or equal to 5V
ECU side is shorted to power 2 The ignition switch is set in the “OFF”
supply or open-circuited position, the connector is not connected
4 The sensor is damaged properly or has poor contact
3 Check whether the MAP sensor signal
terminal is shorted to power supply or
open-circuited
4 Check whether the sensor reference
ground terminal is open-circuited
5 Check whether the sensor is damaged
6 Check whether the MAP sensor signal
pin at ECU side is shorted to power supply,
open-circuited or the ECU internal circuit is
damaged

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-157Control system

DTC DTC definition Possible causes Recommended action

1 The IAT sensor signal
IAT sensor Signal Voltage terminal is shorted to ground
P011200
Low
2 The sensor is damaged
1 The IAT sensor signal
terminal is shorted to power
supply or open-circuited
2 The sensor reference ground
IAT sensor Signal Voltage terminal is open-circuited
P011300
High 3 The IAT sensor signal pin at
ECU side is shorted to power
supply, open-circuited or the
ECU internal circuit is damaged
4 The sensor is damaged
1 Use a multimeter to measure whether
the voltage of IAT sensor signal terminal is
close to or equal to 0V
2 Set the ignition switch in the "OFF"
position, and check whether the IAT
sensor signal terminal is shorted to ground
3 The sensor is damaged
4 The IAT sensor signal pin at ECU side is
shorted to ground
1 Use a multimeter to measure whether
the voltage between the IAT sensor signal
terminal and the ground is close to or
equal to 5V
2 The ignition switch is set in the “OFF”
position, the connector is not connected
properly or has poor contact
3 Check whether the sensor signal
terminal is shorted to power supply or
open-circuited
4 Check whether the sensor reference
ground terminal is open-circuited
5 Check whether the sensor is damaged
6 Check whether the IAT sensor signal pin
at ECU side is shorted to power supply,
open-circuited or the ECU internal circuit is
damaged

1 Use a multimeter to measure whether

the voltage between the IAT sensor signal
terminal and the ground is close to or
1 The IAT sensor signal equal to 5V
terminal has poor contact
2 The ignition switch is set in the “OFF”
Poor Contact in IAT Sensor 2 The connector has poor position, the connector is not connected
P011400
Circuit contact properly or has poor contact
3 The IAT sensor signal pin at 3 Check whether the sensor signal
ECU side has poor contact terminal has poor contact
4 Check whether the IAT sensor signal pin
at ECU side has poor contact
1 Check for contact resistance in the
IAT Sensor Cold Start harness
IAT Sensor Internal Resistance
P00CE24 Check Implausible (Positive 2 Check for excessive deviation between
Implausible
Deviation) the sensor internal resistance and the
normal value
1 Check for contact resistance in the
IAT Sensor Cold Start harness
IAT Sensor Internal Resistance
P00CE23 Check Implausible (Positive 2 Check for excessive deviation between
Implausible
Deviation) the sensor internal resistance and the
normal value
1 Check for contact resistance in the
Charge Air Temperature harness
Sensor Cold Start Check IAT Sensor Internal Resistance
P138024 2 Check for excessive deviation between
Implausible (Positive Implausible
Deviation) the sensor internal resistance and the
normal value
Charge Air Temperature 1 Check for contact resistance in the
Sensor Cold Start Check IAT Sensor Internal Resistance harness
P138023
Implausible (Positive Implausible 2 Check for excessive deviation between
Deviation) the sensor internal resistance and the

GAC Motor 2019

Control system 2-158 Maintenance Manual of 1.5GDI Engine

normal value
1 Check for contact resistance in the
Coolant Temperature harness
Coolant Temperature Sensor
P011623 Sensor 1 Signal 2 Check for excessive deviation between
Internal Resistance Implausible
Implausible the sensor internal resistance and the
normal value
1 Check for contact resistance in the
harness
Coolant Temperature Coolant Temperature Sensor
P011626 2 Check for excessive deviation between
Sensor 1 Signal Stuck Internal Resistance Implausible
the sensor internal resistance and the
normal value
1 Check for contact resistance in the
Coolant Temperature harness
Sensor 1 Cold Start Check Coolant Temperature Sensor
P050C24 2 Check for excessive deviation between
Implausible (Positive Internal Resistance Implausible
Deviation) the sensor internal resistance and the
normal value
1 Check for contact resistance in the
Coolant Temperature harness
Sensor 1 Cold Start Check Coolant Temperature Sensor
P050C23 2 Check for excessive deviation between
Implausible (Negative Internal Resistance Implausible
Deviation) the sensor internal resistance and the
normal value

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-159Control system

DTC DTC definition Possible causes Recommended action

Coolant Temperature
P011700 Sensor 1 Signal Voltage
Low
Coolant Temperature
P011800 Sensor 1 Signal Voltage
High
Coolant Temperature
P011900 Sensor 1 Circuit Voltage
Implausible
Electronic Throttle Position
P012100 Sensor 1 / 2 Signal Voltage
Implausible
1 The signal terminal of coolant
temperature sensor 1 is shorted
to ground
3 The signal pin of coolant
temperature sensor 1 at ECU
side is shorted to ground
4 The sensor is damaged
1 The connector is not
connected properly or has poor
contact
2 The signal terminal of coolant
temperature sensor is shorted
to power supply or open-
circuited
3 The signal pin of coolant
temperature sensor at ECU
side is shorted to power supply
or open-circuited
4 The sensor is damaged
The signal terminal circuit of
coolant temperature sensor has
poor contact
1 The two signal wires of
electronic throttle position
sensor are shorted
2 There is resistance in the 5V
power supply wire or GND wire
of the electronic throttle, which
pulls down the 5V voltage at
signal terminal or pulls up the
null voltage. There is resistance
in the 5V power supply wire or
GND wire of the electronic
throttle, which pulls down the
5V voltage at signal terminal or
pulls up the null voltage
1 Connect the diagnostic scan tool, set the
ignition switch in the "ON" position (do not
start the engine), and observe whether the
“value measured by coolant temperature
sensor” in the data stream is much higher
than the reasonable temperature range.
You can also use a multimeter to measure
whether the voltage of the signal terminal
of coolant temperature sensor 1 is close to
or equal to 0V
2 Set the ignition switch in the "OFF"
position, and check whether the signal
terminal of coolant temperature sensor 1 is
shorted to the ground
3 Check whether the sensor is damaged
4 Check whether the signal pin of coolant
temperature sensor 1 at ECU side is
shorted to ground
1 Connect the diagnostic scan tool, set the
ignition switch in the "ON" position (do not
start the engine), and observe whether the
“value measured by IAT sensor” in the data
stream is much lower than the current
ambient temperature. You can also use a
multimeter to measure whether the voltage
between the signal terminal of coolant
temperature sensor 1 and the ground is
close to or equal to 5V
2 The ignition switch is set in the “OFF”
position, the connector is not connected
properly or has poor contact
3 Check whether the sensor signal terminal
is shorted to power supply or open-
circuited
4 The sensor reference ground terminal is
open-circuited
5 The sensor is damaged
6 The signal pin of coolant temperature
sensor at ECU side is shorted to power
supply, open-circuited or the ECU internal
circuit is damaged
Check whether the signal terminal circuit of
coolant temperature sensor has poor
contact
1 Collect and observe whether the sum of
the voltage values of two DVE signals
ThrVlv_uRawSens1B1 and
ThrVlv_uRawSens2B1 deviates from 5V
2 Check whether actions such as
disconnecting and connecting the
connector, shaking the harness, etc., affect
the occurrence of the fault
3 Measure the voltage drop of each section
on the harness using AD-Scan. If the
harness is in good condition, there will be
no voltage drop. If there is a voltage drop,
it means that there is resistance in the
harness or connector.
4 Verify if the fault is in the harness by
connecting a jumper across the electronic
throttle

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Control system 2-160 Maintenance Manual of 1.5GDI Engine

5 Replace the throttle body to determine

whether there is an internal fault
6 Clear the DTC, restart the engine, and
check whether the DTC is eliminated

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-161Control system

DTC DTC definition Possible causes Recommended action

Electronic Throttle Position
P022100 Sensor 1 / 2 Signal Voltage
Implausible
Accelerator Pedal Position
P212200 Sensor 1 / 2 Signal Voltage
Low
Accelerator Pedal Position
P212700 Sensor 1 / 2 Signal Voltage
Low
Electronic Throttle Position
P012300 Sensor 1 / 2 Signal Voltage
High
1 The two signal wires of
electronic throttle position
sensor are shorted
2 There is resistance in the 5V
power supply wire or GND wire
of the electronic throttle, which
pulls down the 5V voltage at
signal terminal or pulls up the
null voltage. There is resistance
in the 5V power supply wire or
GND wire of the electronic
throttle, which pulls down the
5V voltage at signal terminal or
pulls up the null voltage
1 The 5V power supply wire of
accelerator pedal position
sensor 1 / 2
2 The signal wire of accelerator
pedal position sensor 1 / 2 is
open
3 The signal wire of accelerator
pedal position sensor 1 / 2 is
shorted to GND
1 The 5V power supply wire of
accelerator pedal position
sensor 1 / 2
2 The signal wire of accelerator
pedal position sensor 1 / 2 is
open
3 The signal wire of accelerator
pedal position sensor 1 / 2 is
shorted to GND
1 The signal wire of electronic
throttle position sensor 1 / 2 is
shorted to 5V
2 An open ground wire of
electronic throttle signals will
cause faults of two signal wires
1 Collect and observe whether the sum of
the voltage values of two DVE signals
ThrVlv_uRawSens1B1 and
ThrVlv_uRawSens2B1 deviates from 5V
2 Check whether actions such as
disconnecting and connecting the
connector, shaking the harness, etc., affect
the occurrence of the fault
3 Measure the voltage drop of each
section on the harness using AD-Scan. If
the harness is in good condition, there will
be no voltage drop. If there is a voltage
drop, it means that there is resistance in
the harness or connector.
4 Verify if the fault is in the harness by
connecting a jumper across the electronic
throttle
5 Replace the throttle body to determine
whether there is an internal fault
6 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Collect the voltage values of the two
accelerator pedal signals APP_uRaw1 and
APP_uRaw2, and observe whether the
voltage values drop to about zero at the
moment the fault reappears
2 Check whether actions such as
disconnecting and connecting the
connector, shaking the harness, etc., affect
the occurrence of the fault
3 Verify if the fault is in the harness by
connecting a jumper across the accelerator
pedal
4 Replace the pedal to check whether the
fault is in the pedal
5 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Collect the voltage values of the two
accelerator pedal signals APP_uRaw1 and
APP_uRaw2, and observe whether the
voltage values drop to about zero at the
moment the fault reappears
2 Check whether actions such as
disconnecting and connecting the
connector, shaking the harness, etc., affect
the occurrence of the fault
3 Verify if the fault is in the harness by
connecting a jumper across the accelerator
pedal
4 Replace the pedal to check whether the
fault is in the pedal
5 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Collect and observe whether the voltage
values of the two electronic throttle signals
ThrVlv_uRawSens1B1 and
ThrVlv_uRawSens2B1 are pulled to about
5V
2 Check whether actions such as

GAC Motor 2019

Control system 2-162 Maintenance Manual of 1.5GDI Engine

to be reported at the same time disconnecting and connecting the

connector, shaking the harness, etc., affect
the occurrence of the fault
3 Verify if the fault is caused by the
harness resistance by connecting a jumper
across the electronic throttle
4 Replace the throttle body to determine
whether there is an internal fault
5 Clear the DTC, restart the engine, and
check whether the DTC is eliminated

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine
DTC DTC definition
Electronic Throttle Position
P022300 Sensor 1 / 2 Signal Voltage
High
Thermostat Performance
Implausible (Water
Temperature Cannot Reach
P012800
Nominal Opening
Temperature of
Thermostat)
Upstream Oxygen Sensor
P013000
Compensation Circuit Open
Upstream Oxygen Sensor
Signal Circuit Voltage Low
P013100
(APE / IPE / RE Circuit
Shorted to Ground)
Upstream Oxygen Sensor
Signal Circuit Voltage High
P013200
(APE / IPE / RE Circuit
Shorted to Power Supply)
Possible causes
1 The signal wire of electronic
throttle position sensor 1 / 2 is
shorted to 5V
2 An open ground wire of
electronic throttle signals will
cause faults of two signal wires
to be reported at the same time
1 The thermostat is normally
open
2 The value measured the
water temperature sensor
deviates
Upstream Oxygen Sensor
Compensation Circuit Open
Upstream Oxygen Sensor
Signal Circuit Voltage Low
(APE / IPE / RE Circuit Shorted
to Ground)
Upstream Oxygen Sensor
Signal Circuit Voltage High
(APE / IPE / RE Circuit Shorted
to Power Supply)
2-163Control system
Recommended action
1 Collect and observe whether the voltage
values of the two electronic throttle signals
ThrVlv_uRawSens1B1 and
ThrVlv_uRawSens2B1 are pulled to about
5V
2 Check whether actions such as
disconnecting and connecting the
connector, shaking the harness, etc., affect
the occurrence of the fault
3 Verify if the fault is caused by the
harness resistance by connecting a jumper
across the electronic throttle
4 Replace the throttle body to determine
whether there is an internal fault
5 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Check whether the thermostat is
normally open or damaged
2 The signal pin of coolant temperature
sensor at ECU side is shorted to power
supply, open-circuited or the ECU internal
circuit is damaged
1 Check whether the oxygen sensor
connector (pin for green wire) has poor
contact
2 Check whether the oxygen sensor
harness is open
3 Check whether there is an abnormal pin
at the connector between the harness and
ECU, resulting in poor contact
4 Clear the DTC, start and run the engine
until the coolant temperature reaches the
normal value, and check whether the fault
is reported again
5 Check whether there is any abnormality
in the LSU processing circuit inside the
ECU
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Start the engine, and run it at idle speed
for a period of time while slightly changing
the throttle opening. After that, pierce the
insulation of the red (IP), yellow (VM),
green (IA), and black (UN) wires of the
harness connector at ECU side with the
red tip of the multimeter, ground the black
tip and check whether the voltage is short-
circuited
4 Replace the LSU oxygen sensor and
track whether the fault is still reported
5 Check whether there is any abnormality
in the LSU processing circuit inside the
ECU
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Start the engine, and run it at idle speed
GAC Motor 2019
Control system 2-164 Maintenance Manual of 1.5GDI Engine

for a period of time while slightly changing

the throttle opening. After that, pierce the
insulation of the red (IP), yellow (VM),
green (IA), and black (UN) wires of the
harness connector at ECU side with the
red tip of the multimeter, ground the black
tip and check whether the voltage is
always high and changes little
4 Replace the LSU oxygen sensor and
track whether the fault is still reported
5 Check whether there is any abnormality
in the LSU processing circuit inside the
ECU
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
Upstream Oxygen Sensor The oxygen sensor is aged and
P013300 3 Check the intake and exhaust systems
Aging its response becomes slow
for leakage
4 Replace the upstream LSU oxygen
sensor, return the vehicle to the customer,
and track whether the fault recurs

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine
DTC DTC definition
Electrical Fault of Upstream
P013500
Oxygen Sensor Heater Pole
Downstream Oxygen
P013600
Sensor Signal Circuit Open
Possible causes
1 The oxygen sensor is faulty
2 The harness is faulty
1 The oxygen sensor signal
wire is shorted to the ground
wire of heater power supply
2. The oxygen sensor is
damaged
2-165Control system
Recommended action
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check whether the status of oxygen
sensor connector is abnormal
4 Disconnect the upstream oxygen sensor
harness connector, remove the upstream
oxygen sensor, and allow the oxygen
sensor to cool down at room temperature.
When the oxygen sensor reaches the room
temperature ①, use a multimeter to
measure whether the resistance between
the positive pole and the ground of heater
power supply at the sensor side is greater
than 3Ω.
5 Check for contact resistance in the
oxygen sensor heater harness
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Measure whether the voltage of #1 wire
(white, positive pole of heater power
supply) at oxygen sensor side of the
downstream oxygen sensor harness is 12V
with the oxygen sensor connector
connected
4 Measure whether the voltage of #2 wire
(white, ground of heater power supply) at
oxygen sensor side of the downstream
oxygen sensor harness is 12V with the
oxygen sensor connector connected
5 Measure whether the voltage between #4
wire (black, oxygen sensor signal wire) and
#3 wire (gray, oxygen sensor signal
ground) at ECU side of the downstream
oxygen sensor harness is about 0.45V with
the oxygen sensor connector connected
6 Start and run the engine until the coolant
temperature reaches the normal value, and
then idle it. Measure whether the voltage
between #4 wire (black, oxygen sensor
signal wire) and #3 wire (gray, oxygen
sensor signal ground) at ECU side of the
downstream oxygen sensor harness jumps
between 0V-1V with the oxygen sensor
connector connected
7 Start and run the engine until the coolant
temperature reaches the normal value, and
then idle it.
Measure whether #2 wire (white, ground of
heater power supply) is shorted to #4 wire
(black, oxygen sensor signal wire) at
oxygen sensor side with the downstream
oxygen sensor connector disconnected
8 Connect the downstream oxygen sensor
connector, and repeat steps 5-6 to check
whether the voltage signal jumps between
0.44V-0.46V and 0V-1V respectively
GAC Motor 2019
Control system 2-166 Maintenance Manual of 1.5GDI Engine

DTC DTC definition Possible causes Recommended action

1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Measure whether the voltage between
#4 wire (black, oxygen sensor signal wire)
and #3 wire (gray, oxygen sensor signal
ground) at ECU side of the downstream
oxygen sensor harness is about 0.45V with
the oxygen sensor connector connected
4 Start and run the engine until the coolant
temperature reaches the normal value, and
Downstream Oxygen then idle it. Measure whether the voltage
Downstream Oxygen Sensor between #4 wire (black, oxygen sensor
P013700 Sensor Signal Wire Shorted
Signal Wire Shorted To Ground signal wire) and #3 wire (gray, oxygen
To Ground
sensor signal ground) at ECU side of the
downstream oxygen sensor harness jumps
between 0V-1V with the oxygen sensor
connector connected
5 Measure whether #3 wire (gray, oxygen
sensor signal ground) is shorted to #4 wire
(black, oxygen sensor signal wire) at
sensor side with the downstream oxygen
sensor connector disconnected
6 Connect the downstream oxygen sensor
connector, and repeat steps 3-4 to check
whether the voltage signal jumps between
0.44V-0.46V and 0V-1V respectively
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Measure whether the voltage of #1 wire
(white, positive pole of heater power
supply) at oxygen sensor side of the
downstream oxygen sensor harness is 12V
with the oxygen sensor connector
connected

4 Measure whether the voltage of #2 wire

(white, ground of heater power supply) at
oxygen sensor side of the downstream
oxygen sensor harness is 12V with the
Downstream Oxygen Downstream Oxygen Sensor oxygen sensor connector connected
P013800 Sensor Signal Wire Shorted Signal Wire Shorted to Power
5 Measure whether the voltage between
to Power Supply Supply
#4 wire (black, oxygen sensor signal wire)
and #3 wire (gray, oxygen sensor signal
ground) at ECU side of the downstream
oxygen sensor harness is about 0.45V with
the oxygen sensor connector connected
6 Start and run the engine until the coolant
temperature reaches the normal value, and
then idle it. Measure whether the voltage
between #4 wire (black, oxygen sensor
signal wire) and #3 wire (gray, oxygen
sensor signal ground) at ECU side of the
downstream oxygen sensor harness jumps
between 0V-1V with the oxygen sensor
connector connected
7 Measure whether #1 wire (white, positive
pole of heater power supply) is shorted to

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-167Control system
#4 wire (black, oxygen sensor signal wire)
at the sensor side with the downstream
oxygen sensor connector disconnected.
8 Connect the downstream oxygen sensor
connector, and repeat steps 5-6 to check
whether the voltage signal jumps between
0.44V-0.46V and 0V-1V respectively
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
Slow Rich-Lean Response
The downstream oxygen 3 Replace the downstream oxygen sensor
P013A00 Of Downstream Oxygen
sensor is aged and connect the harness. Start and run the
Sensor
engine until the coolant temperature
reaches the normal value. Repeatedly
coasting at a speed of about 70km/h with
the accelerator pedal released

GAC Motor 2019

Control system 2-168
DTC DTC definition Possible causes
1 The signal terminal of rail
pressure sensor is shorted to
High-Pressure Fuel Rail
ground or power supply
P019000 Pressure Sensor Voltage
2 The fuel rail pressure sensor
Signal Implausible
pin at ECU side is shorted to
power supply or ground
Negative Deviation of
The internal circuit of rail
Characteristic Curve of
P019128 pressure sensor is aged or the
High-Pressure Fuel Rail
harness is aged
Pressure Sensor
Positive Deviation of
The internal circuit of rail
Characteristic Curve of
P019129 pressure sensor is aged or the
High-Pressure Fuel Rail
harness is aged
Pressure Sensor
1 The fuel rail pressure sensor
circuit is shorted to ground
Fuel Rail Pressure Sensor
P019200 2 The fuel rail pressure sensor
Circuit Voltage Low
pin at ECU side is shorted to
ground
1 The fuel rail pressure sensor
circuit is shorted to power
Fuel Rail Pressure Sensor supply
P019300
Circuit Voltage High 2 The fuel rail pressure sensor
pin at ECU side is shorted to
power supply
1 The rail pressure sensor is
damaged
High-Pressure Fuel Rail
2 The injector is clogged or
P019400 Pressure Sensor Signal
damaged
Stuck
3 The status of high-pressure
fuel rail is abnormal
1# Cylinder Injector Control 1 The connector is not
P020100
Circuit Open connected properly or has poor
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
Recommended action
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check whether the sensor signal
terminal is shorted to power supply or
ground
4 Check whether the sensor is damaged
5 Check whether the signal pin of fuel rail
pressure sensor at ECU side is shorted to
power supply or ground, or the ECU
internal circuit is damaged
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check for air in the fuel rail, which
causes failure of building up the rail
pressure quickly
4 Replace the rail pressure sensor, return
the vehicle to the customer, and track
whether the fault is reported again
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check for high contact resistance at the
connector or in the harness of the rail
pressure sensor
4 Replace the rail pressure sensor, return
the vehicle to the customer, and track
whether the fault is reported again
1 Check whether the sensor signal
terminal is shorted to ground
2 Check whether the sensor is damaged
3 Check whether the signal pin of fuel rail
pressure sensor at ECU side is shorted to
power supply, open-circuited or the ECU
internal circuit is damaged
1 Check whether the sensor signal
terminal is shorted to power supply or
open-circuited
2 Check whether the sensor is damaged
3 Check whether the signal pin of fuel rail
pressure sensor at ECU side is shorted to
power supply, open-circuited or the ECU
internal circuit is damaged
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Replace the rail pressure sensor and
drive the vehicle for 10min to check
whether the fault recurs
4 Replace injector and drive the vehicle for
10min to check whether the fault recurs
5 Check the high-pressure fuel rail system
for any abnormalities
6 Repair or replace related parts and drive
the vehicle for 10min to check whether the
fault recurs
1 Check whether the connector is not
connected properly or has poor contact
Maintenance Manual of 1.5GDI Engine
2# Cylinder Injector Control
P020200
Circuit Open
contact
2 The injector circuit is open
3 The injector power supply
terminal is open-circuited or the
injector is damaged
4 The injector control pin at
ECU side is open-circuited or
the ECU internal circuit is
damaged
1 The connector is not
connected properly or has poor
contact
2 The injector circuit is open
3 The injector power supply
terminal is open-circuited or the
injector is damaged
4 The injector control pin at
ECU side is open-circuited or
the ECU internal circuit is
damaged
2-169Control system
2 Check whether the corresponding
injector circuit is open
3 Check whether the corresponding
injector power supply terminal is open-
circuited or the injector is damaged
4 Check whether the injector control pin at
ECU side is open-circuited or the ECU
internal circuit is damaged
1 Check whether the connector is not
connected properly or has poor contact
2 Check whether the corresponding
injector circuit is open
3 Check whether the corresponding
injector power supply terminal is open-
circuited or the injector is damaged
4 Check whether the injector control pin at
ECU side is open-circuited or the ECU
internal circuit is damaged
GAC Motor 2019
Control system 2-170 Maintenance Manual of 1.5GDI Engine

DTC DTC definition Possible causes Recommended action

1 The connector is not
1 Check whether the connector is not
connected properly or has poor
connected properly or has poor contact
contact
2 Check whether the corresponding
2 The injector circuit is open
injector circuit is open
3 The injector power supply
3# Cylinder Injector Control 3 Check whether the corresponding
P020300 terminal is open-circuited or the
Circuit Open injector power supply terminal is open-
injector is damaged
circuited or the injector is damaged
4 The injector control pin at
4 Check whether the injector control pin at
ECU side is open-circuited or
ECU side is open-circuited or the ECU
the ECU internal circuit is
internal circuit is damaged
damaged
1 The connector is not
1 Check whether the connector is not
connected properly or has poor
connected properly or has poor contact
contact
2 Check whether the corresponding
2 The injector circuit is open
injector circuit is open
3 The injector power supply
4# Cylinder Injector Control 3 Check whether the corresponding
P020400 terminal is open-circuited or the
Circuit Open injector power supply terminal is open-
injector is damaged
circuited or the injector is damaged
4 The injector control pin at
4 Check whether the injector control pin at
ECU side is open-circuited or
ECU side is open-circuited or the ECU
the ECU internal circuit is
internal circuit is damaged
damaged
1 The engine speed has been 1 Check whether the engine speed has
artificially increased above the been artificially increased above the
maximum safety speed maximum safety speed
2 Check whether the electronic accelerator
2 The electronic accelerator pedal is stuck in a position with a large
pedal is stuck in a position with opening and cannot return to the zero
P021900 Engine Overspeed
a large opening and cannot position
return to the zero position 3 Check whether the throttle is stuck in a
3 The throttle is stuck in a position with a large opening and cannot
position with a large opening be closed
4 The speed calculation is 4 Check the speed sensor and its speed
incorrect calculation for errors
1 The turbocharger relief valve
1 The turbocharger relief valve is damaged
High Charge Air Pressure is damaged
P023400 2 The waste gate is damaged (normally
of Turbocharger 2 The waste gate is damaged
closed)
(normally closed)
1 The sensor signal terminal pin is shorted
to ground
1 The sensor signal terminal
2 The sensor power supply terminal pin is
pin is shorted to ground
Charge Air Pressure shorted to ground
P023700 2 The sensor signal terminal
Sensor Shorted To Ground 3 The sensor characteristics such as
pin at ECU side is shorted to
resistance deviate or are impaired
ground
4 The sensor signal terminal pin at ECU
side is shorted to ground
1 The connector is not connected properly
or disconnected
1 The sensor signal terminal
2 The sensor signal terminal pin is shorted
pin is shorted to power supply
to power supply or open-circuited
or open-circuited
3 The sensor power supply terminal or
Charge Air Pressure 2 The connector is not
ground terminal pin is open-circuited
P023800 Sensor Shorted to Power connected properly or
4 The sensor characteristics such as
Supply disconnected
resistance deviate or are impaired
3 The sensor signal terminal
5 The sensor signal terminal pin at ECU
pin at ECU side is shorted to
side is shorted to power supply, open-
power supply or open-circuited
circuited or the ECU internal circuit is
damaged
1 The waste gate drive circuit is 1 The connector is not connected properly
open or disconnected
2 The connector is not 2 The pin of waste gate drive circuit is
Waste Gate Control Circuit
P024300 connected properly or open-circuited
Open
disconnected 3 The power supply terminal of waste gate
3 The corresponding pin at is open-circuited
ECU side is open-circuited 4 The drive pin at ECU side is open-

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine
1 The connector is not
connected properly or has poor
contact
2 The pin of waste gate drive
Waste Gate Control Circuit
P024500 circuit is shorted to power
Voltage High or Low
supply or ground
3 The drive pin at ECU side is
shorted to power supply or
ground
1 The connector is not
connected properly or has poor
contact
2 The pin of waste gate drive
Waste Gate Control Circuit
P024600 circuit is shorted to power
Voltage High or Low
supply or ground
3 The drive pin at ECU side is
shorted to power supply or
ground
1 The positive or negative
control circuit of flow control
Flow Control Valve Positive
valve is open
P025100 or Negative Control Circuit
2 The positive or negative
Open
control circuit of flow control
valve at ECU side is open
2-171Control system
circuited or ECU internal circuit is damaged
1 The connector is not connected properly
or has poor contact
2 The pin of waste gate drive circuit is
shorted to power supply or ground
3 The drive pin at ECU side is shorted to
power supply or ground or the ECU
internal circuit is damaged
1 The connector is not connected properly
or has poor contact
2 The pin of waste gate drive circuit is
shorted to power supply or ground
3 The drive pin at ECU side is shorted to
power supply or ground or the ECU
internal circuit is damaged
1 Check whether the actuator is open-
circuited
2 Check whether the actuator pin at ECU
side is open-circuited or the ECU internal
circuit is damaged
GAC Motor 2019
Control system 2-172 Maintenance Manual of 1.5GDI Engine

DTC DTC definition Possible causes Recommended action

Flow Control Valve High
P025300 Side Control Circuit Voltage
Low
Flow Control Valve High
P025400 Side Control Circuit Voltage
High
Flow Control Valve Low
P025800 Side Control Circuit Voltage
Low
Flow Control Valve Low
P025900 Side Control Circuit Voltage
High
1# Cylinder Injector Low
P026100 Side Control Circuit Voltage
Low
1# Cylinder Injector Low
P026200 Side Control Circuit Shorted
to Power Supply
1# Cylinder Injector Control
P026300 Circuit Current Rise Time
Implausible
2# Cylinder Injector Low
P026400 Side Control Circuit Voltage
Low
2# Cylinder Injector Low
P026500 Side Control Circuit Shorted
to Power Supply
2# Cylinder Injector Control
P026600 Circuit Current Rise Time
Implausible
P026700 3# Cylinder Injector Low
1 The flow control valve circuit
is shorted to power or ground
2 The power supply terminal of
flow control valve is shorted to
power supply or ground
3 The control pin of flow control
valve at ECU side is shorted to
power supply or ground
1 The flow control valve circuit
is shorted to power or ground
2 The power supply terminal of
flow control valve is shorted to
power supply or ground
3 The control pin of flow control
valve at ECU side is shorted to
power supply or ground
1 The flow control valve circuit
is shorted to power or ground
2 The power supply terminal of
flow control valve is shorted to
power supply or ground
3 The control pin of flow control
valve at ECU side is shorted to
power supply or ground
1 The flow control valve circuit
is shorted to power or ground
2 The power supply terminal of
flow control valve is shorted to
power supply or ground
3 The control pin of flow control
valve at ECU side is shorted to
power supply or ground
1 The injector circuit is shorted
to power supply or ground
2 The injector power supply
terminal is shorted to power
supply or ground
3 The injector control pin at
ECU side is shorted to power
supply or ground
1# Cylinder Injector Low Side
Control Circuit Shorted to
Power Supply
The injector is damaged
1 The injector circuit is shorted
to power supply or ground
2 The injector power supply
terminal is shorted to power
supply or ground
3 The injector control pin at
ECU side is shorted to power
supply or ground
2# Cylinder Injector Low Side
Control Circuit Shorted to
Power Supply
The injector is damaged
1 The injector circuit is shorted
1 Check whether the corresponding flow
control valve is shorted to power or ground
2 Check whether the control pin of flow
control valve at ECU side is shorted to
power supply or ground
1 Check whether the corresponding flow
control valve is shorted to power or ground
2 Check whether the control pin of flow
control valve at ECU side is shorted to
power supply or ground
1 Check whether the corresponding flow
control valve is shorted to power or ground
2 Check whether the control pin of flow
control valve at ECU side is shorted to
power supply or ground
1 Check whether the corresponding flow
control valve is shorted to power or ground
2 Check whether the control pin of flow
control valve at ECU side is shorted to
power supply or ground
1 Check whether the corresponding
injector circuit is shorted to power supply
or ground
2 Check whether the injector control pin at
ECU side is shorted to power supply or
ground
1 Check whether the corresponding
injector circuit is shorted to power supply
2 Check whether the injector control pin at
ECU side is shorted to power supply
Replace the corresponding injector and
check whether the injector is damaged
1 Check whether the corresponding
injector circuit is shorted to power supply
or ground
2 Check whether the injector control pin at
ECU side is shorted to power supply or
ground
1 Check whether the corresponding
injector circuit is shorted to power supply
2 Check whether the injector control pin at
ECU side is shorted to power supply
Replace the corresponding injector and
check whether the injector is damaged
1 Check whether the corresponding

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine
Side Control Circuit Voltage
Low
3# Cylinder Injector Low
P026800 Side Control Circuit Shorted
to Power Supply
3# Cylinder Injector Control
P026900 Circuit Current Rise Time
Implausible
to power supply or ground
2 The injector power supply
terminal is shorted to power
supply or ground
3 The injector control pin at
ECU side is shorted to power
supply or ground
3# Cylinder Injector Low Side
Control Circuit Shorted to
Power Supply
The injector is damaged
2-173Control system
injector circuit is shorted to power supply
or ground
2 Check whether the injector control pin at
ECU side is shorted to power supply or
ground
1 Check whether the corresponding
injector circuit is shorted to power supply
2 Check whether the injector control pin at
ECU side is shorted to power supply
Replace the corresponding injector and
check whether the injector is damaged
GAC Motor 2019
Control system 2-174
DTC DTC definition
1 The injector circuit is shorted
4# Cylinder Injector Low
P027000 Side Control Circuit Voltage
Low
4# Cylinder Injector Low
P027100 Side Control Circuit Shorted
to Power Supply
4# Cylinder Injector Control
P027200 Circuit Current Rise Time
Implausible
turbine and the exhaust pipe is
3 The waste gate or relief valve
Low Charge Air Pressure of
P029900
Turbocharger
4 The turbocharger is damaged
compressor impeller are dirty or
Short Circuit between 1#
Cylinder Injector High Side
P02EE00
and Low Side Control
Circuits
Short Circuit between 2#
Cylinder Injector High Side
P02EF00
and Low Side Control
Circuits
Short Circuit between 3#
Cylinder Injector High Side
P02F000
and Low Side Control
Circuits
Short Circuit between 4#
Cylinder Injector High Side
P02F100
and Low Side Control
Circuits
P030000 Multiple-cylinder Misfire
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
Possible causes
to power supply or ground
2 The injector power supply
terminal is shorted to power
supply or ground
3 The injector control pin at
ECU side is shorted to power
supply or ground
4# Cylinder Injector Low Side
Control Circuit Shorted to
Power Supply
The injector is damaged
1 The pipeline between the
compressor outlet and the
throttle is leaking
2 The pipeline between the
2 The pipeline between the turbine and the
leaking
is faulty
5 Working parts such as
damaged
6 The exhaust manifold is
leaking or clogged
7 The air cleaner is dirty
The injector high side control
circuit is shorted to low side
control circuit
The injector high side control
circuit is shorted to low side
control circuit
The injector high side control
circuit is shorted to low side
control circuit
The injector high side control
circuit is shorted to low side
control circuit
1 The injector circuit is faulty
2 The ignition coil circuit is
faulty
3 The injector control pin or
ignition coil pin at ECU side is
faulty
Recommended action
1 Check whether the corresponding
injector circuit is shorted to power supply
or ground
2 Check whether the injector control pin at
ECU side is shorted to power supply or
ground
1 Check whether the corresponding
injector circuit is shorted to power supply
2 Check whether the injector control pin at
ECU side is shorted to power supply
Replace the corresponding injector and
check whether the injector is damaged
1 The pipeline between the compressor
outlet and the throttle is leaking
exhaust pipe is leaking
3 The exhaust manifold is leaking or
clogged
4 The air cleaner is dirty
5 The waste gate or relief valve is faulty
and stuck open
6 Working parts such as compressor
impeller are dirty or damaged
7 The turbocharger is damaged
Check whether the high side control circuit
is shorted to low side control circuit of the
corresponding injector
Check whether the high side control circuit
is shorted to low side control circuit of the
corresponding injector
Check whether the high side control circuit
is shorted to low side control circuit of the
corresponding injector
Check whether the high side control circuit
is shorted to low side control circuit of the
corresponding injector
1 Check whether there is a DTC related to
the corresponding cylinder and injector
2 The connector is not connected properly
or disconnected
3 Check whether the ignition coil signal
terminal is open-circuited or shorted to
ground or power supply
4 Check whether the power supply
terminal of ignition coil is open-circuited or
shorted to ground
5 Check whether the ignition coil ground
terminal is open-circuited or shorted to
power supply
6 Check whether the ignition coil itself is
faulty
7 Check whether the status of spark plug
is abnormal
8 Check whether the ignition coil control
pin at ECU side is open-circuited or the
Maintenance Manual of 1.5GDI Engine
1 The injector circuit is faulty
2 The ignition coil circuit is
1# Cylinder Misfire faulty
P030100
Detected 3 The injector control pin or
ignition coil pin at ECU side is
faulty
2-175Control system
ECU internal circuit is damaged
1 Check whether there is a DTC related to
the corresponding cylinder and injector
2 The connector is not connected properly
or disconnected
3 Check whether the ignition coil signal
terminal is open-circuited or shorted to
ground or power supply
4 Check whether the power supply
terminal of ignition coil is open-circuited or
shorted to ground
5 Check whether the ignition coil ground
terminal is open-circuited or shorted to
power supply
6 Check whether the ignition coil itself is
faulty
7 Check whether the status of spark plug
is abnormal
8 Check whether the ignition coil control
pin at ECU side is open-circuited or the
ECU internal circuit is damaged
GAC Motor 2019
Control system 2-176 Maintenance Manual of 1.5GDI Engine

DTC DTC definition Possible causes Recommended action

1 The injector circuit is faulty
2 The ignition coil circuit is
2# Cylinder Misfire faulty
P030200
Detected 3 The injector control pin or
ignition coil pin at ECU side is
faulty
1 The injector circuit is faulty
2 The ignition coil circuit is
3# Cylinder Misfire faulty
P030300
Detected 3 The injector control pin or
ignition coil pin at ECU side is
faulty
1 The injector circuit is faulty
2 The ignition coil circuit is
4# Cylinder Misfire faulty
P030400
Detected 3 The injector control pin or
ignition coil pin at ECU side is
faulty
1 Check whether there is a DTC related to
the corresponding cylinder and injector
2 The connector is not connected properly
or disconnected
3 Check whether the ignition coil signal
terminal is open-circuited or shorted to
ground or power supply
4 Check whether the power supply
terminal of ignition coil is open-circuited or
shorted to ground
5 Check whether the ignition coil ground
terminal is open-circuited or shorted to
power supply
6 Check whether the ignition coil itself is
faulty
7 Check whether the status of spark plug is
abnormal
8 Check whether the ignition coil control
pin at ECU side is open-circuited or the
ECU internal circuit is damaged
1 Check whether there is a DTC related to
the corresponding cylinder and injector
2 The connector is not connected properly
or disconnected
3 Check whether the ignition coil signal
terminal is open-circuited or shorted to
ground or power supply
4 Check whether the power supply
terminal of ignition coil is open-circuited or
shorted to ground
5 Check whether the ignition coil ground
terminal is open-circuited or shorted to
power supply
6 Check whether the ignition coil itself is
faulty
7 Check whether the status of spark plug is
abnormal
8 Check whether the ignition coil control
pin at ECU side is open-circuited or the
ECU internal circuit is damaged
1 Check whether there is a DTC related to
the corresponding cylinder and injector
2 The connector is not connected properly
or disconnected
3 Check whether the ignition coil signal
terminal is open-circuited or shorted to
ground or power supply
4 Check whether the power supply
terminal of ignition coil is open-circuited or
shorted to ground
5 Check whether the ignition coil ground
terminal is open-circuited or shorted to
power supply
6 Check whether the ignition coil itself is
faulty
7 Check whether the status of spark plug is
abnormal

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine
1 The injector circuit is faulty
2 The ignition coil circuit is
Cylinder deactivation due to faulty
P036300
misfire 3 The injector control pin or
ignition coil pin at ECU side is
faulty
2-177Control system
8 Check whether the ignition coil control
pin at ECU side is open-circuited or the
ECU internal circuit is damaged
1 Check whether there is a DTC related to
the corresponding cylinder and injector
2 The connector is not connected properly
or disconnected
3 Check whether the ignition coil signal
terminal is open-circuited or shorted to
ground or power supply
4 Check whether the power supply
terminal of ignition coil is open-circuited or
shorted to ground
5 Check whether the ignition coil ground
terminal is open-circuited or shorted to
power supply
6 Check whether the ignition coil itself is
faulty
7 Check whether the status of spark plug is
abnormal
8 Check whether the ignition coil control
pin at ECU side is open-circuited or the
ECU internal circuit is damaged
GAC Motor 2019
Control system 2-178 Maintenance Manual of 1.5GDI Engine

DTC DTC definition Possible causes Recommended action

Knock Sensor Circuit
P032500
Voltage Low 2 The signal terminal is open-
Knock Sensor Circuit
P032600
Voltage High 3 The status of the engine is
Knock Sensor Signal
P032700 The knock sensor is damaged
Shorted to Ground (A side)
Knock Sensor Signal
P032714
Shorted to Ground (B side)
Knock Sensor Signal
P032800 Shorted to Power Supply (A
side)
Knock Sensor Signal
P032815 Shorted to Power Supply (B
side)
P033500 Speed Sensor Reverse
1 The connector is not
connected properly or
disconnected
circuited
3 The sensor is damaged
1 The sensor is damaged
2. The ECU is damaged
abnormal
The knock sensor is faulty
The knock sensor is faulty
The knock sensor is faulty
1 The connector is not
1 Check whether the connector is not
connected properly or has poor contact
2 Check whether the knock sensor signal
terminal is shorted to ground or open-
circuited
3 Check whether the knock sensor
connecting harness is a non-standard
shielded wire and is subject to
electromagnetic interference
4 Check whether the knock sensor is
damaged
5 Check whether the knock sensor pin or
circuit at ECU side is damaged
1 Check whether the knock sensor is
damaged
2 Check whether the ECU is damaged
3 Check whether the status of the engine
is abnormal
1 The connector is not connected properly
or has poor contact
2 Check whether the knock sensor signal
terminal pin is shorted to ground or open-
circuited
3 Replace the knock sensor, reconnect it,
and check whether the fault is eliminated
4 Check whether the knock sensor signal
terminal pin at ECU side is shorted to
ground or open-circuited
1 The connector is not connected properly
or has poor contact
2 Check whether the knock sensor signal
terminal pin is shorted to ground or open-
circuited
3 Replace the knock sensor, reconnect it,
and check whether the fault is eliminated
4 Check whether the knock sensor signal
terminal pin at ECU side is shorted to
ground or open-circuited
1 The connector is not connected properly
or has poor contact
2 Check whether the knock sensor signal
terminal pin is shorted to power supply
3 Replace the knock sensor, reconnect it,
and check whether the fault is eliminated
4 Check whether the knock sensor signal
terminal pin at ECU side is shorted to
power supply
1 The connector is not connected properly
or has poor contact
2 Check whether the knock sensor signal
terminal pin is shorted to power supply
3 Replace the knock sensor, reconnect it,
and check whether the fault is eliminated
4 Check whether the knock sensor signal
terminal pin at ECU side is shorted to
power supply
1 Connect the diagnostic scan tool and set

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine
Signal Implausible connected properly or
disconnected
2 The sensor is faulty
3 There is signal interference
when the engine starts or stops
4 The signal from the signal
wheel is incorrect
6 Check whether the original signal of the
2-179Control system
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check whether the connector is not
connected properly or has poor contact
4 Check the harness for external
interference
5 Check whether the speed sensor is
damaged or faulty
speed signal wheel is faulty
GAC Motor 2019
Control system 2-180
DTC DTC definition Possible causes
1 The connector is not
connected properly or
Speed Sensor Signal disconnected
P033900
Implausible 2 The signal terminal is open-
circuited
3 The sensor is damaged
1 The connector is not
connected properly or
disconnected
P261700 Speed Sensor Signal Lost
2 The signal terminal is open-
circuited
3 The sensor is damaged
1 The connector is not
connected properly or
disconnected
2 The relative installation
position of the intake phase
Intake Camshaft Phase
P034100 sensor and its signal wheel
Sensor Signal Implausible
does not meet the installation
requirements
3 There is a mechanical failure
in the intake phase signal
wheel teeth
1 The power supply of intake
phase sensor is faulty
2 The signal terminal of intake
Intake Camshaft Phase
phase sensor is shorted to
P034200 Signal Circuit Voltage
ground
Always High
3 The signal terminal pin of
intake phase sensor at ECU
side is shorted to ground
1 The ground terminal of intake
phase sensor is faulty
Intake Camshaft Phase 2 The signal terminal of intake
P034300 Signal Circuit Height phase sensor is shorted to the
Always Low power supply
3 The signal terminal pin of
intake phase sensor at ECU
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
Recommended action
1 The connector is not connected properly
or disconnected
2 The speed sensor signal terminal is
open-circuited
3 The sensor signal terminal pin is shorted
to power supply or ground, or the pins are
shorted to each
4 The sensor is damaged
5 The speed sensor signal pin at ECU side
is faulty
1 The connector is not connected properly
or disconnected
2 The speed sensor signal terminal is
open-circuited
3 The sensor signal terminal pin is shorted
to power supply or ground, or the pins are
shorted to each
4 The sensor is damaged
5 The speed sensor signal pin at ECU side
is faulty
1 Check whether the connector is not
connected properly or has poor contact
2 Check the harness for external
interference
3 Check whether the relative installation
position of the intake phase sensor and its
signal wheel does not meet the installation
requirements (such as too far apart, not
aligned, etc.)
4 Check whether there is a mechanical
failure in the intake phase signal wheel
teeth
1 Disconnect the intake phase sensor
connector from the harness, and use a
multimeter to check whether the voltage
between the power supply terminal pin and
the ground terminal pin of the phase
sensor is about 12V
2 Check whether the voltage between the
signal terminal pin and the ground terminal
pin of the intake phase sensor is about 0V
3 Check whether the power supply terminal
pin of intake phase sensor is open-
circuited or shorted to ground, and whether
the ground terminal pin has poor contact
4 Check whether the signal terminal pin of
intake phase sensor is shorted to ground
5 Check whether signal terminal pin of
intake phase sensor at ECU side is shorted
to ground
1 Disconnect the intake phase sensor
connector from the harness, and use a
multimeter to check whether the voltage
between the power supply terminal pin and
the ground terminal pin of the phase
sensor is about 12V.
2 Check whether the voltage between the
Maintenance Manual of 1.5GDI Engine 2-181Control system
side is shorted to power supply signal terminal pin and the power supply
terminal pin of the intake phase sensor is
about 12V
3 Check whether the ground terminal pin of
intake phase sensor is open-circuited or
shorted to power supply
4 Check whether the signal terminal pin of
intake phase sensor is shorted to power
supply or open-circuited
5 Check whether the signal terminal pin of
intake phase sensor at ECU side is shorted
to power supply, open-circuited or the ECU
internal circuit is damaged
1 Check whether the corresponding
1 The ignition coil circuit is
ignition coil circuit is shorted to ground or
shorted to ground or open
1# Cylinder Ignition Coil open
P035100 2 The ignition coil control pin at
Control Circuit Open 2 Check whether the ignition coil control
ECU side is shorted to ground
pin at ECU side is shorted to ground or
or open-circuited
open-circuited
1 Check whether the corresponding
1 The ignition coil circuit is
ignition coil circuit is shorted to ground or
shorted to ground or open
2# Cylinder Ignition Coil open
P035200 2 The ignition coil control pin at
Control Circuit Open 2 Check whether the ignition coil control
ECU side is shorted to ground
pin at ECU side is shorted to ground or
or open-circuited
open-circuited

GAC Motor 2019

Control system 2-182
DTC DTC definition Possible causes
1 The ignition coil circuit is
shorted to ground or open
3# Cylinder Ignition Coil
P035300 2 The ignition coil control pin at
Control Circuit Open
ECU side is shorted to ground
or open-circuited
1 The ignition coil circuit is
shorted to ground or open
4# Cylinder Ignition Coil
P035400 2 The ignition coil control pin at
Control Circuit Open
ECU side is shorted to ground
or open-circuited
1 The connector is not
connected properly or
disconnected
2 The relative installation
position of the exhaust phase
Exhaust Camshaft Phase
P036600 sensor and its signal wheel
Sensor Signal Implausible
does not meet the installation
requirements
3 There is a mechanical failure
in the exhaust phase signal
wheel teeth
1 The power supply of exhaust
phase sensor is faulty
2 The signal terminal of
Exhaust Camshaft Phase
exhaust phase sensor is
P036700 Signal Circuit Voltage
shorted to ground
Shorted to Ground
3 The signal terminal pin of
exhaust phase sensor at ECU
side is shorted to ground
1 The ground terminal of
exhaust phase sensor is faulty
2 The signal terminal of
Exhaust Camshaft Phase
exhaust phase sensor is
P036800 Signal Circuit Voltage
shorted to the power supply
Shorted to Power Supply
3 The signal terminal pin of
exhaust phase sensor at ECU
side is shorted to power supply
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
Recommended action
1 Check whether the corresponding
ignition coil circuit is shorted to ground or
open
2 Check whether the ignition coil control
pin at ECU side is shorted to ground or
open-circuited
1 Check whether the corresponding
ignition coil circuit is shorted to ground or
open
2 Check whether the ignition coil control
pin at ECU side is shorted to ground or
open-circuited
1 Check whether the connector is not
connected properly or has poor contact
2 Check the harness for external
interference
3 Check whether the relative installation
position of the exhaust phase sensor and
its signal wheel does not meet the
installation requirements (such as too far
apart, not aligned, etc.)
4 Check whether there is a mechanical
failure in the exhaust phase signal wheel
teeth
1 Disconnect the exhaust phase sensor
connector from the harness, and use a
multimeter to check whether the voltage
between the power supply terminal pin and
the ground terminal pin of the phase
sensor is about 12V
2 Check whether the voltage between the
signal terminal pin and the ground terminal
pin of the exhaust phase sensor is about
0V
3 Check whether the power supply terminal
pin of exhaust phase sensor is open-
circuited or shorted to ground, and whether
the ground terminal pin has poor contact
4 Check whether the signal terminal pin of
exhaust phase sensor is shorted to ground
5 Check whether signal terminal pin of
exhaust phase sensor at ECU side is
shorted to ground
1 Disconnect the exhaust phase sensor
connector from the harness, and use a
multimeter to check whether the voltage
between the power supply terminal pin and
the ground terminal pin of the phase
sensor is about 12V.
2 Check whether the voltage between the
signal terminal pin and the power supply
terminal pin of the exhaust phase sensor is
about 12V
3 Check whether the ground terminal pin of
exhaust phase sensor is open-circuited or
shorted to power supply
4 Check whether the signal terminal pin of
exhaust phase sensor is shorted to power
supply or open-circuited
5 Check whether the signal terminal pin of
Maintenance Manual of 1.5GDI Engine 2-183Control system
exhaust phase sensor at ECU side is
shorted to power supply, open-circuited or
the ECU internal circuit is damaged
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
1 Check whether the exhaust
information
system is leaking and whether
Three-way Catalytic the gasket is damaged 3 Check whether the exhaust system is
P042000
Converter OSC Aging leaking and whether the gasket is
2 The catalytic converter is
damaged
aged
4 Replace the catalytic converter, return
the vehicle to the customer, and track
whether the fault recurs

GAC Motor 2019

Control system 2-184
DTC DTC definition Possible causes
1 The fuel filler cap is not
tightened or there are leaks
2 The canister vent valve
cannot be completely closed
1.0mm Leaks in 3 There are leaks between the
P044200
Evaporation System fuel tank-pipeline-canister
valve-canister solenoid valve-
canister vent valve
4 The canister solenoid valve
cannot be completely closed
1 The connector is not
connected properly or has poor
contact
Canister Control Valve
P044400 2 The canister control valve
Control Circuit Open
circuit is open
3 The canister control valve
circuit at ECU side is open
1 The connector is not
connected properly or has poor
contact
2 The control circuit of canister
vent valve is open
3 The power supply terminal of
canister vent valve control
Canister Vent Valve Control circuit is open-circuited or
P044700
Circuit Open shorted to ground
4 The fuse of canister vent
valve control circuit is blown or
damaged
5 The pin of canister vent valve
control circuit at ECU side is
open-circuited or the ECU
internal circuit is damaged
1 The fuel tank pressure sensor
Fuel Tank Pressure Sensor is damaged
P045125 Signal Oscillation
Implausible 2 The canister valve is
damaged
1 The fuel tank pressure sensor
Fuel Tank Pressure Sensor
P045128 is damaged
Signal Deviation
2 The pipeline from fuel tank to
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
Recommended action
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check whether the fuel filler cap is
tightened
4 Check the fuel tank-pipeline-canister
valve-canister solenoid valve-canister vent
valve for leakage/blockage, and whether
the connectors are installed properly
5 Check whether the canister vent valve
can be completely closed, which can be
realized by short-circuiting the pin
6 Check whether the canister solenoid
valve is completely closed with the power
on
1 The connector is not connected properly
or has poor contact
2 The signal terminal pin of canister control
valve is open-circuited
3 The power supply terminal pin of canister
control valve is open-circuited
4 The canister control valve is damaged
5 The canister control pin at ECU side is
open-circuited or the ECU internal circuit is
damaged
1 The connector is not connected properly
or has poor contact
2 The control circuit of canister vent valve
is open
3 The power supply terminal of canister
vent valve control circuit is open-circuited
or shorted to ground
4 The fuse of canister vent valve control
circuit is blown or damaged
5 The pin of canister vent valve control
circuit at ECU side is open-circuited or the
ECU internal circuit is damaged
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Replace the fuel tank pressure sensor,
restart the engine, and wait for 10min to
see if the fault recurs
4. Replace the ECU. Restart the engine,
and wait for 10min to see if the fault recurs
5 Check the canister valve harness and
replace the canister valve, restart the
engine, and wait for 10min to see if the
fault recurs
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
Maintenance Manual of 1.5GDI Engine
canister is clogged
1 The canister solenoid valve is
stuck open or closed
2 The pipeline from fuel tank to
canister is clogged or
disconnected
Fuel Tank Pressure Sensor
P04512A
Signal Stuck 3 The pipeline between
canister and canister valve is
clogged or disconnected
4 The fuel tank pressure sensor
is damaged
2-185Control system
information
3 Replace the fuel tank pressure sensor
and track whether the fault recurs
4 Check whether the pipeline from fuel
tank to canister is clogged
5 Replace the ECU and check whether the
fault recurs
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check whether the canister solenoid
valve is stuck open or closed
4 Check whether the pipeline from fuel
tank to canister is clogged or disconnected
5 Check whether the pipeline between
canister and canister valve is clogged or
disconnected
6 Replace the fuel tank pressure sensor.
Start and run the engine for 10min, and
check whether the fault recurs
GAC Motor 2019
Control system 2-186
DTC DTC definition Possible causes
1 The signal terminal of fuel
tank pressure sensor is shorted
to ground
Fuel Tank Pressure Sensor
P045200
Signal Shorted to Ground 2 The signal pin of fuel tank
pressure sensor at ECU side is
shorted to ground
1 The signal terminal of fuel
tank pressure sensor is shorted
Fuel Tank Pressure Sensor to power supply
P045300 Signal Shorted to Power
Supply 2 The signal pin of fuel tank
pressure sensor at ECU side is
shorted to power supply
1 The fuel filler cap is not
tightened or there are leaks
2 The canister vent valve
cannot be completely closed
2.2mm Leaks in
3 There are leaks between the
P045500 Evaporation System or
fuel tank-pipeline-canister
Loose Fuel Filler Cap
valve-canister solenoid valve-
canister vent valve
4 The canister solenoid valve
cannot be completely closed
1 The signal terminal of
canister control valve is shorted
Canister Control Valve to ground
P045800
Circuit Voltage Low
2 The canister control pin at
ECU side is shorted to ground
1 The signal terminal of
canister control valve is shorted
to power supply
2 The canister control pin at
Drive Channel Self-
P045900 ECU side is shorted to power
Diagnosis Fault
supply
2 The canister control pin at
ECU side is shorted to power
supply
P046000 Fuel Level Sensor Original 1 The fuel level sensor harness
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
Recommended action
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Use a multimeter to measure whether the
voltage of fuel tank pressure signal wire is
close to or equal to 0V
4 Measure whether the voltage of harness
terminal corresponding to the fuel tank
pressure signal is close to or equal to 0V
5 Check whether the MAP sensor signal
pin at ECU side is shorted to ground or the
ECU internal circuit is damaged
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Use a multimeter to measure whether the
voltage of fuel tank pressure signal wire is
close to or equal to 5V
4 Measure whether the voltage of harness
terminal corresponding to the fuel tank
pressure signal is close to or equal to 5V
5 Check whether the MAP sensor signal
pin at ECU side is shorted to power supply
or the ECU internal circuit is damaged
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check whether the fuel filler cap is
tightened
4 Check the fuel tank-pipeline-canister
valve-canister solenoid valve-canister vent
valve for leakage/blockage, and whether
the connectors are installed properly
5 Check whether the canister vent valve
can be completely closed, which can be
realized by short-circuiting the pin
6 Check whether the canister solenoid
valve is completely closed with the power
on
1 The signal terminal of canister control
valve is shorted to ground
2 The power supply terminal pin of canister
control valve is shorted to ground
3 The canister control pin at ECU side is
shorted to ground
1 The signal terminal of canister control
valve is shorted to power supply
2 The canister control pin at ECU side is
shorted to power supply
1 Connect the diagnostic scan tool and set
Maintenance Manual of 1.5GDI Engine
Signal Out of Range is not connected properly
2 The fuel level sensor is
damaged
3 The ECU internal circuit is
abnormal
1 The CAN signal of ECU is
Fuel Level Sensor abnormal
P046129
Implausible 2 The fuel level sensor is
damaged
2-187Control system
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Use a multimeter to measure whether the
voltage of sensor pin is normal, and check
whether the CAN signal is normal
4 Check whether the harness is normal
5 Replace the ECU and check whether the
fault recurs
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3. Check whether the CAN signal is normal
4 Replace the ECU and track whether the
fault recurs
5 Replace the fuel level sensor and track
whether the fault recurs
GAC Motor 2019
Control system 2-188
DTC DTC definition Possible causes
1 The fuel level sensor harness
is not connected properly
Fuel Level Sensor Circuit 2 The fuel level sensor is
P046200
Voltage Low damaged
3 The ECU internal circuit is
abnormal
1 The fuel level sensor harness
is not connected properly
Fuel Level Sensor Circuit 2 The fuel level sensor is
P046300
Voltage High damaged
3 The ECU internal circuit is
abnormal
1 The signal terminal of
pressure sensor is shorted to
High-Load Desorption ground
P046700 Pipeline Pressure Sensor 2 The signal pin of high-load
Circuit Voltage Low desorption pipeline pressure
sensor at ECU side is shorted
to ground
1 The signal terminal of
pressure sensor is shorted to
High-Load Desorption power supply
P046800 Pipeline Pressure Sensor 2 The signal pin of high-load
Circuit Voltage High desorption pipeline pressure
sensor at ECU side is shorted
to power supply
1 The cooling fan relay control
circuit is open
Cooling Fan Relay Control
P048000 2 The pin of cooling fan relay
Circuit Fault
control circuit at ECU side is
open-circuited
Cooling Fan Plausibility
P048371 The fan is stalled
Fault Type 1
Cooling Fan Plausibility
P048372 The fan is overloaded
Fault Type 2
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
Recommended action
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Use a multimeter to measure whether the
voltage of sensor pin is normal, and check
whether the CAN signal is normal
4 Check whether the harness is normal
5 Replace the ECU and check whether the
fault recurs
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Use a multimeter to measure whether the
voltage of sensor pin is normal, and check
whether the CAN signal is normal
4 Check whether the harness is normal
5 Replace the ECU and check whether the
fault recurs
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Use a multimeter to measure whether the
voltage of signal wire of high-load
desorption pipeline pressure sensor is
close to or equal to 0V
4 Measure whether the voltage of pressure
sensor harness terminal is close to or
equal to 0V
5 Check whether the signal pin of high-load
desorption pipeline pressure sensor at
ECU side is shorted to ground or the ECU
internal circuit is damaged
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Use a multimeter to measure whether the
voltage of signal wire of high-load
desorption pipeline pressure sensor is
close to or equal to 5V
4 Measure whether the voltage of pressure
sensor harness terminal is close to or
equal to 5V
5 Check whether the signal pin of high-load
desorption pipeline pressure sensor at
ECU side is shorted to power supply or the
ECU internal circuit is damaged
1 The connector is not connected properly
or has poor contact
2 The signal terminal of cooling fan relay
circuit is open-circuited
3 The cooling fan relay is faulty (fuse blown
or damaged)
4 The cooling fan relay pin at ECU side is
open-circuited or the ECU internal circuit is
damaged
Check whether the cooling fan is blocked
Check whether the cooling fan is
overloaded
Maintenance Manual of 1.5GDI Engine 2-189Control system
Cooling Fan Plausibility Fan Supply Voltage High or Check whether the supply voltage of
P048373
Fault Type 3 Low cooling fan is too high or low
Cooling Fan Plausibility The fan control circuit is Check whether the cooling fan control
P048374
Fault Type 4 overheated circuit is shorted or overloaded
Cooling Fan Plausibility Replace the fan to see if the fault is still
P048375 The fan has internal fault
Fault Type 5 reported
1 Check whether the corresponding fan
The fan has a typical fault
circuit is shorted to power supply or ground
(overtemperature, short circuit,
or open-circuited
Cooling Fan Plausibility open circuit, stall, or abnormal
P048376 2 Replace the fan ECU and check whether
Fault Type 6 signal, depending on the
the fan ECU is damaged
definition by different fan
3 Replace the fan motor and check
suppliers)
whether the fan motor is damaged

GAC Motor 2019

Control system 2-190 Maintenance Manual of 1.5GDI Engine

DTC DTC definition Possible causes Recommended action

1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Keep the sensor connector normal, and
1 The canister solenoid valve
use a multimeter to check whether the
Canister Solenoid Valve cannot be completely closed
P049600 voltage of canister valve pin is too high or
Stuck Open 2 The fuel tank pressure
shorted to power supply
sensor signal is abnormal
4 Use a multimeter to check whether the
voltage of fuel tank pressure sensor is
normal
5 Remove the canister valve and check
whether it is stuck open
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
1 The low-load desorption
information
pipeline, check valve or
3 Check whether the desorption pipeline,
Low-load Desorption connection between canister
check valve (if any) or connection between
P049700 Pipeline Fault - Canister valve and engine is clogged or
canister valve and engine is clogged or
Valve Stuck Closed disconnected
disconnected
2 The canister valve is stuck
4 Replace the corresponding pipeline
closed or open
5 Check whether the canister valve
hardware is stuck closed or open
6 Replace the canister valve
1 The control circuit of canister
1 The control circuit of canister vent valve
vent valve is shorted to ground
Canister Vent Valve Control is shorted to ground
P049800 2 The pin of canister vent valve
Circuit Shorted to Ground 2 The pin of canister vent valve control
control circuit is shorted to
circuit is shorted to ground
ground
1 The control circuit of canister
1 The control circuit of canister vent valve
vent valve is shorted to power
Canister Vent Valve Control is shorted to power supply
supply
P049900 Circuit Shorted to Power 2 The pin of canister vent valve control
2 The pin of canister vent valve
Supply circuit at ECU side is shorted to power
control circuit at ECU side is
supply
shorted to power supply
1 The high-load pipeline of
1 Check whether the high-load pipeline of
crankcase ventilation system
Crankcase Ventilation crankcase ventilation system has come off
has come off
P04DB00 System High-Load Pipeline 2 Check whether high-load pipeline of
2 The high-load pipeline of
Disconnected crankcase ventilation system is obviously
crankcase ventilation system is
leaking
obviously leaking
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
1 The high-load desorption
information
pipeline, check valve, venturi
3 Check whether the desorption pipeline,
tube or connection between
check valve (if any), venturi tube (if any) or
High-load Desorption canister valve and engine is
connection between canister valve and
P04F000 Pipeline Fault - Canister clogged or disconnected
engine is clogged or disconnected
Valve Fault 2 The check valve of low-load
4 Replace the corresponding pipeline
pipeline is damaged
5 Check whether the check valve of low-
3 The canister valve is stuck
load pipeline is damaged
closed or open
6 Check whether the canister valve
hardware is stuck closed or open
7 Replace the canister valve
1 The road speed signal sent
1 Check whether the communication
from ESP is incorrect
Road Speed Sensor Input between ESP and ECU is lost
P050000 2 The road speed signal frame
Signal Fault 2 Check whether the CAN signal sent from
communication between ESP
ESP is always 0
and ECU is lost
Road Speed Sensor 1 There is interference in the 1 Connect the diagnostic scan tool and set
Performance Fault (Low harness the ignition switch in the "ON" position
P050165
Road Speed during Vehicle 2 The road speed sensor is 2 Read and save the fail-frost frame
Coasting and Fuel Cutoff) damaged information
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine 2-191Control system
3 Check the harness for external
interference
4 Check whether the road speed sensor is
damaged
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
1 There is interference in the 2 Read and save the fail-frost frame
Road Speed Implausible -
harness information
P050166 Low Road Speed under
2 The road speed sensor is 3 Check the harness for external
Heavy Engine Load
damaged interference
4 Check whether the road speed sensor is
damaged
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
1 There is interference in the 2 Read and save the fail-frost frame
harness information
P050300 Speed Stuck
2 The road speed sensor is 3 Check the harness for external
damaged interference
4 Check whether the road speed sensor is
damaged

GAC Motor 2019

Control system 2-192 Maintenance Manual of 1.5GDI Engine

DTC DTC definition Possible causes Recommended action

1 The electronic throttle is stuck
1 Check whether the electronic throttle is
in a position with a small
stuck in a position with a small opening
opening
due to icing or oil dirt
Control Idle Speed Lower 2 The intake manifold is
P050600 2 Check whether the intake manifold is
than Target Idle Speed leaking; the injector is clogged;
leaking; whether the injector is clogged;
the exhaust resistance is too
whether the exhaust resistance is too high;
high; the fuel supply pressure is
whether the fuel supply pressure is too low
too low
1 The electronic throttle is stuck
1 Check whether the electronic throttle is
in a position with a small
stuck in a position with a small opening
opening
Low Engine Idle Speed due to icing or oil dirt
P050A21 during Catalytic Converter 2 The intake manifold is
2 Check whether the intake manifold is
Heating leaking; the injector is clogged;
leaking; whether the injector is clogged;
the exhaust resistance is too
whether the exhaust resistance is too high;
high; the fuel supply pressure is
whether the fuel supply pressure is too low
too low
1 Check whether the electronic throttle is
1 The electronic throttle is stuck
stuck in a position with a large opening due
in a position with a large
Engine Idle Speed to icing or oil dirt
opening
P050500 Implausible - Large 2 Check whether the system is leaking;
Fluctuations 2 The system is leaking; the
whether the fuel injector is dripping;
fuel injector is dripping; the fuel
whether the fuel supply pressure is too
supply pressure is too high
high
1 Check whether the electronic throttle is
1 The electronic throttle is stuck
stuck in a position with a large opening due
in a position with a large
to icing or oil dirt
Control Idle Speed Higher opening
P050700 2 Check whether the system is leaking;
than Target Idle Speed 2 The system is leaking; the
whether the fuel injector is dripping;
fuel injector is dripping; the fuel
whether the fuel supply pressure is too
supply pressure is too high
high
1 Check whether the electronic throttle is
1 The electronic throttle is stuck
stuck in a position with a large opening due
in a position with a large
High Engine Idle Speed to icing or oil dirt
opening
P050A22 during Catalytic Converter 2 Check whether the system is leaking;
Heating 2 The system is leaking; the
whether the fuel injector is dripping;
fuel injector is dripping; the fuel
whether the fuel supply pressure is too
supply pressure is too high
high
1 There are other DTCs such
as throttle fault or misfire,
1 Use a diagnostic scan tool to check
resulting in a decrease in intake
whether there are other faults such as
flow and abnormal ignition
misfire and throttle fault
angle efficiency
Ignition Angle Efficiency 2 The electronic throttle is stuck in a of
2 The electronic throttle is stuck
Monitoring during Catalytic position with a small opening
P050B00 in a position with a small
Converter Heating (Idle opening 3 Check whether the intake manifold is
Speed) leaking; whether the exhaust resistance is
3 The intake manifold is
too high; whether the fuel supply pressure
leaking; the exhaust resistance
is too low
is too high; the fuel supply
pressure is too low 4 Check whether the ECU is faulty
4 The ECU is faulty
1 There are other DTCs such 1 Use a diagnostic scan tool to check
as throttle fault or misfire, whether there are other faults such as
resulting in a decrease in intake misfire and throttle fault
Ignition Angle Efficiency flow and abnormal ignition 2 The electronic throttle is stuck in a of
Monitoring during Catalytic angle efficiency
P050B20 position with a small opening
Converter Heating (Partial
Load) 2 The electronic throttle is stuck 3 Check whether the intake manifold is
in a position with a small leaking; whether the exhaust resistance is
opening too high; whether the fuel supply pressure
3 The intake manifold is is too low

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine
leaking; the exhaust resistance
is too high; the fuel supply
pressure is too low
4 The ECU is faulty
1 The electronic throttle is stuck
Parking Idle Speed
in a position with a large
Fluctuation Out of Range
opening
P050D00 during Catalytic Converter
Heating and without Fuel 2 The system is leaking; the
Cutoff fuel injector is dripping; the fuel
supply pressure is too high
Crankcase Vent Pipe The diagnosis circuit of
P051C00 Diagnosis Circuit Voltage crankcase vent pipe is shorted
Low to ground
Crankcase Vent Pipe The diagnosis circuit of
P051D00 Diagnosis Circuit Voltage crankcase vent pipe is shorted
High to power supply or open-
circuited
2-193Control system
4 Check whether the ECU is faulty
1 Check whether the electronic throttle is
stuck in a position with a large opening due
to icing or oil dirt
2 Check whether the system is leaking;
whether the fuel injector is dripping;
whether the fuel supply pressure is too
high
Set the ignition switch in the "OFF"
position, and check whether the signal
terminal of brake vacuum sensor is shorted
to ground
1 Use a multimeter to measure whether
the voltage between the signal terminal of
crankcase vent pipe diagnostic circuit and
the ground is close to or equal to 5V
2 The ignition switch is set in the “OFF”
position, the connector is not connected
properly or has poor contact
3 Check whether the signal pin of brake
vacuum sensor at ECU side is shorted to
power supply, open-circuited or the ECU
internal circuit is damaged
GAC Motor 2019
Control system 2-194
DTC DTC definition
Crankcase Vent Pipe
P051E00 Pressure Sensor Zero
Voltage Deviation
Intake VVT Actual Position
P052A00 Deviation during Catalytic
Converter Heating
High-Pressure Fuel
Passage Pressure Low
P053F21
during Catalytic Converter
Heating
High-Pressure Fuel
Passage Pressure High
P053F22
during Catalytic Converter
Heating
Particulate Filter Upstream
P054500 Temperature Sensor Circuit
Voltage Low
Particulate Filter Upstream
P054600 Temperature Sensor Circuit
Voltage High
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
Possible causes
1 The PCV signal pin is shorted
to power supply or ground
2 The PCV pressure sensor is
damaged
1 Connect the diagnostic scan tool and set
1 The oil control system is
leaking
2 The OCV is stuck
3 There is interference in the
harness
1. The fuel passage is leaking
2 The fuel is insufficient
3 The low-pressure fuel pump
is damaged
4 The working capacity of the
high-pressure fuel pump is
impaired
1 The high-pressure fuel pump
control is faulty
2 The pressure relief valve is
clogged
the voltage of signal terminal of particulate
filter upstream temperature sensor is close
1 The signal terminal of
particulate filter upstream
temperature sensor is shorted
to ground
2 The sensor is damaged
upstream temperature sensor at ECU side
1 The signal terminal of
particulate filter upstream
temperature sensor is shorted
to power supply or open-
circuited
2 The signal pin of particulate
filter upstream temperature
sensor at ECU side is shorted
to power supply, open-circuited
or the ECU internal circuit is
damaged
3 The sensor is damaged
Recommended action
1 Check whether the PCV signal circuit is
shorted to power supply or ground
2 Check whether the PCV signal pin at
ECU side is shorted to power supply or
ground
3 Replace the PCV pressure sensor
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
4 Check the harness for external
interference
3 Check whether the oil control system is
leaking
4 Check whether the OCV is stuck
1 Check for leaks in the fuel passage
2 Check whether the fuel is insufficient
3 Check whether the low-pressure fuel
pump is damaged
4 Check whether the working capacity of
the high-pressure fuel pump is impaired
1 Check whether the high-pressure fuel
pump control is normal
2 Check whether the pressure relief valve
is clogged or not working properly
1 Use a multimeter to measure whether
to or equal to 0V
2 Set the ignition switch in the "OFF"
position, and check whether the signal
terminal of particulate filter upstream
temperature sensor is shorted to ground
3 The sensor is damaged
4 The signal pin of particulate filter
is shorted to ground
1 Use a multimeter to measure whether
the voltage between the signal terminal of
particulate filter upstream temperature
sensor and the ground is close to or equal
to 5V
2 The ignition switch is set in the “OFF”
position, the connector is not connected
properly or has poor contact
3 Check whether the sensor signal
terminal is shorted to power supply or
open-circuited
4 Check whether the sensor reference
ground terminal is open-circuited
5 Check whether the sensor is damaged
6 Check whether the signal pin of
particulate filter upstream temperature
sensor at ECU side is shorted to power
supply, open-circuited or the ECU internal
circuit is damaged
Maintenance Manual of 1.5GDI Engine 2-195Control system

1 Check whether the cam phase regulator

2 The OCV oil valve pressure is
Exhaust VVT Actual
insufficient
P054A00 Position Deviation during
Catalytic Converter Heating 3 The OCV oil valve is clogged
or leaking
1 The signal terminal of brake
vacuum sensor is shorted to
ground
2 The sensor 5V reference
Brake Chamber Vacuum
P055700 voltage terminal is open-
Sensor Voltage Low
circuited
3 The signal pin of brake
vacuum sensor at ECU side is
shorted to ground
works normally (blockage due to dirt, oil
leakage, stuck)
2 Check whether the OCV oil control valve
works normally
1 Connect the diagnostic scan tool, set the
ignition switch in the "ON" position (do not
start the engine), and use a multimeter to
measure whether the voltage of signal
terminal of brake vacuum sensor is close
to or equal to 0V
2 Set the ignition switch in the "OFF"
position, and check whether the signal
terminal of brake vacuum sensor is shorted
to ground
3 Check whether the sensor 5V reference
voltage terminal is open-circuited
4 Check whether the signal pin of brake
vacuum sensor at ECU side is shorted to
ground

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Control system 2-196
DTC DTC definition Possible causes
1 The signal terminal of brake
vacuum sensor is shorted to
power supply or open-circuited
2 The reference ground
terminal of brake vacuum
Brake Chamber Vacuum sensor is open-circuited
P055800
Sensor Voltage High
3 The signal pin of brake
vacuum sensor at ECU side is
shorted to power supply or
open-circuited
4 The sensor is damaged
1 Battery breakdown
P056000 Battery Voltage Implausible
2 Alternator fault
1 Any of the pins connected to
the battery or main relay on the
P056200 Low Battery Voltage ECU is open-circuited
2 The battery is leaking or
damaged
1 The engine harness ground
point is faulty
System Battery Voltage 2 The alternator regulator is
P056300
High faulty and cannot effectively
control the power generation of
the motor
Brake Pedal Signal Brake Pedal Signal
P057100
Synchronization Fault Synchronization Fault
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
Recommended action
1 Connect the diagnostic scan tool, set the
ignition switch in the "ON" position (do not
start the engine), and use a multimeter to
measure whether the voltage between the
signal terminal of brake vacuum sensor
and the ground is close to or equal to 5V
2 The ignition switch is set in the “OFF”
position, the connector is not connected
properly or has poor contact
3 Check whether the signal terminal of
brake vacuum sensor is shorted to power
supply or open-circuited
4 Check whether the sensor reference
ground terminal is open-circuited
5 Check whether the sensor is damaged
6 Check whether the signal pin of brake
vacuum sensor at ECU side is shorted to
power supply, open-circuited or the ECU
internal circuit is damaged
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check the battery for irreversible
breakdown
4 Check the alternator system for any fault
1 Connect the diagnostic scan tool, set the
ignition switch in the "OFF" position, and
use a multimeter to measure whether the
battery voltage is too low
2 Check whether any of the pins
connected to the battery or main relay on
the ECU is open-circuited
3 Check whether the engine harness
ground point is faulty
4 The regulator is faulty
5 The battery is leaking or damaged
6 Alternator fault
1 Connect the diagnostic scan tool, set the
ignition switch in the "OFF" position, and
use a multimeter to measure whether the
battery voltage is too high
2 Check whether the engine harness
ground point is faulty
3 The alternator regulator is faulty and
cannot effectively control the power
generation of the motor
1 Collect and check whether the brake
switch main signal Brk_stMn and brake
redundancy signal Brk_stRed meet the
requirements of connection: do not set the
signals by lightly touching the brake pedal,
and the out-sync interval of the two signals
should not be too long
2 Check whether the brake pedal harness
connection is reliable and whether the
brake pedal mechanical structure is
abnormal
Maintenance Manual of 1.5GDI Engine
1 The cruise control connector
is not connected properly or
has poor contact
Cruise Control Circuit
P057700 2 The cruise control circuit is
Voltage High
open
3 Any button of cruise control is
stuck in “pressed” position
1 The cruise control connector
is not connected properly or
has poor contact
Cruise Control Signal
P057500 2 The cruise control circuit is
Implausible
open
3 Any button of cruise control is
stuck in “pressed” position
2-197Control system
3 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 The cruise control connector is not
connected properly or has poor contact
2 The cruise control circuit is open
3 Check whether any button of cruise
control is stuck in “pressed” position
4 The cruise control pin at ECU side is
open-circuited or the circuit is faulty
1 The cruise control connector is not
connected properly or has poor contact
2 The cruise control circuit is open
3 Check whether any button of cruise
control is stuck in “pressed” position
4 The cruise control pin at ECU side is
open-circuited or the circuit is faulty
GAC Motor 2019
Control system 2-198
DTC DTC definition
P058500 ACC AD Conversion Fault
Multiple Injection
P05EC00 Monitoring Faults during
Catalytic Converter Heating
2nd Layer Accelerator
P060D00
Pedal Monitoring Fault
Starter Relay Control
P061500
Circuit High Side Fault
Starter Relay Control High
P061600
Side Circuit Voltage Low
Starter Relay Control
P061700 Circuit High Side Voltage
High
Safety Monitoring Torque
P061A00
Out of Range
Electronic Throttle Safety
Monitoring Function Fault
P061C00
(2nd Layer Engine Speed
Monitoring Fault)
Fuel Pump Enabling
P062700
Control Circuit Open
Fuel Pump Enabling
P062800
Control Circuit Voltage Low
Fuel Pump Enabling
P062900
Control Circuit Voltage High
GAC Motor 2019
Possible causes
1 The cruise control connector
is not connected properly or
has poor contact
2 The cruise control circuit is
open
3 Any button of cruise control is
stuck in “pressed” position
1 The high-pressure fuel
injection system has faults
2 ECU control
1 The ECU data setting is
incorrect, usually because the
EGAS safety monitoring
function is not matched or
preset
1 During data setting, the pedal
module application layer data
does not match the monitoring
layer data
1 The connector is not
connected properly or has poor
contact
2 The high side of starter relay
control is open-circuited
3 The starter control high side
pin at ECU side is open-
circuited or damaged
1 The high side of starter
control circuit is shorted to
ground
2 The starter control high side
pin at ECU side is shorted to
ground
1 The high side of starter
control circuit is shorted to
power supply
2 The starter control high side
pin at ECU side is shorted to
power supply
1 The ECU data setting is
incorrect, usually because the
EGAS safety monitoring
function is not matched or
preset
2 The external torque increase
request was not considered
during data setting
After 40 consecutive trouble-
free warm-up cycles, the DTC
will be deleted
1 The control circuit of low-
pressure fuel pump is open
2 The pin of low-pressure fuel
pump at ECU side is open-
circuited
1 The control circuit of low-
pressure fuel pump is shorted
to ground
2 The pin of low-pressure fuel
pump at ECU side is shorted to
ground
1 The control circuit of low-
pressure fuel pump is shorted
Maintenance Manual of 1.5GDI Engine
Recommended action
1 The cruise control connector is not
connected properly or has poor contact
2 The cruise control circuit is open
3 Check whether any button of cruise
control is stuck in “pressed” position
4 The cruise control pin at ECU side is
open-circuited or the circuit is faulty
1 Check whether there are DTCs related to
the high-pressure fuel injection system
2 Check whether the ECU is faulty
1 Communicate with the EGAS safety
monitoring matching engineer to determine
whether to preset or match the safety
monitoring
2 Confirm with the customer whether the
pedal model has been changed
3 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 The connector is not connected properly
or has poor contact
2 The high side of starter relay control is
open-circuited
3 The fuse of starter relay 1 is blown or
damaged
4 The starter control high side pin at ECU
side is open-circuited or damaged
1 The high side of starter control circuit is
shorted to ground
2 The starter control high side pin at ECU
side is shorted to ground
1 The high side of starter relay control
circuit is shorted to power supply
2 The high side of starter control pin is
shorted to power supply
1 Communicate with the EGAS safety
monitoring matching engineer to determine
whether to preset or match the safety
monitoring
2 Confirm with the customer whether there
is an external torque increase request
(from ESP, TCU, etc.)
3 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Replace the ECU
2 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Check whether the actuator is open-
circuited
2 Check whether the actuator pin at ECU
side is open-circuited
1 Check whether the actuator terminal is
shorted to ground
2 Check whether the actuator pin at ECU
side is shorted to ground
1 Check whether the actuator terminal is
shorted to power supply
Maintenance Manual of 1.5GDI Engine 2-199Control system
to power supply 2 Check whether the actuator pin at ECU
2 The pin of low-pressure fuel side is shorted to power supply
pump at ECU side is shorted to
power supply
1 The data written by PAV is
incomplete 1 After the ECU is completely powered off,
EEPROM Write or Read
P062F42 2 The storage structure no fault will be reported
Failure
changes after software refresh 2 Replace the ECU
3 Flash module is damaged
1 The data written by PAV is
incomplete 1 After the ECU is completely powered off,
EEPROM Write or Read
P062F43 2 The storage structure no fault will be reported
Failure
changes after software refresh 2 Replace the ECU
3 Flash module is damaged

GAC Motor 2019

Control system 2-200 Maintenance Manual of 1.5GDI Engine

DTC DTC definition Possible causes Recommended action

1 The control circuit of cooling
fan relay is shorted to power 1 The control circuit of cooling fan relay is
Cooling Fan Driver Chip supply shorted to power supply
P063400
Overheated 2 The control pin of cooling fan 2 Check whether there is a fault in the
relay at ECU side is shorted to internal chip of the ECU
power supply
1 The sensor heat consumption
increases abnormally
Chip Power Supply 1 After the ECU is completely powered off,
2 The sensor power supply is
P063442 Channel 1 / 2 no fault will be reported
shorted
Overtemperature 2 Replace the ECU
3 The ECU is overheated
4 The device is faulty
1 The sensor heat consumption
increases abnormally
Chip Power Supply 1 After the ECU is completely powered off,
2 The sensor power supply is
P063443 Channel 1 / 2 no fault will be reported
shorted
Overtemperature 2 Replace the ECU
3 The ECU is overheated
4 The device is faulty
The 5V power supply module 1
5V Power Supply Module 1
P064100 has overvoltage or There is signal interference in the harness
Fault
undervoltage
1 The connector is not
connected properly or has poor
1 The connector is not connected properly
contact
or has poor contact
2 The control circuit of A/C
2 The control circuit of A/C compressor
compressor relay is open
relay is open
3 The power supply terminal of
3 The power supply terminal of A/C
A/C compressor relay control
A/C Compressor Relay compressor relay control circuit is open-
P064500 circuit is open-circuited or
Circuit Fault circuited or shorted to ground
shorted to ground
4 The A/C compressor relay fuse is blown
4 The A/C compressor relay
or damaged
fuse is blown or damaged
5 The A/C compressor control pin at ECU
5 The A/C compressor control
side is open-circuited or the ECU internal
pin at ECU side is open-
circuit is damaged
circuited or the ECU internal
circuit is damaged
1 The control circuit of A/C
compressor relay is shorted to 1 The control circuit of A/C compressor
A/C Compressor Relay ground relay is shorted to ground
P064600
Circuit Voltage Low 2 The A/C compressor relay pin 2 The A/C compressor relay pin at ECU
at ECU side is shorted to side is shorted to ground
ground
1 The A/C compressor relay
circuit is shorted to power 1 The A/C compressor relay circuit is
A/C Compressor Relay supply shorted to power supply
P064700
Voltage High 2 The A/C compressor relay pin 2 The A/C compressor relay pin at ECU
at ECU side is shorted to power side is shorted to power supply
supply
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
1 The LSU oxygen sensor is 2 Read and save the fail-frost frame
damaged information
P064D00 LSU Integrated Chip Fault
2 The ECU internal 3 Replace the oxygen sensor, and check
communication is abnormal whether the fault recurs
4 Replace the ECU and check whether the
fault recurs
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
LSU Integrated Chip Supply information
P064D16 The oxygen sensor is faulty
Voltage Low 3. Replace the ECU. Start and run the
engine until the coolant temperature
reaches the normal value. Reproduce the
fault
P064D17 LSU Integrated Chip The oxygen sensor is faulty 1 Connect the diagnostic scan tool and set
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine 2-201Control system
Corrected Voltage High the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3. Replace the ECU. Start and run the
engine until the coolant temperature
reaches the normal value. Reproduce the
fault
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
LSU Integrated Chip SPI information
P064D81 The oxygen sensor is faulty
Communication Fault 3. Replace the ECU. Start and run the
engine until the coolant temperature
reaches the normal value. Reproduce the
fault

GAC Motor 2019

Control system 2-202 Maintenance Manual of 1.5GDI Engine
DTC DTC definition Possible causes
The 5V power supply module
55V Power Supply
P065100 2 has overvoltage or
Module 2 Fault
undervoltage
1 The external power supply
of the ECU is abnormal
Chip 6V Supply
P065900 2 The 6V supply voltage
Overvoltage
inside the ECU is shorted
3 The device is faulty, etc.
ECM/PCM Main Relay 1 The main relay is stuck
P068600 Stuck or Shorted to 2 There is interference in the
Ground harness
1 The battery connector has
been manually connected
Premature Opening of
P068A00 and disconnected for several
ECM or PCM Main Relay
consecutive driving cycles
2 The relay is open-circuited
ECM/PCM Main Relay The alternator system is
P069000
Voltage High faulty
1 The control circuit of
cooling fan relay is shorted to
Cooling Fan Control ground
P069100
Circuit Voltage Low 2 The control pin of cooling
fan relay at ECU side is
shorted to ground
1 The control circuit of
cooling fan relay is shorted to
Cooling Fan Control power supply
P069200
Circuit Voltage High 2 The control pin of cooling
fan relay at ECU side is
shorted to power supply
1 The external relay or
harness is shorted
Main Relay
P06AA00 2 The relay internal
Overtemperature
resistance is too low
3 The device is faulty
1 The connector is not
connected properly or has
poor contact
2 The pin of two-stage oil
Two-stage Oil Pump pump drive circuit is open-
P06DA00
Drive Circuit Open circuited
3 The pin of two-stage oil
pump drive circuit at ECU
side is open-circuited or ECU
internal circuit is damaged
GAC Motor 2019
Recommended action
There is signal interference in the
harness
1 After the ECU is completely powered
off, no fault will be reported
2 Replace the ECU
1 Connect the diagnostic scan tool and
set the ignition switch in the "ON"
position
2 Read and save the fail-frost frame
information
3 Check whether the main relay is
damaged
4 There is interference in the UBR
harness, and it is shorted to UBD
1 Connect the diagnostic scan tool and
set the ignition switch in the "ON"
position
2 Read and save the fail-frost frame
information
3 Check whether the battery connector
has been manually connected and
disconnected for several consecutive
driving cycles
4 Check the harness for external
interference
5 The transmission line between main
relay and ECU is damaged or
interrupted
1 Connect the diagnostic scan tool and
set the ignition switch in the "ON"
position
2 Read and save the fail-frost frame
information
3 Check the alternator system for any
fault
1 The control circuit of cooling fan relay
is shorted to ground
2 The control pin of cooling fan relay at
ECU side is shorted to ground
1 The control circuit of cooling fan relay
is shorted to power supply
2 The control pin of cooling fan relay at
ECU side is shorted to power supply
1 After the ECU is completely powered
off, no fault will be reported
2 Check whether the relay is damaged
and whether the harness is shorted
3 Replace the ECU
1 Check whether the connector is not
connected properly or has poor contact
2 Check whether the pin of two-stage oil
pump drive circuit is open-circuited
3 Check whether the pin of two-stage oil
pump drive circuit at ECU side is open-
circuited or the ECU internal circuit is
damaged
Maintenance Manual of 1.5GDI Engine 2-203Control system
1 The two-stage oil pump
1 Check pin of two-stage oil pump drive
drive circuit is shorted to
Two-stage Oil Pump circuit is shorted to ground
ground
P06DB00 Drive Circuit Shorted to 2 Check whether the pin of two-stage oil
2 The two-stage oil pump
Ground pump drive circuit at ECU side is
drive circuit at ECU side is
shorted to ground
shorted to ground
1 The two-stage oil pump 1 Check whether the pin of two-stage oil
drive circuit is shorted to pump drive circuit is shorted to power
Two-stage Oil Pump
power supply supply
P06DC00 Drive Circuit Shorted to
2 The two-stage oil pump 2 Check whether the pin of two-stage oil
Power Supply
drive circuit at ECU side is pump drive circuit at ECU side is
shorted to power supply shorted to power supply
Request for MIL from Check whether the TCU fault memory is
P070000 The TCU is faulty
TCU faulty
Road Speed Sensor
Performance Fault (Road The road speed signal sent Check whether the CAN signal sent
P121200
Speed above Upper from ESP is incorrect from ESP is too high
Limit)
1 Connect the diagnostic scan tool and
set the ignition switch in the "ON"
position
1 The canister vent valve is 2 Read and save the fail-frost frame
closed information
Fuel Tank Pressure
2 The pipeline from fuel tank 3 Check whether the canister vent valve
P128200 Sensor Signal Out of
to canister is clogged is closed
Range (Positive)
3 The fuel tank pressure 4 Check whether the pipeline from fuel
sensor is damaged tank to canister is clogged
5 Replace the fuel tank pressure sensor.
Start and run the engine for 10min, and
check whether the fault recurs

GAC Motor 2019

Control system 2-204 Maintenance Manual of 1.5GDI Engine
DTC DTC definition Possible causes
1 The canister vent valve is
closed
3 Check whether the canister vent valve
2 The pipeline from fuel tank
Fuel Tank Pressure
to canister is clogged
P128300 Sensor Signal Out of
3 The fuel tank pressure
Range (Negative)
sensor is damaged
5 Replace the fuel tank pressure sensor.
4 The canister valve is stuck
Start and run the engine for 10min, and
open
1 The CAN signal of ECU is
abnormal
Fuel Level Sensor
2 The fuel level sensor is
P128400 Original Signal Out of
damaged
Range
3 The fuel level float inside
the fuel tank is abnormal
1 The signal terminal of
pressure sensor is shorted to
power supply
2 The signal pin of high-load
desorption pipeline pressure
sensor at ECU side is
High-load Desorption shorted to power supply
P128500 Pipeline Pressure Sensor 3 The high-load desorption
load desorption pipeline pressure sensor
Signal above Upper Limit pipeline pressure sensor is
damaged
4 The check valve of low-
load desorption pipeline is
damaged
5 The venturi tube is
disconnected
1 The signal terminal of
pressure sensor is shorted to
ground
2 The signal pin of high-load
desorption pipeline pressure
High-load Desorption sensor at ECU side is
P128600 Pipeline Pressure Sensor shorted to ground
Signal below Lower Limit 3 The high-load desorption
pipeline pressure sensor is
damaged
4 The venturi tube or the
check valve of high-load
desorption pipeline is
GAC Motor 2019
Recommended action
1 Connect the diagnostic scan tool and
set the ignition switch in the "ON"
position
2 Read and save the fail-frost frame
information
is closed
4 Check whether the pipeline from fuel
tank to canister is clogged
check whether the fault recurs
6 Check whether the canister valve is
stuck open
1 Connect the diagnostic scan tool and
set the ignition switch in the "ON"
position
2 Read and save the fail-frost frame
information
3 Replace the fuel level sensor and
check whether the fault recurs
4 Check whether the fuel level float
inside the fuel tank is normal
5 Replace the ECU and check whether
the fault recurs
1 Connect the diagnostic scan tool and
set the ignition switch in the "ON"
position
2 Read and save the fail-frost frame
information
3 Use a multimeter to measure whether
the voltage of signal wire of high-load
desorption pipeline pressure sensor is
close to or equal to 5V
4 Measure whether the voltage of
pressure sensor harness terminal is
close to or equal to 5V
5 Check whether the signal pin of high-
at ECU side is shorted to power supply
or the ECU internal circuit is damaged
6 Replace the high-load desorption
pipeline pressure sensor, drive the
vehicle under a heavy load, and check
whether the fault recurs
7 Replace the check valve of low-load
desorption pipeline, drive the vehicle
under a heavy load, and check whether
the fault recurs
8 Check whether the venturi tube is
disconnected
1 Connect the diagnostic scan tool and
set the ignition switch in the "ON"
position
2 Read and save the fail-frost frame
information
3 Use a multimeter to measure whether
the voltage of signal wire of high-load
desorption pipeline pressure sensor is
close to or equal to 0V
4 Measure whether the voltage of
pressure sensor harness terminal is
close to or equal to 0V
5 Check whether the signal pin of high-
Maintenance Manual of 1.5GDI Engine 2-205Control system
blocked load desorption pipeline pressure sensor
at ECU side is shorted to ground or the
ECU internal circuit is damaged
6 Replace the high-load desorption
pipeline pressure sensor, drive the
vehicle, and check whether the fault
recurs
7 Replace the check valve of high-load
desorption pipeline or the venturi tube,
drive the vehicle, and check whether the
fault recurs
Particulate Filter 1 The differential pressure 1 Check whether the differential
Differential Pressure sensor is faulty pressure sensor pipeline is frozen
P129100
Sensor Dynamic 2 The sampling pipeline is 2 Replace the sensor and check whether
Response Implausible frozen the fault is rectified
Particulate Filter 1 Check whether the differential
Differential Pressure The differential pressure pressure sensor harness is faulty
U060100
Sensor Sent sensor is faulty 2 Check whether the sensor itself is
Communication Fault faulty
Particulate Filter 1 Check whether the differential
Differential Pressure The differential pressure pressure sensor harness is faulty
U060141
Sensor Data Check sensor is faulty 2 Check whether the sensor itself is
Implausible faulty
Particulate Filter
1 Check whether the differential
Differential Pressure
The differential pressure pressure sensor harness is faulty
P129300 Sensor Channel 1 Digital
sensor is faulty 2 Check whether the sensor itself is
Signal Implausible (SENT
faulty
Signal High or Low)

GAC Motor 2019

Control system 2-206
DTC DTC definition
Particulate Filter Differential
Pressure Sensor Channel 2
P129400
Digital Signal Implausible
(SENT Signal High or Low)
Particulate Filter Differential
P129600 Pressure Sensor Signal
Stuck
Particulate Filter Differential
P12A200 Pressure Sensor Pipeline
Connection Error
Abnormal or Completely
Clogged Connecting
Pipeline of Rear Pipe or
P12A300
Abnormal Signal of
Particulate Filter Differential
Pressure Sensor
Particulate Filter
P12B100
Backpressure High
Response Timeout of LIN
P140100 Bus for Communication
between EMS and EBS
Frame Error of LIN Bus for
P140200 Communication between
EMS and EBS
Checksum Error of LIN Bus
P140300 for Communication
between EMS and EBS
Readback Error of LIN Bus
for Communication
P141400
between EMS and
Intelligent Alternator
Response Timeout of LIN
Bus for Communication
P141500
between EMS and
Intelligent Alternator
Frame Error of LIN Bus for
Communication between
P141600
EMS and Intelligent
Alternator
Checksum Error of LIN Bus
for Communication
P141700
between EMS and
Intelligent Alternator
P143000 Battery Type Changed
P143100 EBS or Battery Fault
P143200 EBS Communication Load
GAC Motor 2019
Possible causes
The differential pressure
sensor is faulty
The differential pressure
sensor is faulty
1 The front/rear differential
pressure sensor pipeline
comes off or leaks
2 The front and rear differential
pressure sensor pipelines are
mixed
1 The front/rear differential
pressure sensor pipeline
comes off or leaks
2 The front/rear pressure
differential pipeline is clogged
3 The sensor signal is
abnormal
1 The carbon load of
particulate filter is too high
2 The particulate filter is full of
ash
3 The particulate filter is
abnormally clogged
1 The LIN bus connector is not
connected properly or has poor
contact
2 The EBS control circuit of is
open
The LIN bus for communication
between EMS and EBS is
shorted to power supply
EBS node error
The LIN bus for communication
between EMS and intelligent
alternator is shorted to ground
1 The LIN bus connector of
alternator is not connected
properly or has poor contact
2 There is interference in the
LIN harness
3 The LIN harness is broken or
interrupted
4 The alternator is damaged
and cannot normally transmit
signals to the ECU
The LIN bus for communication
between EMS and intelligent
alternator is shorted to power
supply
The LIN communication
version of intelligent alternator
is inconsistent with that of the
ECU
The battery type has been
changed
1 The EBS circuit is open
2. The EBS is damaged
There is interference in the
Maintenance Manual of 1.5GDI Engine
Recommended action
1 Check whether the differential pressure
sensor harness is faulty
2 Check whether the sensor itself is faulty
1 Check whether the differential pressure
sensor harness is faulty
2 Check whether the sensor itself is faulty
1 Check whether the front/rear differential
pressure sensor pipeline comes off or
leaks
2 Check whether the front and rear
differential pressure sensor pipelines are
mixed
1 Check whether the front/rear differential
pressure sensor pipeline comes off or
leaks
2 Check whether the front/rear pressure
differential pipeline is clogged
3 Check whether the sensor signal is
abnormal
1 Activate the regeneration of particulate
filter, return the vehicle to the customer,
and check whether the fault disappears
2 Replace the particulate filter and see if
the fault is still reported
1 The LIN bus connector is not connected
properly or has poor contact
2 The EBS control circuit of is open
The LIN bus for communication between
EMS and EBS is shorted to power supply
EBS node error
The LIN bus for communication between
EMS and intelligent alternator is shorted to
ground
1 The LIN bus connector of alternator is
not connected properly or has poor contact
2 There is signal interference in the
harness
3 The alternator LIN harness is broken or
interrupted
4 The alternator is damaged and cannot
normally transmit signals to the ECU
The LIN bus for communication between
EMS and intelligent alternator is shorted to
power supply
Check whether the LIN communication
version of intelligent alternator is
inconsistent with that of the ECU
Check whether the battery type has been
changed
1 Check whether the EBS circuit is open
2. The EBS is damaged
Check whether there is interference in the
Maintenance Manual of 1.5GDI Engine
Rate High EBS LIN communication
harness
There is interference in or
P144000 Alternator Circuit Fault damage to alternator LIN
harness
The mechanical part of the
P144100 Alternator Mechanical Fault
alternator is stuck or damaged
The electronic part of the
P142000 Alternator Electronic Fault
alternator is damaged
1 The starter power supply
Starter Damaged or Its
circuit is open or damaged
P14AC00 Power Supply Circuit
2 The starter body is damaged
Interrupted
or cannot work normally
1 The engine crankshaft or
Engine Stalling or
flywheel is stuck
P14AD00 Engagement between
2 The starter cannot engage
Starter and Flywheel Failed
with the flywheel
2-207Control system
EBS LIN communication harness
Check whether there is interference in or
damage to alternator LIN communication
module
Check whether the mechanical part of the
alternator is stuck or damaged
Check whether the electronic part of the
alternator is damaged
1 Check whether the starter power supply
circuit is open or damaged
2 Check whether the starter body is
damaged or cannot work normally
1 Check whether the engine crankshaft or
flywheel is stuck by foreign materials
2 Turn the key to the “Start” position, and
check whether the starter can engage with
the flywheel normally
GAC Motor 2019
Control system 2-208
DTC DTC definition
Key Start Switch Feedback
P14AE00 Voltage Signal Wire (KL50r)
Shorted to Power Supply
Key Start Switch Feedback
P14AF00 Voltage Signal Wire (KL50r)
Shorted To Ground
Collision and Fuel Cutoff
P150000
Signal Received by Vehicle
Airbag Communication
P150100
Information Implausible
Knock Sensor Signal
P151000
Evaluation and Diagnosis
Load Forecasting
P152000
Monitoring Fault
Fuel Passage Monitoring
P152100
Fault in Fuel Cutoff Mode
Fuel Passage Monitoring
P152200
Fault in Fuel Supply Mode
Load Comparison
P152500
Monitoring Fault
GAC Motor 2019
Possible causes
1 The feedback signal wire of
start switch is shorted to power
supply
2 The starter relay R1 switch is
stuck
1 The feedback signal wire of
start switch is shorted to
ground
2 The feedback signal wire of
start switch is shorted to
ground
1 The vehicle is involved in a
collision, and the airbag
deploys
2 There is electromagnetic
interference in the harness
between the airbag and ECU
3 The signal sent from the
airbag to ECU is implausible
1 There is interference in the
harness or the signal is not
sent out reliably
2 The signal sent from the SRS
to engine ECU failed the
verification, and the signal is
abnormal
1 The sensor is damaged
2. The ECU is damaged
1 The ECU data setting is
incorrect, usually because the
EGAS safety monitoring
function is not matched or
preset
2 There is an error in the
application layer calculation
from load to fuel injection
volume
1 The ECU data setting is
incorrect, usually because the
EGAS safety monitoring
function is not matched or
preset
2 There is an error in the
application layer calculation
from load to fuel injection
volume
1 The ECU data setting is
incorrect, usually because the
EGAS safety monitoring
function is not matched or
preset
2 There is an error in the
application layer calculation
from load to fuel injection
volume
1 The ECU data setting is
incorrect, usually because the
EGAS safety monitoring
function is not matched or
preset
2 There is an error in the
application layer calculation
Maintenance Manual of 1.5GDI Engine
Recommended action
1 Check whether the feedback signal wire
of start switch is shorted to power supply
2 Check whether the starter relay R1
switch is stuck
Check whether the feedback signal wire of
start switch is shorted to ground or open-
circuited
1 The vehicle is involved in a collision, and
the airbag deploys
2 There is electromagnetic interference in
the harness between the airbag and ECU
3 The signal sent from the airbag to ECU
is implausible
1 There is interference in the harness or
the signal is not sent out reliably
2 The signal sent from the SRS to engine
ECU failed the verification, and the signal
is abnormal
1 Check whether the knock sensor is
damaged
2 Check whether the ECU is damaged
1 Communicate with the EGAS safety
monitoring matching engineer to determine
whether to preset or match the safety
monitoring
2 Check whether there is an error in the
application layer calculation from load to
fuel injection volume
3 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Communicate with the EGAS safety
monitoring matching engineer to determine
whether to preset or match the safety
monitoring
2 Check whether there is an error in the
application layer calculation from load to
fuel injection volume
3 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Communicate with the EGAS safety
monitoring matching engineer to determine
whether to preset or match the safety
monitoring
2 Check whether there is an error in the
application layer calculation from load to
fuel injection volume
3 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Communicate with the EGAS safety
monitoring matching engineer to determine
whether to preset or match the safety
monitoring
2 Check whether there is an error in the
application layer calculation from load to
fuel injection volume
Maintenance Manual of 1.5GDI Engine
from load to fuel injection
volume
1 The ECU data setting is
incorrect, usually because the
EGAS safety monitoring
function is not matched or
Gas Mixture Monitoring
P152300 preset
Fault
2 There is an error in the
application layer calculation
from load to fuel injection
volume
2-209Control system
3 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Communicate with the EGAS safety
monitoring matching engineer to determine
whether to preset or match the safety
monitoring
2 Check whether there is an error in the
application layer calculation from load to
fuel injection volume
3 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
GAC Motor 2019
Control system 2-210
DTC DTC definition
Working Mode Monitoring
P152400
Fault
Ignition Angle Signal,
P152600
Harness or ECU Fault
1st Layer Safe Fuel Cutoff
P152700
Monitoring Fault
2nd Layer Safe Fuel Cutoff
P152800
Monitoring Fault
Starter Control Monitoring
P152900
Fault
AD Converter Null Voltage
P153000
Test Monitoring Fault
AD Converter Set Voltage
P153100
Test Monitoring Fault
Monitoring Fault Response
P157300
Fault
DVE Drive Cutoff Fault due
P157500
to Overvoltage
Electronic Throttle Safety
P154000
Monitoring Torque Limit
Electronic Throttle Self-
P155000 learning / Throttle Initial
Self-learning Failed
Electronic Throttle Self-
P155100 learning / Throttle Initial
Self-learning Failed
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
Possible causes Recommended action
1 The ECU data setting is 1 Communicate with the EGAS safety
incorrect, usually because the monitoring matching engineer to determine
EGAS safety monitoring whether to preset or match the safety
function is not matched or monitoring
preset 2 Check whether there is an error in the
2 There is an error in the application layer calculation from load to
application layer calculation fuel injection volume
from load to fuel injection 3 Clear the DTC, restart the engine, and
volume check whether the DTC is eliminated
1 Replace the ECU
ECU internal fault 2 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Replace the ECU
ECU internal fault 2 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Replace the ECU
ECU internal fault 2 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Replace the ECU
ECU internal fault 2 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Replace the ECU
ECU internal fault 2 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Replace the ECU
ECU internal fault 2 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Replace the ECU
ECU internal fault 2 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Replace the ECU
ECU internal fault 2 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Check whether the safety monitoring
The safety monitoring data is
data is set incorrectly
set incorrectly or the ECU has
2 Clear the DTC, restart the engine, and
an internal fault
check whether the DTC is eliminated
1 The conditions for DVE self-
learning are not met. See the 7
conditions above
2 When the water temperature
sensor or IAT sensor is faulty,
the temperature conditions will
not be met because the correct
Replace the VCU
temperature cannot be
collected.
3 Some OEMs do not turn on
heating in the workshops in
winter, and the fault may be
caused when the temperature
is too low
1 The conditions for DVE self-
learning are not met. See the 7
conditions above
2 When the water temperature
sensor or IAT sensor is faulty,
the temperature conditions will
not be met because the correct
Replace the VCU
temperature cannot be
collected.
3 Some OEMs do not turn on
heating in the workshops in
winter, and the fault may be
caused when the temperature
is too low
Maintenance Manual of 1.5GDI Engine
DTC DTC definition
Electronic Throttle Self-
P155F00 learning / Throttle Initial
Self-learning Failed
Electronic Throttle Spring
Inspection Fault at Min. /
P155400 Max. Opening / Deviation
Between Target and Actual
Throttle Openings
Electronic Throttle Spring
Inspection Fault at Min. /
P155500 Max. Opening / Deviation
Between Target and Actual
Throttle Openings
Electronic Throttle Spring
Inspection Fault at Min. /
P156100 Max. Opening / Deviation
Between Target and Actual
Throttle Openings
Electronic Throttle Limp
P155C00
Position Self-learning Error
Electronic throttle PID
P155D0
Adjustment Fault
Electronic throttle PID
P155E00
Adjustment Fault
2-211Control system
Possible causes Recommended action
1 The conditions for DVE self-
learning are not met. See the 7
conditions above
2 When the water temperature
sensor or IAT sensor is faulty,
the temperature conditions will
not be met because the correct
Replace the VCU
temperature cannot be
collected.
3 Some OEMs do not turn on
heating in the workshops in
winter, and the fault may be
caused when the temperature
is too low
1 The pin of electronic throttle
drive motor is open-circuited or
shorted somewhere. The pin of
electronic throttle drive motor is
open-circuited or shorted
somewhere.
Replace the VCU
2 The valve plate of electronic
throttle body is stuck by dirt or
foreign materials. The valve
plate of electronic throttle body
is stuck by dirt or foreign
materials.
1 The pin of electronic throttle
drive motor is open-circuited or
shorted somewhere. The pin of
electronic throttle drive motor is
open-circuited or shorted
somewhere.
Replace the VCU
2 The valve plate of electronic
throttle body is stuck by dirt or
foreign materials. The valve
plate of electronic throttle body
is stuck by dirt or foreign
materials.
1 The pin of electronic throttle
drive motor is open-circuited or
shorted somewhere. The pin of
electronic throttle drive motor is
open-circuited or shorted
somewhere.
Replace the VCU
2 The valve plate of electronic
throttle body is stuck by dirt or
foreign materials. The valve
plate of electronic throttle body
is stuck by dirt or foreign
materials.
The throttle or ECU is abnormal
Replace the ECU or throttle
during throttle self-learning
1 The pin of electronic throttle
drive motor is open-circuited or
shorted somewhere. The pin of
electronic throttle drive motor is
open-circuited or shorted
somewhere. Replace the VCU
2 The valve plate of electronic
throttle body is stuck by dirt or
foreign materials
3 The internal throttle drive chip
in ECU is abnormal
1 The pin of electronic throttle
drive motor is open-circuited or Replace the VCU
shorted somewhere. The pin of
GAC Motor 2019
Control system 2-212 Maintenance Manual of 1.5GDI Engine

electronic throttle drive motor is

open-circuited or shorted
somewhere.
2 The valve plate of electronic
throttle body is stuck by dirt or
foreign materials
3 The internal throttle drive chip
in ECU is abnormal

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-213Control system

DTC DTC definition Possible causes Recommended action

Electronic Throttle
The throttle or ECU is abnormal
P156600 Mechanical BDC Re-self-
learning Error
Monitoring Module
P157000
Feedback Fault
ECU Fault (5V Overvoltage
P157600
Monitoring Fault)
ECU Fault (5V Overvoltage
P157700
Monitoring Fault)
Monitoring Module Inquiry
P157800
Fault
P161500 Immobilizer Fault
immobilizer status is incorrect
P051300 Immobilizer Fault
immobilizer status is incorrect
P161700 Immobilizer Fault
immobilizer status is incorrect
P161600 Immobilizer Fault
immobilizer status is incorrect
P063300 Immobilizer Fault
immobilizer status is incorrect
P161000 Immobilizer Fault
immobilizer status is incorrect
P161100 Immobilizer Fault
immobilizer status is incorrect
during throttle self-learning
ECU internal fault
ECU internal fault
ECU internal fault
ECU internal fault
The ECM has not performed
immobilizer matching or the
5 The immobilizer module circuit is faulty
The ECM has not performed
immobilizer matching or the
5 The immobilizer module circuit is faulty
The ECM has not performed
immobilizer matching or the
5 The immobilizer module circuit is faulty
The ECM has not performed
immobilizer matching or the
5 The immobilizer module circuit is faulty
The ECM has not performed
immobilizer matching or the
5 The immobilizer module circuit is faulty
The ECM has not performed
immobilizer matching or the
5 The immobilizer module circuit is faulty
The ECM has not performed
immobilizer matching or the
Replace the ECU or throttle
Replace the ECU
Replace the ECU
Replace the ECU
Replace the ECU
1 The immobilizer connector is not
connected properly or disconnected
2 The immobilizer circuit is faulty
3 If the ECU has been replaced, check
whether the immobilizer authentication
code is incorrect or not updated
4 The immobilizer is faulty
1 The immobilizer connector is not
connected properly or disconnected
2 The immobilizer circuit is faulty
3 If the ECU has been replaced, check
whether the immobilizer authentication
code is incorrect or not updated
4 The immobilizer is faulty
1 The immobilizer connector is not
connected properly or disconnected
2 The immobilizer circuit is faulty
3 If the ECU has been replaced, check
whether the immobilizer authentication
code is incorrect or not updated
4 The immobilizer is faulty
1 The immobilizer connector is not
connected properly or disconnected
2 The immobilizer circuit is faulty
3 If the ECU has been replaced, check
whether the immobilizer authentication
code is incorrect or not updated
4 The immobilizer is faulty
1 The immobilizer connector is not
connected properly or disconnected
2 The immobilizer circuit is faulty
3 If the ECU has been replaced, check
whether the immobilizer authentication
code is incorrect or not updated
4 The immobilizer is faulty
1 The immobilizer connector is not
connected properly or disconnected
2 The immobilizer circuit is faulty
3 If the ECU has been replaced, check
whether the immobilizer authentication
code is incorrect or not updated
4 The immobilizer is faulty
1 The immobilizer connector is not
connected properly or disconnected
2 The immobilizer circuit is faulty
3 If the ECU has been replaced, check
whether the immobilizer authentication
code is incorrect or not updated
4 The immobilizer is faulty
GAC Motor 2019
Control system 2-214 Maintenance Manual of 1.5GDI Engine

5 The immobilizer module circuit is faulty

1 The immobilizer connector is not
connected properly or disconnected
2 The immobilizer circuit is faulty
The ECM has not performed
3 If the ECU has been replaced, check
P161400 Immobilizer Fault immobilizer matching or the
whether the immobilizer authentication
immobilizer status is incorrect
code is incorrect or not updated
4 The immobilizer is faulty
5 The immobilizer module circuit is faulty

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine
DTC DTC definition
P161200 Immobilizer Fault
P161300 Immobilizer Fault
Particulate Filter Upstream
P20802A Temperature Sensor Signal
Stuck
Excessive Deviation
between Signal Model and
P208062 Actual Condition of
Particulate Filter Upstream
Temperature Sensor
Intake VVT Control Circuit
P208800
Voltage Low
Intake VVT Control Circuit
P208900
Voltage High
Exhaust VVT Control
P209000
Circuit Voltage Low
Exhaust VVT Control
P209100
Circuit Voltage High
P209600 Closed-loop Correction
Possible causes
The ECM has not performed
immobilizer matching or the
immobilizer status is incorrect
The ECM has not performed
immobilizer matching or the
immobilizer status is incorrect
1 There is interference in the
upstream temperature sensor
circuit of particulate filter
2 The characteristics of
particulate filter upstream
temperature sensor deviate
due to aging
1 There is interference in the
upstream temperature sensor
circuit of particulate filter
2 The characteristics of
particulate filter upstream
temperature sensor deviate
due to aging
1 The signal terminal of intake
VVT control solenoid valve is
shorted to ground
2 The power supply terminal of
intake VVT control solenoid
valve is shorted to ground
3 The signal terminal pin of
intake VVT control solenoid
valve at ECU side is shorted to
ground
1 The signal terminal of intake
VVT control solenoid valve is
shorted to power supply
2 The signal terminal pin of
intake VVT control solenoid
valve at ECU side is shorted to
power supply
1 The signal terminal of
exhaust VVT control solenoid
valve is shorted to ground
2 The power supply terminal of
exhaust VVT control solenoid
valve is shorted to ground
3 The signal terminal pin of
exhaust VVT control solenoid
valve at ECU side is shorted to
ground
1 The signal terminal of
exhaust VVT control solenoid
valve is shorted to power
supply
2 The signal terminal pin of
exhaust VVT control solenoid
valve at ECU side is shorted to
power supply
1 The upstream oxygen sensor
2-215Control system
Recommended action
1 The immobilizer connector is not
connected properly or disconnected
2 The immobilizer circuit is faulty
3 If the ECU has been replaced, check
whether the immobilizer authentication
code is incorrect or not updated
4 The immobilizer is faulty
5 The immobilizer module circuit is faulty
1 The immobilizer connector is not
connected properly or disconnected
2 The immobilizer circuit is faulty
3 If the ECU has been replaced, check
whether the immobilizer authentication
code is incorrect or not updated
4 The immobilizer is faulty
5 The immobilizer module circuit is faulty
1 Check whether there is interference in
the GPF temperature sensor circuit
2 Check whether the characteristics of
GPF temperature sensor deviate due to
aging
1 Check whether there is interference in
the upstream temperature sensor circuit of
particulate filter
2 Check whether the characteristics of
particulate filter upstream temperature
sensor deviate due to aging
1 The signal terminal of intake VVT control
solenoid valve is shorted to ground
2 The power supply terminal of intake VVT
control solenoid valve is shorted to ground
3 The signal terminal pin of intake VVT
control solenoid valve at ECU side is
shorted to ground
1 The signal terminal of intake VVT control
solenoid valve is shorted to power supply
2 The signal terminal pin of intake VVT
control solenoid valve at ECU side is
shorted to power supply
1 The signal terminal of exhaust VVT
control solenoid valve is shorted to ground
2 The power supply terminal of exhaust
VVT control solenoid valve is shorted to
ground
3 The signal terminal pin of exhaust VVT
control solenoid valve at ECU side is
shorted to ground
1 The signal terminal of exhaust VVT
control solenoid valve is shorted to power
supply
2 The signal terminal pin of exhaust VVT
control solenoid valve at ECU side is
shorted to power supply
1 Connect the diagnostic scan tool and set
GAC Motor 2019
Control system 2-216
Value Based on has a positive characteristic
Downstream Oxygen deviation (biased lean)
Sensor below Lower Limit - 2 The downstream oxygen
Biased Lean sensor ages to a certain extent
3 There is leakage in the intake
/ exhaust system
4 The catalytic converter is
seriously degraded
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check the intake and exhaust systems
for leakage
4 Replace the upstream LSU oxygen
sensor, return the vehicle to the customer,
and track whether the fault recurs
5 Replace the downstream oxygen sensor
and track whether the fault recurs
6 Check whether the catalytic converter is
degraded
7 Replace the catalytic converter and track
whether the fault recurs
Maintenance Manual of 1.5GDI Engine
DTC DTC definition Possible causes
1 The upstream oxygen sensor
has a negative characteristic
Closed-loop Correction deviation (biased rich)
Value Based on 2 The downstream oxygen
P209700 Downstream Oxygen sensor ages to a certain extent
Sensor above Upper Limit - 3 There is leakage in the intake
Biased Rich / exhaust system
4 The catalytic converter is
seriously degraded
1 There is interference in the
upstream temperature sensor
Particulate Filter Upstream
circuit of particulate filter
Temperature Sensor Cold
P20E223 2 The characteristics of
Start Check Implausible
particulate filter upstream
(Negative Deviation)
temperature sensor deviate
due to aging
1 There is interference in the
upstream temperature sensor
Particulate Filter Upstream
circuit of particulate filter
Temperature Sensor Cold
P20E224 2 The characteristics of
Start Check Implausible
particulate filter upstream
(Positive Deviation)
temperature sensor deviate
due to aging
1 The throttle is faulty (valve
Electronic Throttle Drive plate stuck or motor fault)
P210000
Stage Fault 2 The throttle drive module
inside the ECU is faulty
1 The throttle is faulty (valve
Electronic Throttle Drive plate stuck or motor fault)
P210300
Stage Fault 2 The throttle drive module
inside the ECU is faulty
1 The throttle is faulty (valve
Electronic Throttle Drive plate stuck or motor fault)
P210600
Stage Fault 2 The throttle drive module
inside the ECU is faulty
1 The throttle is faulty (valve
Electronic Throttle Drive plate stuck or motor fault)
P211800
Stage Fault 2 The throttle drive module
inside the ECU is faulty
1 The GND wire of accelerator
pedal position sensor 1 / 2 is
Accelerator Pedal Position
open
P212300 Sensor 1 / 2 Signal Voltage
2 The signal wire of accelerator
High
pedal position sensor 1 / 2 is
shorted to 5V
2-217Control system
Recommended action
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check the intake and exhaust systems
for leakage
4 Replace the upstream LSU oxygen
sensor, return the vehicle to the customer,
and track whether the fault recurs
5 Replace the downstream oxygen sensor
and track whether the fault recurs
6 Check whether the catalytic converter is
degraded
7 Replace the catalytic converter and track
whether the fault recurs
1 Check whether there is interference in
the upstream temperature sensor circuit of
particulate filter
2 Check whether the characteristics of
particulate filter upstream temperature
sensor deviate due to aging
1 Check whether there is interference in
the upstream temperature sensor circuit of
particulate filter
2 Check whether the characteristics of
particulate filter upstream temperature
sensor deviate due to aging
1 Replace the throttle body to determine
whether there is an internal fault
2 Replace the ECU to determine whether
the fault is in the throttle drive module
inside the ECU
3 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Replace the throttle body to determine
whether there is an internal fault
2 Replace the ECU to determine whether
the fault is in the throttle drive module
inside the ECU
3 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Replace the throttle body to determine
whether there is an internal fault
2 Replace the ECU to determine whether
the fault is in the throttle drive module
inside the ECU
3 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Replace the throttle body to determine
whether there is an internal fault
2 Replace the ECU to determine whether
the fault is in the throttle drive module
inside the ECU
3 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Collect the voltage values of the two
accelerator pedal signals APP_uRaw1 and
APP_uRaw2, and observe whether the
voltage values rise to about 5V at the
moment the fault reappears
2 Check whether actions such as
disconnecting and connecting the
connector, shaking the harness, etc., affect
the occurrence of the fault
GAC Motor 2019
Control system 2-218 Maintenance Manual of 1.5GDI Engine

3 Verify if the fault is in the harness by

connecting a jumper across the accelerator
pedal
4 Replace the pedal to check whether the
fault is in the pedal
5 Clear the DTC, restart the engine, and
check whether the DTC is eliminated

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine
DTC DTC definition
Accelerator Pedal Position
P212800 Sensor 1 / 2 Signal Voltage
High
Deviation between
Accelerator Pedal Position
P213800
Sensor Signals Out of
Range
4# Cylinder Injector High
Side Control Circuit Voltage
P214700 Low or 4# Cylinder Low
Side Control Circuit Voltage
Low
2# and 3# Cylinder Injector
High Side Control Circuit
P215000 Voltage Low or 2# Cylinder
Low Side Control Circuit
Voltage Low
1# / 4# Cylinder Injector
P214800 High Side Control Circuit
Shorted to Power Supply
2# / 3# Cylinder Injector
P215100 High Side Control Circuit
Shorted to Power Supply
Possible causes
1 The GND wire of accelerator
pedal position sensor 1 / 2 is
open
2 The signal wire of accelerator
pedal position sensor 1 / 2 is
shorted to 5V
1 There is a short circuit or
resistance between the two
signal wires of accelerator
pedal position sensor.
There is a short circuit or
resistance between the two
signal wires of accelerator
pedal position sensor.
2 There is resistance in the 5V
power supply wire or GND wire
of accelerator pedal position
sensor 1 / 2, which pulls down
the 5V voltage at pedal side or
pulls up the null voltage. There
is resistance in the 5V power
supply wire or GND wire of
accelerator pedal position
sensor 1 / 2, which pulls down
the 5V voltage at pedal side or
pulls up the null voltage
1 The injector circuit is shorted
to power supply or ground
2 The injector power supply
terminal is shorted to power
supply or ground
3 The injector control pin at
ECU side is shorted to power
supply or ground
1 The injector circuit is shorted
to power supply or ground
2 The injector power supply
terminal is shorted to power
supply or ground
3 The injector control pin at
ECU side is shorted to power
supply or ground
1 The high side control circuit of
injector is shorted to power
supply
2 The high side control pin of
injector at ECU side is shorted
to power supply
1 The high side control circuit of
injector is shorted to power
supply
2 The high side control pin of
injector at ECU side is shorted
to power supply
2-219Control system
Recommended action
1 Collect the voltage values of the two
accelerator pedal signals APP_uRaw1 and
APP_uRaw2, and observe whether the
voltage values rise to about 5V at the
moment the fault reappears
2 Check whether actions such as
disconnecting and connecting the
connector, shaking the harness, etc., affect
the occurrence of the fault
3 Verify if the fault is in the harness by
connecting a jumper across the accelerator
pedal
4 Replace the pedal to check whether the
fault is in the pedal
5 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Collect the voltage values of the two
accelerator pedal signals APP_uRaw1 and
APP_uRaw2, and observe whether the
voltage values double at the moment the
fault reappears
2 Check whether actions such as
disconnecting and connecting the
connector, shaking the harness, etc., affect
the occurrence of the fault
3 Measure the voltage drop of each
section on the harness using AD-Scan. If
the harness is in good condition, there will
be no voltage drop. If there is a voltage
drop, it means that there is resistance in
the harness or connector.
4 Verify if the fault is caused by the
harness resistance by connecting a jumper
across the accelerator pedal
5 Replace the pedal to determine whether
there is an internal fault
6 Clear the DTC, restart the engine, and
check whether the DTC is eliminated
1 Check whether the corresponding
injector circuit is shorted to power supply
or ground
2 Check whether the injector control pin at
ECU side is shorted to power supply or
ground
1 Check whether the corresponding
injector circuit is shorted to power supply
or ground
2 Check whether the injector control pin at
ECU side is shorted to power supply or
ground
1 Check whether the corresponding high
side control circuit of injector is shorted to
power supply
2 Check whether the pin of injector high
side control circuit at ECU side is shorted
to power supply
1 Check whether the corresponding high
side control circuit of injector is shorted to
power supply
2 Check whether the pin of injector high
side control circuit at ECU side is shorted
to power supply
GAC Motor 2019
Control system 2-220 Maintenance Manual of 1.5GDI Engine

DTC DTC definition Possible causes Recommended action

Air/fuel Ratio Closed-loop
Control Self-learning Value
P217700
above Upper Limit (Medium
Load Area)
GAC Motor 2019
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Connect the fuel pressure gauge (to the
front end of fuel inlet pipe of fuel
distribution pipe assembly), start the
engine, and check whether the fuel
pressure is normal during idling and when
the vacuum pipe of fuel pressure regulator
is removed
4 Use a special instrument to check
whether the injector is leaking or clogged
5 Check the fuel condition, and ask the
customer whether to add the designated
grade of gasoline After refueling, check
whether the vehicle works abnormally
6 Check whether the intake pipeline is
clogged, leaking, squashed or damaged;
whether the canister control valve is stuck;
whether the valve clearance is abnormal;
whether the throttle body is contaminated,
causing the air passage to be clogged
7 Check whether the ignition coil, ignition
cable or spark plug works abnormally
8 Measure whether the voltage of #1 wire
(white, positive pole of heater power
1 There fuel passage system supply) at oxygen sensor side of the
hardware is leaking or clogged upstream oxygen sensor harness is 12V
with the oxygen sensor connector
2 The intake pipeline is faulty connected
3 The oxygen sensor harness
connector is faulty
9 Measure whether the voltage of #2 wire
4 The oxygen sensor is faulty (white, ground of heater power supply) at
oxygen sensor side of the upstream
oxygen sensor harness is 12V with the
oxygen sensor connector connected
10 Pierce the insulation of #1 wire (white,
positive pole of heater power supply) of
harness connector at ECU side with the
red tip of a multimeter, pierce the insulation
of #2 wire (white, ground of heater power
supply) of harness connector at ECU side
with the black tip, and measure whether
the voltage is about 12V.
11 Measure whether the voltage between
#4 wire (black, oxygen sensor signal wire)
and #3 wire (gray, oxygen sensor signal
ground) at ECU side of the downstream
oxygen sensor harness is about 0.45V with
the oxygen sensor connector connected
12 Start and run the engine until the
coolant temperature reaches the normal
value, and then idle it. Pierce the insulation
of #4 wire (black, oxygen sensor signal
wire) of harness connector at ECU side
with the red tip of a multimeter, pierce the
insulation of #3 wire (gray, oxygen sensor
signal ground) of harness connector at
ECU side with the black tip, and measure
whether the voltage jumps between 0V-1V
13 Measure whether #3 port (gray, oxygen
Maintenance Manual of 1.5GDI Engine 2-221Control system
sensor signal ground) is shorted to #4 port
(black, oxygen sensor signal wire) at
sensor side with the upstream oxygen
sensor connector disconnected
14 Connect the upstream oxygen sensor
connector, and repeat steps 6-7 to check
whether the voltage signal jumps between
0.44V-0.46V and 0V-1V respectively

GAC Motor 2019

Control system 2-222 Maintenance Manual of 1.5GDI Engine

DTC DTC definition Possible causes Recommended action

Air/fuel Ratio Closed-loop
Control Self-learning Value
P217800
below Lower Limit (Medium
Load Area)
GAC Motor 2019
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Connect the fuel pressure gauge (to the
front end of fuel inlet pipe of fuel
distribution pipe assembly), start the
engine, and check whether the fuel
pressure is normal during idling and when
the vacuum pipe of fuel pressure regulator
is removed
4 Use a special instrument to check
whether the injector is leaking or clogged
5 Check the fuel condition, and ask the
customer whether to add the designated
grade of gasoline After refueling, check
whether the vehicle works abnormally
6 Check whether the intake pipeline is
clogged, leaking, squashed or damaged;
whether the canister control valve is stuck;
whether the valve clearance is abnormal;
whether the throttle body is contaminated,
causing the air passage to be clogged
7 Check whether the ignition coil, ignition
cable or spark plug works abnormally
8 Measure whether the voltage of #1 wire
(white, positive pole of heater power
1 There fuel passage system supply) at oxygen sensor side of the
hardware is leaking or clogged upstream oxygen sensor harness is 12V
with the oxygen sensor connector
2 The intake pipeline is faulty
connected
3 The oxygen sensor harness
9 Measure whether the voltage of #2 wire
connector is faulty
(white, ground of heater power supply) at
4 The oxygen sensor is faulty oxygen sensor side of the upstream
oxygen sensor harness is 12V with the
oxygen sensor connector connected
10 Pierce the insulation of #1 wire (white,
positive pole of heater power supply) of
harness connector at ECU side with the
red tip of a multimeter, pierce the insulation
of #2 wire (white, ground of heater power
supply) of harness connector at ECU side
with the black tip, and measure whether
the voltage is about 12V.
11 Measure whether the voltage between
#4 wire (black, oxygen sensor signal wire)
and #3 wire (gray, oxygen sensor signal
ground) at ECU side of the downstream
oxygen sensor harness is about 0.45V with
the oxygen sensor connector connected
12 Start and run the engine until the
coolant temperature reaches the normal
value, and then idle it. Pierce the insulation
of #4 wire (black, oxygen sensor signal
wire) of harness connector at ECU side
with the red tip of a multimeter, pierce the
insulation of #3 wire (gray, oxygen sensor
signal ground) of harness connector at
ECU side with the black tip, and measure
whether the voltage jumps between 0V-1V
13 Measure whether #3 port (gray, oxygen
sensor signal ground) is shorted to #4 port
Maintenance Manual of 1.5GDI Engine 2-223Control system
(black, oxygen sensor signal wire) at
sensor side with the upstream oxygen
sensor connector disconnected
14 Connect the upstream oxygen sensor
connector, and repeat steps 6-7 to check
whether the voltage signal jumps between
0.44V-0.46V and 0V-1V respectively

GAC Motor 2019

Control system 2-224 Maintenance Manual of 1.5GDI Engine

DTC DTC definition Possible causes Recommended action

Air/fuel Ratio Closed-loop
Control Self-learning Value
P218700
above Upper Limit (Idle
Speed)
GAC Motor 2019
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Connect the fuel pressure gauge (to the
front end of fuel inlet pipe of fuel
distribution pipe assembly), start the
engine, and check whether the fuel
pressure is normal during idling and when
the vacuum pipe of fuel pressure regulator
is removed
4 Use a special instrument to check
whether the injector is leaking or clogged
5 Check the fuel condition, and ask the
customer whether to add the designated
grade of gasoline After refueling, check
whether the vehicle works abnormally
6 Check whether the intake pipeline is
clogged, leaking, squashed or damaged;
whether the canister control valve is stuck;
whether the valve clearance is abnormal;
whether the throttle body is contaminated,
causing the air passage to be clogged
7 Check whether the ignition coil, ignition
cable or spark plug works abnormally
8 Measure whether the voltage of #1 wire
(white, positive pole of heater power
1 There fuel passage system supply) at oxygen sensor side of the
hardware is leaking or clogged upstream oxygen sensor harness is 12V
with the oxygen sensor connector
2 The intake pipeline is faulty
connected
3 The oxygen sensor harness
9 Measure whether the voltage of #2 wire
connector is faulty
(white, ground of heater power supply) at
4 The oxygen sensor is faulty oxygen sensor side of the upstream
oxygen sensor harness is 12V with the
oxygen sensor connector connected
10 Pierce the insulation of #1 wire (white,
positive pole of heater power supply) of
harness connector at ECU side with the
red tip of a multimeter, pierce the insulation
of #2 wire (white, ground of heater power
supply) of harness connector at ECU side
with the black tip, and measure whether
the voltage is about 12V.
11 Measure whether the voltage between
#4 wire (black, oxygen sensor signal wire)
and #3 wire (gray, oxygen sensor signal
ground) at ECU side of the downstream
oxygen sensor harness is about 0.45V with
the oxygen sensor connector connected
12 Start and run the engine until the
coolant temperature reaches the normal
value, and then idle it. Pierce the insulation
of #4 wire (black, oxygen sensor signal
wire) of harness connector at ECU side
with the red tip of a multimeter, pierce the
insulation of #3 wire (gray, oxygen sensor
signal ground) of harness connector at
ECU side with the black tip, and measure
whether the voltage jumps between 0V-1V
13 Measure whether #3 port (gray, oxygen
sensor signal ground) is shorted to #4 port
Maintenance Manual of 1.5GDI Engine 2-225Control system
(black, oxygen sensor signal wire) at
sensor side with the upstream oxygen
sensor connector disconnected
14 Connect the upstream oxygen sensor
connector, and repeat steps 6-7 to check
whether the voltage signal jumps between
0.44V-0.46V and 0V-1V respectively

GAC Motor 2019

Control system 2-226 Maintenance Manual of 1.5GDI Engine

DTC DTC definition Possible causes Recommended action

Air/fuel Ratio Closed-loop
Control Self-learning Value
P218800
above Upper Limit (Idle
Speed)
GAC Motor 2019
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Connect the fuel pressure gauge (to the
front end of fuel inlet pipe of fuel
distribution pipe assembly), start the
engine, and check whether the fuel
pressure is normal during idling and when
the vacuum pipe of fuel pressure regulator
is removed
4 Use a special instrument to check
whether the injector is leaking or clogged
5 Check the fuel condition, and ask the
customer whether to add the designated
grade of gasoline After refueling, check
whether the vehicle works abnormally
6 Check whether the intake pipeline is
clogged, leaking, squashed or damaged;
whether the canister control valve is stuck;
whether the valve clearance is abnormal;
whether the throttle body is contaminated,
causing the air passage to be clogged
7 Check whether the ignition coil, ignition
cable or spark plug works abnormally
8 Measure whether the voltage of #1 wire
(white, positive pole of heater power
1 There fuel passage system supply) at oxygen sensor side of the
hardware is leaking or clogged upstream oxygen sensor harness is 12V
with the oxygen sensor connector
2 The intake pipeline is faulty
connected
3 The oxygen sensor harness
9 Measure whether the voltage of #2 wire
connector is faulty
(white, ground of heater power supply) at
4 The oxygen sensor is faulty oxygen sensor side of the upstream
oxygen sensor harness is 12V with the
oxygen sensor connector connected
10 Pierce the insulation of #1 wire (white,
positive pole of heater power supply) of
harness connector at ECU side with the
red tip of a multimeter, pierce the insulation
of #2 wire (white, ground of heater power
supply) of harness connector at ECU side
with the black tip, and measure whether
the voltage is about 12V.
11 Measure whether the voltage between
#4 wire (black, oxygen sensor signal wire)
and #3 wire (gray, oxygen sensor signal
ground) at ECU side of the downstream
oxygen sensor harness is about 0.45V with
the oxygen sensor connector connected
12 Start and run the engine until the
coolant temperature reaches the normal
value, and then idle it. Pierce the insulation
of #4 wire (black, oxygen sensor signal
wire) of harness connector at ECU side
with the red tip of a multimeter, pierce the
insulation of #3 wire (gray, oxygen sensor
signal ground) of harness connector at
ECU side with the black tip, and measure
whether the voltage jumps between 0V-1V
13 Measure whether #3 port (gray, oxygen
sensor signal ground) is shorted to #4 port
Maintenance Manual of 1.5GDI Engine 2-227Control system
(black, oxygen sensor signal wire) at
sensor side with the upstream oxygen
sensor connector disconnected
14 Connect the upstream oxygen sensor
connector, and repeat steps 6-7 to check
whether the voltage signal jumps between
0.44V-0.46V and 0V-1V respectively

GAC Motor 2019

Control system 2-228 Maintenance Manual of 1.5GDI Engine

DTC DTC definition Possible causes Recommended action

1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
LSU Oxygen Sensor 1 There is leakage in the information
P219500 Characteristic Deviation exhaust system 3 Check the intake and exhaust systems
(Biased Lean) 2 The oxygen sensor is aged for leakage
4 Replace the upstream LSU oxygen
sensor, return the vehicle to the customer,
and track whether the fault recurs
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
LSU Oxygen Sensor 1 There is leakage in the information
P219600 Characteristic Deviation exhaust system 3 Check the intake and exhaust systems
(Biased Rich) 2 The oxygen sensor is aged for leakage
4 Replace the upstream LSU oxygen
sensor, return the vehicle to the customer,
and track whether the fault recurs
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Measure whether the voltage of #1 wire
(white, positive pole of heater power
supply) at oxygen sensor side of the
upstream oxygen sensor harness is 12V
with the oxygen sensor connector
connected
4 Measure whether the voltage of #2 wire
(white, ground pole of heater power
1 The heater circuit is faulty supply) at oxygen sensor side of the
Upstream Oxygen Sensor
P223100 2 The oxygen sensor resister is upstream oxygen sensor harness is 12V
Heater Circuit Fault
aged with the oxygen sensor connector
connected
5 Disconnect the upstream oxygen sensor
harness connector, remove the upstream
oxygen sensor, and allow the oxygen
sensor to cool down at room temperature.
When the oxygen sensor reaches the room
temperature ①, use a multimeter to
measure whether the resistance between
the #1 port (white, positive pole of heater
power supply) and #2 port (white, ground
of heater power supply) at the sensor side
is greater than 15Ω
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
1 The downstream oxygen 3 Measure whether the voltage of positive
sensor harness or connector is pole of heater power supply at oxygen
Coupling of Downstream abnormal sensor side of the downstream oxygen
P223200 Oxygen Sensor Signal Wire 2 The oxygen sensor signal sensor harness is 12V with the oxygen
to Heater Wire wire is shorted to the ground of sensor connector connected
heater power supply at oxygen 4 Measure whether the voltage of ground
sensor side of heater power supply at oxygen sensor
side of the downstream oxygen sensor
harness is 12V with the oxygen sensor
connector connected
5 Measure whether the voltage between
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine 2-229Control system
oxygen sensor signal wire and oxygen
sensor signal ground at ECU side of the
downstream oxygen sensor harness is
about 0.45V with the oxygen sensor
connector connected
6 Start and run the engine until the coolant
temperature reaches the normal value, and
then idle it. Measure whether the voltage
between oxygen sensor signal wire and
oxygen sensor signal ground at ECU side
of the downstream oxygen sensor harness
jumps between 0V-1V with the oxygen
sensor connector connected
7 Start and run the engine until the coolant
temperature reaches the normal value, and
then idle it. Measure whether the ground of
heater power supply is shorted to oxygen
sensor signal wire at oxygen sensor side
with the downstream oxygen sensor
connector disconnected.
8 Connect the downstream oxygen sensor
connector, and repeat steps 5-6 to check
whether the voltage signal jumps between
0.44V-0.46V and 0V-1V respectively

GAC Motor 2019

Control system 2-230 Maintenance Manual of 1.5GDI Engine

DTC DTC definition Possible causes Recommended action

LSU Oxygen Sensor IP
P223700
Circuit Open
Upstream Oxygen Sensor
P224300
RE Circuit Open
Upstream Oxygen Sensor Upstream Oxygen Sensor IPE
P225100
IPE Circuit Open
Turbocharger Relief Valve
P226100 2 The relief valve is damaged
Mechanical Fault
3 The relief valve pin or circuit
1 The particulate filter has been
P226D00 Particulate Filter Removed
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check the oxygen sensor harness and
The oxygen sensor is faulty connector for disconnection or false
connection
4 Replace the upstream oxygen sensor
Start and run the engine until the coolant
temperature reaches the normal value.
Reproduce the fault
1 Check whether the pin for black wire at
the oxygen sensor connector has poor
contact
2 Check whether the oxygen sensor
harness is open
3 Check whether there is an abnormal pin
at the connector between the harness and
Upstream Oxygen Sensor RE
ECU, resulting in poor contact
Circuit Open
4 Clear the DTC, start and run the engine
until the coolant temperature reaches the
normal value, and check whether the fault
is reported again
5 Check whether there is any abnormality
in the LSU processing circuit of oxygen
sensor inside the ECU
1 Check whether the pin for yellow wire at
the oxygen sensor connector has poor
contact
2 Check whether the oxygen sensor
harness is open
3 Check whether there is an abnormal pin
at the connector between the harness and
ECU, resulting in poor contact
Circuit Open
4 Clear the DTC, start and run the engine
until the coolant temperature reaches the
normal value, and check whether the fault
is reported again.
5 Check whether there is any abnormality
in the LSU processing circuit of oxygen
sensor inside the ECU
1 The relief valve harness is
1 The relief valve harness is interrupted
interrupted
2 The relief valve is damaged
3 The relief valve pin or circuit at ECU side
is damaged
at ECU side is damaged
1 Check whether the particulate filter has
been removed
removed
2 Check whether the particulate filter is
2 The particulate filter is burnt
burnt

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine
DTC DTC definition
Downstream Oxygen
P227000 Sensor Aging (Biased
Lean) 2 The oxygen sensor is aged
Downstream Oxygen
P227100
Sensor Aging (Biased Rich)
2 The oxygen sensor is aged
2-231Control system
Possible causes Recommended action
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check whether the exhaust system is
leaking and whether the gasket is
damaged.
4 Downstream oxygen sensor: Pierce the
insulation of #4 wire (black, oxygen sensor
signal wire) of harness connector at ECU
side with the red tip of a multimeter, pierce
the insulation of #3 wire (gray, oxygen
sensor signal ground) of harness
connector at ECU side with the black tip,
and measure whether the voltage is
between 0.44V-0.46V
5 Start and run the engine until the coolant
temperature reaches the normal value, and
1 There is leakage in the then idle it. Downstream oxygen sensor:
exhaust system Pierce the insulation of #4 wire (black,
oxygen sensor signal wire) of harness
connector at ECU side with the red tip of a
multimeter, pierce the insulation of #3 wire
(gray, oxygen sensor signal ground) of
harness connector at ECU side with the
black tip, and measure whether the voltage
is between 0V-1V
6 Start and run the engine until the coolant
temperature reaches the normal value, and
then idle it. Depress and then release the
accelerator pedal repeatedly for 90s, at the
same time, pierce the insulation of #4 wire
(black, oxygen sensor signal wire) of
harness connector of downstream oxygen
sensor at ECU side with the red tip of a
multimeter, pierce the insulation of #3 wire
(gray, oxygen sensor signal ground) of
harness connector at ECU side with the
black tip, and measure whether the voltage
changes through ① 0.55V-0.65V
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Check whether the exhaust system is
leaking and whether the gasket is
damaged
4 Downstream oxygen sensor: Pierce the
insulation of #4 wire (black, oxygen sensor
signal wire) of harness connector at ECU
1 There is leakage in the
side with the red tip of a multimeter, pierce
exhaust system
the insulation of #3 wire (gray, oxygen
sensor signal ground) of harness
connector at ECU side with the black tip,
and measure whether the voltage is
between 0.44V-0.46V
5 Start and run the engine until the coolant
temperature reaches the normal value, and
then idle it. Downstream oxygen sensor:
Pierce the insulation of #4 wire (black,
oxygen sensor signal wire) of harness
connector at ECU side with the red tip of a
multimeter, pierce the insulation of #3 wire
GAC Motor 2019
Control system 2-232 Maintenance Manual of 1.5GDI Engine

(gray, oxygen sensor signal ground) of

harness connector at ECU side with the
black tip, and measure whether the voltage
is between 0V-1V
6 Start and run the engine until the coolant
temperature reaches the normal value, and
then idle it. Depress and then release the
accelerator pedal repeatedly for 90s, at the
same time, pierce the insulation of #4 wire
(black, oxygen sensor signal wire) of
harness connector of downstream oxygen
sensor at ECU side with the red tip of a
multimeter, pierce the insulation of #3 wire
(gray, oxygen sensor signal ground) of
harness connector at ECU side with the
black tip, and measure whether the voltage
changes through ② 0.55V-0.65V

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine
DTC DTC definition
1# Cylinder Ignition Coil
P230100
Control Circuit Voltage High
2# Cylinder Ignition Coil
P230400
Control Circuit Voltage High
3# Cylinder Ignition Coil
P230700
Control Circuit Voltage High
4# Cylinder Ignition Coil
P231000
Control Circuit Voltage High
1# Cylinder Ignition Coil
P230000
Control Circuit Voltage Low
2# Cylinder Ignition Coil
P23300
Control Circuit Voltage Low
3# Cylinder Ignition Coil
P230600
Control Circuit Voltage Low
4# Cylinder Ignition Coil
P230900
Control Circuit Voltage Low
Upstream Oxygen Sensor
P241400
Output Voltage Implausible
P242200 Canister Vent Valve Stuck
Possible causes
1 The ignition coil circuit is
shorted to power supply
2 The power supply terminal of
ignition coil is shorted to power
supply
3 The ignition coil control pin at
ECU side is shorted to power
supply
1 The ignition coil circuit is
shorted to power supply
2 The power supply terminal of
ignition coil is shorted to power
supply
3 The ignition coil control pin at
ECU side is shorted to power
supply
1 The ignition coil circuit is
shorted to power supply
2 The power supply terminal of
ignition coil is shorted to power
supply
3 The ignition coil control pin at
ECU side is shorted to power
supply
1 The ignition coil circuit is
shorted to power supply
2 The power supply terminal of
ignition coil is shorted to power
supply
3 The ignition coil control pin at
ECU side is shorted to power
supply
1 The connector is shorted to
ground
2 The ignition coil circuit is
shorted to ground
3 The ignition coil control pin at
ECU side is shorted to ground
1 The connector is shorted to
ground
2 The ignition coil circuit is
shorted to ground
3 The ignition coil control pin at
ECU side is shorted to ground
1 The connector is shorted to
ground
2 The ignition coil circuit is
shorted to ground
3 The ignition coil control pin at
ECU side is shorted to ground
1 The connector is shorted to
ground
2 The ignition coil circuit is
shorted to ground
3 The ignition coil control pin at
ECU side is shorted to ground
The LSU is exposed to the
atmosphere or the LSU
connector has poor contact
1 The voltage of canister vent
2-233Control system
Recommended action
1 Check whether the corresponding
ignition coil circuit is shorted to power
supply
2 Check whether the ignition coil control
pin at ECU side is shorted to power supply
1 Check whether the corresponding
ignition coil circuit is shorted to power
supply
2 Check whether the ignition coil control
pin at ECU side is shorted to power supply
1 Check whether the corresponding
ignition coil circuit is shorted to power
supply
2 Check whether the ignition coil control
pin at ECU side is shorted to power supply
1 Check whether the corresponding
ignition coil circuit is shorted to power
supply
2 Check whether the ignition coil control
pin at ECU side is shorted to power supply
1 Check whether the connector is shorted
to ground
2 Check whether the corresponding
ignition coil circuit is shorted to ground
4 Check whether the ignition coil control
pin at ECU side is shorted to ground
1 Check whether the connector is shorted
to ground
2 Check whether the corresponding
ignition coil circuit is shorted to ground
4 Check whether the ignition coil control
pin at ECU side is shorted to ground
1 Check whether the connector is shorted
to ground
2 Check whether the corresponding
ignition coil circuit is shorted to ground
4 Check whether the ignition coil control
pin at ECU side is shorted to ground
1 Check whether the connector is shorted
to ground
2 Check whether the corresponding
ignition coil circuit is shorted to ground
4 Check whether the ignition coil control
pin at ECU side is shorted to ground
1 Check whether the oxygen sensor is not
installed correctly - outside the exhaust
manifold and exposed to the atmosphere
2 Check whether the regulating resistor in
the oxygen sensor connector is invalid -
the resistance is infinite
3 Check the oxygen sensor processing
circuit inside ECU - whether the resistance
between IA and IP circuits is infinite
1 Connect the diagnostic scan tool and set
GAC Motor 2019
Control system 2-234
Closed valve pin is low, which makes
the canister vent valve closed
2 The canister vent valve is
stuck closed and cannot be
open
3 The pipe of canister vent
valve is clogged
4 The canister valve is stuck
open
5 The fuel tank pressure sensor
is damaged
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Keep the sensor connector normal, and
use a multimeter to check whether the
voltage of canister vent valve pin is too low
or shorted to ground
4 Remove the pipeline at the canister vent
valve and observe whether it is clogged
5 Check whether the hardware of canister
vent valve is stuck closed
6 Check whether the canister valve is stuck
open
7 Replace the fuel tank pressure sensor,
restart the engine, and run it for 10min to
see if the fault recurs
Maintenance Manual of 1.5GDI Engine
DTC DTC definition Possible causes
Particulate Filter Differential
The differential pressure sensor
P245400 Pressure Sensor Circuit
circuit is shorted to ground
Voltage Low
Particulate Filter Differential The differential pressure sensor
P245500 Pressure Sensor Circuit circuit is shorted to power
Voltage High supply
1 The CAN signal of ECU is
abnormal
Fuel Level Sensor Signal 2 The fuel level sensor is
P25B000
Stuck damaged
3 The fuel level float inside the
fuel tank is stuck
Engine off Timer The data of engine off timer is
P261000
Implausible implausible
Starter Relay R1 Stuck The starter relay R1 switch is
P26F000
Closed stuck
1 The starter relay R1 is
Starter Relay R1 or
damaged
P26F100 Powertrain State Relay R2
2 The powertrain state relay R2
Stuck Open
is damaged
Powertrain State Relay R2 The powertrain state relay R2
P26F200
Stuck Closed switch is stuck
1 The CAN1 bus connector is
not connected properly or has
poor contact
2 The CAN1 bus connector pin
is shorted to power/ground or
U007300 CAN1 Bus OFF open-circuited
3 The CAN1 bus connector pin
at ECU side is shorted to power
supply / ground, open-circuited
or the ECU internal circuit is
damaged
1 The TCM connector is not
connected properly or
disconnected
2 The transmission line
Lost Communication
U010100 between TCM and ECU is
between ECU and TCM
damaged or interrupted
3 The TCM is damaged and
cannot normally transmit
signals to the ECU
1 The ESP connector is not
connected properly or
disconnected
2 The transmission line
Lost Communication
U012200 between ESP and ECU is
between ECU and ESP
damaged or interrupted
3 The ESP is damaged and
cannot normally transmit
signals to the ECU
1 The SAS connector is not
Lost Communication
U012600 connected properly or
between ECU and SAS
disconnected
2-235Control system
Recommended action
1 Check whether the harness of differential
pressure sensor circuit is shorted to
ground
2 Check whether the sensor itself is
shorted
1 Check whether the harness of differential
pressure sensor circuit is shorted to power
supply
2 Check whether the sensor itself is
shorted
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Replace the fuel level sensor and track
whether the fault recurs
4 Check whether the fuel level float inside
the fuel tank is stuck
5 Replace the ECU and track whether the
fault recurs
Turn the ignition off and wait until the ECM
is completely powered off, then turn the
ignition on and check whether the fault is
eliminated
Check whether the starter relay R1 switch
is stuck
1. Check whether the starter relay R1 is
damaged
2 Check whether the powertrain state relay
R2 is damaged
Check whether the powertrain state relay
R2 switch is stuck
1 The CAN1 bus connector is not
connected properly or has poor contact
2 The CAN1 bus connector pin is shorted
to power/ground or open-circuited
3 There is signal interference in the
harness
4 The CAN1 bus connector pin at ECU
side is shorted to power supply / ground,
open-circuited or the ECU internal circuit is
damaged
1 The TCM connector is not connected
properly or disconnected
2 There is signal interference in the
harness
3 The transmission line between TCM and
ECU is damaged or interrupted
4 Check the CAN hardware circuit for any
fault
5 The TCM is damaged and cannot
normally transmit signals to the ECU
1 The ESP connector is not connected
properly or disconnected
2 There is signal interference in the
harness
3 The transmission line between ESP and
ECU is damaged or interrupted
4 Check the CAN hardware circuit for any
fault
5 The ESP is damaged and cannot
normally transmit signals to the ECU
1 The SAS connector is not connected
properly or disconnected
2 There is signal interference in the
GAC Motor 2019
Control system 2-236 Maintenance Manual of 1.5GDI Engine

2 The transmission line harness

between SAS and ECU is 3 The transmission line between SAS and
damaged or interrupted ECU is damaged or interrupted
3 The SAS is damaged and 4 Check the CAN hardware circuit for any
cannot normally transmit fault
signals to the ECU 5 The SAS is damaged and cannot
normally transmit signals to the ECU
1 The CAN connector for
refreshing and the body is not
1 The CAN connector for refreshing and
connected properly or has poor
Lost Communication the body is not connected properly or has
U012800 contact
between EMS and EPB poor contact
2 The EPB control circuit is open
2 The EPB control circuit is
open
1 The BCM connector is not connected
1 The BCM connector is not
properly or disconnected
connected properly or
2 There is signal interference in the
disconnected
harness
2 The transmission line
Lost Communication 3 The transmission line between BCM and
U014000 between BCM and ECU is
between ECM and BCM ECU is damaged or interrupted
damaged or interrupted
4 Check the CAN hardware circuit for any
3 The BCM is damaged and
fault
cannot normally transmit
5 The BCM is damaged and cannot
signals to the ECU
normally transmit signals to the ECU

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-237Control system

DTC DTC definition Possible causes Recommended action

1 The SRS connector is not
connected properly or
disconnected
2 The transmission line
Lost Communication
U1015100 between SRS and ECU is
between ECU and SRS
damaged or interrupted
3 The SRS is damaged and
cannot normally transmit
signals to the ECU
1 The CAN signal of ECU is
abnormal
Fuel Level Sensor Signal 2 The fuel level sensor is
U067600
Lost / Failure / Check Error damaged
3 The fuel level sensor harness
is not connected properly
1 The CAN bus connector is
not connected properly or has
poor contact
2 The CAN bus connector pin
is shorted to power/ground or
CAN Module Input Voltage
U350100 open-circuited
Low
3 The CAN bus connector pin
at ECU side is shorted to
power supply / ground, open-
circuited or the ECU internal
circuit is damaged
1 The CAN bus connector is
not connected properly or has
poor contact
2 The CAN bus connector pin
is shorted to power/ground or
CAN Module Input Voltage
U350200 open-circuited
High
3 The CAN bus connector pin
at ECU side is shorted to
power supply / ground, open-
circuited or the ECU internal
circuit is damaged
1 The SRS connector is not connected
properly or disconnected
2 There is signal interference in the
harness
3 The transmission line between SRS and
ECU is damaged or interrupted
4 Check the CAN hardware circuit for any
fault
5 The SRS is damaged and cannot
normally transmit signals to the ECU
1 Connect the diagnostic scan tool and set
the ignition switch in the "ON" position
2 Read and save the fail-frost frame
information
3 Use a multimeter to measure whether
the voltage of sensor pin is normal, and
check whether the CAN signal is normal
4 Check whether the harness is normal
5 Replace the ECU and check whether the
fault recurs
1 The CAN bus connector is not
connected properly or has poor contact
2 The CAN bus connector pin is shorted to
power/ground or open-circuited
3 There is signal interference in the
harness
4 The CAN bus connector pin at ECU side
is shorted to power supply / ground, open-
circuited or the ECU internal circuit is
damaged
1 The CAN bus connector is not
connected properly or has poor contact
2 The CAN bus connector pin is shorted to
power/ground or open-circuited
3 There is signal interference in the
harness
4 The CAN bus connector pin at ECU side
is shorted to power supply / ground, open-
circuited or the ECU internal circuit is
damaged

2.8.6.6 DTC: P000A00, P001000......

DTC Description
P000A00 Intake VVT Operation Fault (Slow Response)
P001000 Intake VVT Control Circuit Open
P001100 Intake Camshaft Locking Position Operation
Implausible
P003C00 Intake VVT Operation Fault (Stuck)
P208800 Intake VVT Control Circuit Voltage Low
P208900 Intake VVT Control Circuit Voltage High
P052A00 Intake VVT Actual Position Deviation during
Catalytic Converter Heating

1. Circuit diagram

GAC Motor 2019

Control system 2-238 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine
compartment
PDU

Canist Wa Rel VCT VCT

er ste ief (intake) (exhaust)
solenoi gat val
d valve e ve

ECM

Pressure Temperat
sensor ure
sensor

Charge air temperature Phase sensor (intake) Phase sensor (exhaust) Speed sensor
and pressure sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

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Maintenance Manual of 1.5GDI Engine 2-239Control system

Step 2 Check the VCT (intake).

VCT (intake) A Set the ENGINE START/STOP button to “OFF”

position.
B Remove the VCT (intake).
C Measure whether the resistance across the VCT
(intake) is normal. Standard resistance: 8±0.5Ω
(@20℃)
N Replace the VCT (intake)

Step 3 Check the VCT (intake) fuse EF30.

A Check whether the fuse EF30 is blown.

N Go to step 5.

Step 4 Check and repair the fuse EF30 circuit.

A Check whether the fuse EF30 circuit is shorted.

B Repair the circuit and check that there is no
short circuit.
C Replace the fuse with one with rated current.
The fuse is rated at EF30 10A
D Verify if the VCT (intake) works normally.
Y The system is working normally.

Step 5 Check the power supply circuit of VCT (intake).

GAC Motor 2019

Control system 2-240 Maintenance Manual of 1.5GDI Engine

A Set the ENGINE START/STOP button to “OFF”

VCT (intake) harness connector
position.
B Disconnect the VCT (intake) harness connector
VCT (intake) power supply EN24.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the VCT (intake) harness connector EN24
and the body ground.
Standard voltage: 11~14V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 6 Check whether the circuit between the VCT (intake) and the ECM is open.

VCT (intake) harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the VCT (intake) harness connector
VCT (intake) signal EN24 and the ECM harness connector EN01.
C Measure the resistance of circuit between
terminal 2 of the VCT (intake) harness connector
EN24 and terminal 20 of the ECM harness
connector EN01.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

ECM harness connector

VCT (intake) signal

Step 7 Check whether the control circuit of VCT (intake) is shorted to ground.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-241Control system

A Set the ENGINE START/STOP button to “OFF”

VCT (intake) harness connector
position.
B Disconnect the VCT (intake) harness connector
VCT (intake) signal EN24 and the ECM harness connector EN01.
C Measure the resistance of circuit between
terminal 2 of the VCT (intake) harness connector
EN24 and the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 8 Check whether the control circuit of VCT (intake) is shorted to power supply.

A Set the ENGINE START/STOP button to “OFF”

VCT (intake) harness connector
position.
B Disconnect the VCT (intake) harness connector
VCT (intake) signal EN24 and the ECM harness connector EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
2 of the VCT (intake) harness connector EN24
and the body ground.
Standard voltage: 0V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 9 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 10 End.
2.8.6.7 DTC: P000B00, P001300......
DTC Description

GAC Motor 2019

Control system 2-242 Maintenance Manual of 1.5GDI Engine

P000B00 Exhaust VVT Operation Fault (Slow Response)

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-243Control system

P001300 Exhaust VVT Control Circuit Open

P001400 Exhaust Camshaft Locking Position Operation
Implausible
P005A00 Exhaust VVT Operation Fault (Stuck)
P209000 Exhaust VVT Control Circuit Voltage Low
P209100 Exhaust VVT Control Circuit Voltage High
P054A00 Exhaust VVT Actual Position Deviation during
Catalytic Converter Heating
1. Circuit diagram

(Main relay)

Engine
compartment
PDU

Canist Wa Rel VCT VCT

er ste ief (intake) (exhaust)
solenoi gat val
d valve e ve

ECM

Pressure Temperat
sensor ure
sensor

Charge air temperature Phase sensor (intake) Phase sensor (exhaust) Speed sensor
and pressure sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.

GAC Motor 2019

Control system 2-244 Maintenance Manual of 1.5GDI Engine

D Start the engine, idle it for about 5 minutes, and

carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

Step 2 Check the VCT (exhaust).

VCT (exhaust) A Set the ENGINE START/STOP button to “OFF”

position.
B Remove the VCT (exhaust).
C Measure whether the resistance across the VCT
(exhaust) is normal.
Standard resistance: 8±0.5Ω (@20℃)
N Replace the VCT (exhaust).

Step 3 Check the VCT (exhaust) fuse EF30.

A Check whether the fuse EF30 is blown.

N Go to step 5.

Step 4 Check and repair the fuse EF30 circuit.

A Check whether the fuse EF30 circuit is shorted.

B Repair the circuit and check that there is no
short circuit.
C Replace the fuse with one with rated current.
The fuse is rated at EF30 10A
D Verify if the VCT (exhaust) works normally.
Y The system is working normally.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-245Control system
N

GAC Motor 2019

Control system 2-246 Maintenance Manual of 1.5GDI Engine

Step 5 Check the power supply circuit of the VCT (exhaust).

A Set the ENGINE START/STOP button to “OFF”

VCT (exhaust) harness connector
position.
B Disconnect the VCT (exhaust) harness
VCT (exhaust) power supply connector EN25.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the VCT (exhaust) harness connector EN25
and the body ground.
Standard voltage: 11~14V
E Verify if the voltage is consistent with the
standard value.
N Replace or repair the harness or
connector.

Step 6 Check whether the circuit between the VCT (exhaust) and the ECM is open.

A Set the ENGINE START/STOP button to “OFF”

VCT (exhaust) harness connector
position.
B Disconnect the VCT (exhaust) harness
VCT (exhaust) signal connector EN25 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 2 of the VCT (exhaust) harness connector
EN25 and terminal 5 of the ECM harness
connector EN01.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
N Replace or repair the harness or
connector.
ECM harness connector

VCT (exhaust) signal

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Maintenance Manual of 1.5GDI Engine 2-247Control system

Step 7 Check whether the control circuit of VCT (exhaust) is shorted to ground.

A Set the ENGINE START/STOP button to “OFF”

VCT (exhaust) harness connector
position.
B Disconnect the VCT (exhaust) harness
VCT (exhaust) signal connector EN25 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 2 of the VCT (exhaust) harness connector
EN25 and the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 8 Check whether the control circuit of VCT (exhaust) is shorted to power supply.

A Set the ENGINE START/STOP button to “OFF”

VCT (exhaust) harness connector
position.
B Disconnect the VCT (exhaust) harness
VCT (exhaust) signal connector EN25 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
2 of the VCT (exhaust) harness connector EN25
and the body ground.
Standard voltage: 0V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 9 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

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Control system 2-248 Maintenance Manual of 1.5GDI Engine

Step 10 End.

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Maintenance Manual of 1.5GDI Engine 2-249Control system

2.8.6.8 DTC: P001676, P001678

DTC Description
Crankshaft-Intake Camshaft Initial Installation
P001676
Position Implausible (Bank1)
Excessive Relative Position Deviation between
P001678
Crankshaft and Intake Camshaft (Bank1)

1. Circuit diagram

(Main relay)

Engine
compartment
PDU

Canist Wa Rel VCT VCT

er ste ief (intake) (exhaust)
solenoi gat val
d valve e ve

ECM

Pressure Temperat
sensor ure
sensor

Charge air temperature Phase sensor (intake) Phase sensor (exhaust) Speed sensor
and pressure sensor

2. Diagnostic procedure
Step 1 Check the DTC status.
A Connect the diagnostic scan tool to the OBD
DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.

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Control system 2-250 Maintenance Manual of 1.5GDI Engine

E Read the DTC again.

F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault.
Check whether there is any intermittent
N
fault.

Step 2 Re-calibrate the relative position between the intake camshaft phaser and the camshaft.

A Set the ENGINE START/STOP button to “OFF”

position.
B Re-calibrate the relative position between the
intake camshaft phaser and the camshaft.
C Set the ENGINE START/STOP button to “ON”
position.
D Read the DTC again.
E Check whether the same DTC appears.
N The system is working normally.

Step 3 Check the status of engine oil.

A Open the oil filler cap and pull out the oil dipstick
to check whether the oil is too dark and thick and
has been used for a long time, or if the oil level is
too low.
Change the engine oil and replace the oil
filter or repair the engine oil leak.
Y

Step 4 Check the intake valve timing oil circuit.

A Check whether the intake valve timing oil circuit

is clogged by foreign materials.
Y Remove the foreign materials.

Step 5 Check the basic valve timing.

A Check whether the basic valve timing is correct

with proper tools.
N Replace the intake camshaft phaser.

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Maintenance Manual of 1.5GDI Engine 2-251Control system

Step 6 Replace the the ECM.

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Control system 2-252 Maintenance Manual of 1.5GDI Engine

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.9 DTC: P001776, P001778
DTC Description
P001776 Crankshaft-Exhaust Camshaft Initial Installation
Position Implausible (Bank1)
P001778 Excessive Relative Position Deviation between
Crankshaft and Exhaust Camshaft (Bank1)

1. Circuit diagram

(Main relay)

Engine
compartment
PDU

Canist Wa Rel VCT VCT

er ste ief (intake) (exhaust)
solenoi gat val
d valve e ve

ECM

Pressure Temperat
sensor ure
sensor

Charge air temperature Phase sensor (intake) Phase sensor (exhaust) Speed sensor
and pressure sensor

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Maintenance Manual of 1.5GDI Engine 2-253Control system
2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

Step 2 Re-calibrate the relative position between the exhaust camshaft phaser and the camshaft.

A Set the ENGINE START/STOP button to “OFF”

position.
B Re-calibrate the relative position between the
exhaust camshaft phaser and the camshaft.
C Set the ENGINE START/STOP button to “ON”
position.
D Read the DTC again.
E Check whether the same DTC appears.
N The system is working normally.

Step 3 Check the status of engine oil.

A Open the oil filler cap and pull out the oil dipstick
to check whether the oil is too dark and thick and
has been used for a long time, or if the oil level is
too low.
Change the engine oil and replace the oil
filter or repair the engine oil leak.
Y

Step 4 Check the exhaust valve timing oil circuit.

A Check whether the exhaust valve timing oil

circuit is clogged by foreign materials.

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Control system 2-254 Maintenance Manual of 1.5GDI Engine

Y Remove the foreign materials.

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Maintenance Manual of 1.5GDI Engine 2-255Control system

Step 5 Check the basic valve timing.

A Check whether the basic valve timing is correct

with proper tools.
N Replace the exhaust camshaft phaser.

Step 6 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.10 DTC: P003000, P003100......
DTC Description
P003000 Upstream Oxygen Sensor Heater Control Circuit
Open
P003100 Upstream Oxygen Sensor Heater Control Circuit
Voltage Low
P003200 Upstream Oxygen Sensor Heater Control Circuit
Voltage High
P005300 Upstream Oxygen Sensor Internal Resistance
High

1. Circuit diagram

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Control system 2-256 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine
compartment
PDU

Upstre Downstream
am oxygen
oxygen sensor
sensor

ECM

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

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Maintenance Manual of 1.5GDI Engine 2-257Control system

Step 2 Check the upstream oxygen sensor heater.

Upstream oxygen sensor

A Set the ENGINE START/STOP button to “OFF”
position.
B Remove the upstream oxygen sensor.
C Measure whether the resistance across
upstream oxygen sensor heater is normal.
Standard resistance: 2.6±0.26Ω (@20℃)
N Replace the upstream oxygen sensor.

Step 3 Check the fuse EF31 of upstream oxygen sensor.

A Check whether the fuse EF31 is blown.

N Go to step 5.

Step 4 Check and repair the fuse EF31 circuit.

A Check whether the fuse EF31 circuit is shorted.

B Repair the circuit and check that there is no
short circuit.
C Replace the fuse with one with rated current.
The fuse is rated at EF31 10A
D Verify if the upstream oxygen sensor heater
works normally.
Y The system is working normally.

Step 5 Check the power supply circuit of upstream oxygen sensor.

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Control system 2-258 Maintenance Manual of 1.5GDI Engine

Upstream oxygen sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the upstream oxygen sensor
Upstream oxygen sensor heater +
harness connector EN04.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
4 of the upstream oxygen sensor harness
connector EN04 and the body ground.
Standard voltage: 11~14V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 6 Check whether the circuit between the upstream oxygen sensor and the ECM is open.

Upstream oxygen sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Upstream oxygen sensor heater -
B Disconnect the upstream oxygen sensor
harness connector EN04 and the ECM harness
connector FB46.
C Measure the resistance of circuit between
terminal 3 of the upstream oxygen sensor harness
connector EN04 and terminal 94 of the ECM
harness connector FB46.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.
ECM harness connector

Upstream oxygen sensor heater -

Step 7 Check whether the control circuit of upstream oxygen sensor heater is shorted to ground.

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Maintenance Manual of 1.5GDI Engine 2-259Control system

Upstream oxygen sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the upstream oxygen sensor
Upstream oxygen sensor heater -
harness connector EN04 and the ECM harness
connector FB46.
C Measure the resistance of circuit between
terminal 3 of the upstream oxygen sensor harness
connector EN04 and the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N
connector.

Step 8 Check whether the control circuit of upstream oxygen sensor heater is shorted to power
supply.

Upstream oxygen sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Upstream oxygen sensor heater -
B Disconnect the upstream oxygen sensor
harness connector EN04 and the ECM harness
connector FB46.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
3 of the upstream oxygen sensor harness
connector EN04 and the body ground.
Standard voltage: 0V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 9 Replace the upstream oxygen sensor.

A Replace the upstream oxygen sensor.

B Verify if the fault is eliminated after the upstream
oxygen sensor is replaced.
Y The system is working normally.

Step 10 Replace the the ECM.

A Replace the ECM.

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Control system 2-260 Maintenance Manual of 1.5GDI Engine

B Verify if the fault is eliminated after the ECM is

replaced.
Y The system is working normally.

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Maintenance Manual of 1.5GDI Engine 2-261Control system

Next step

Step 11 End.
2.8.6.11 DTC: P003300, P003400......

DTC Description
P003300 Turbocharger Relief Valve Control Circuit Open
Turbocharger Relief Valve Control Circuit Voltage
P003400
Low
Turbocharger Relief Valve Control Circuit Voltage
P003500
High
P226100 Turbocharger Waste Gate Mechanical Fault
1. Circuit diagram

(Main relay)

Engine
compartment
PDU

Canist Wa Rel VCT VCT

er ste ief (intake) (exhaust)
solenoi gat val
d valve e ve

ECM

Pressure Temperat
sensor ure
sensor

Charge air temperature Phase sensor (intake) Phase sensor (exhaust) Speed sensor
and pressure sensor

2. Diagnostic procedure

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Control system 2-262 Maintenance Manual of 1.5GDI Engine

Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault.
Check whether there is any intermittent
N fault.

Step 2 Check the turbocharger relief valve.

Relief valve A Set the ENGINE START/STOP button to “OFF”

position.
B Remove the turbocharger relief valve.
C Measure whether the resistance across the
turbocharger relief valve is normal.
Standard resistance: 13.2±0.5Ω (@23℃)
N Replace the turbocharger relief valve.

Step 3 Check the fuse EF30 of turbocharger relief valve.

A Check whether the fuse EF30 is blown.

N Go to step 5.

Step 4 Check and repair the fuse EF30 circuit.

A Check whether the fuse EF30 circuit is shorted.

B Repair the circuit and check that there is no
short circuit.

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Maintenance Manual of 1.5GDI Engine 2-263Control system
C Replace the fuse with one with rated current.

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Control system 2-264 Maintenance Manual of 1.5GDI Engine

The fuse is rated at EF30 10A

D Verify if the turbocharger relief valve works
normally.
Y The system is working normally.

Step 5 Check the power supply circuit of turbocharger relief valve.

Relief valve harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the turbocharger relief valve harness
connector EN23.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
2 of the turbocharger relief valve harness
connector EN23 and the body ground.
Relief valve + Standard voltage: 11~14V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 6 Check whether the circuit between the turbocharger relief valve and the ECM is open.

Relief valve harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the turbocharger relief valve harness
connector EN23 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of the turbocharger relief valve harness
connector EN23 and terminal 19 of the ECM
harness connector EN01.
Relief valve -
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

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Maintenance Manual of 1.5GDI Engine 2-265Control system

ECM harness connector

Relief valve -

Step 7 Check whether the control circuit of turbocharger relief valve is shorted to ground.

A Set the ENGINE START/STOP button to “OFF”

Relief valve harness connector
position.
B Disconnect the turbocharger relief valve harness
connector EN23 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of the turbocharger relief valve harness
connector EN23 and the body ground.
Standard resistance: 10kΩ or higher
Relief valve - D Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 8 Check whether the control circuit of turbocharger relief valve is shorted to power supply.

Relief valve harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the turbocharger relief valve harness
connector EN23 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the turbocharger relief valve harness
Relief valve - connector EN23 and the body ground.
Standard voltage: 0V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

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Control system 2-266 Maintenance Manual of 1.5GDI Engine

Step 9 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 10 End.
2.8.6.12 DTC: P003600, P003700......
DTC Description
Downstream Oxygen Sensor Heater Control
P003600
Circuit Open
Downstream Oxygen Sensor Heater Control
P003700
Circuit Voltage Low
Downstream Oxygen Sensor Heater Control
P003800
Circuit Voltage High
Downstream Oxygen Sensor Heater Internal
P005400
Resistance Implausible

1. Circuit diagram

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Maintenance Manual of 1.5GDI Engine 2-267Control system

(Main relay)

Engine
compartment
PDU

Upstre Downstream
am oxygen sensor
oxygen
sensor

ECM

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault.
Check whether there is any intermittent
N fault.

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Control system 2-268 Maintenance Manual of 1.5GDI Engine

Step 2 Check the downstream oxygen sensor heater.

Downstream oxygen sensor A Set the ENGINE START/STOP button to “OFF”

position.
B Remove the downstream oxygen sensor.
C Measure whether the resistance across
downstream oxygen sensor heater is normal.
Standard resistance: 2.6±0.26Ω (@20℃)
N Replace the downstream oxygen sensor.

Step 3 Check the fuse EF31 of downstream oxygen sensor.

A Check whether the fuse EF31 is blown.

N Go to step 5.

Step 4 Check and repair the fuse EF31 circuit.

A Check whether the fuse EF31 circuit is shorted.

B Repair the circuit and check that there is no
short circuit.
C Replace the fuse with one with rated current.
The fuse is rated at EF31 10A
D Verify if the downstream oxygen sensor heater
works normally.
Y The system is working normally.

Step 5 Check the power supply circuit of downstream oxygen sensor.

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Maintenance Manual of 1.5GDI Engine 2-269Control system

Downstream oxygen sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the downstream oxygen sensor
harness connector EN05.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
4 of the downstream oxygen sensor harness
connector EN05 and the body ground.
Downstream oxygen sensor
heater + Standard voltage: 11~14V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 6 Check whether the circuit between the downstream oxygen sensor and the ECM is open.

Downstream oxygen sensor harness connector
Downstream oxygen sensor
heater -
ECM harness connector
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the downstream oxygen sensor
harness connector EN05 and the ECM harness
connector FB46.
C Measure the resistance of circuit between
terminal 3 of the downstream oxygen sensor
harness connector EN05 and terminal 72 of the
ECM harness connector FB46.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Downstream oxygen sensor

heater -

Step 7 Check whether the control circuit of downstream oxygen sensor heater is shorted to ground.

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Control system 2-270 Maintenance Manual of 1.5GDI Engine

Downstream oxygen sensor harness connector
Downstream oxygen sensor
heater -
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the downstream oxygen sensor
harness connector EN05 and the ECM harness
connector FB46.
C Measure the resistance of circuit between
terminal 3 of the downstream oxygen sensor
harness connector EN05 and the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 8 Check whether the control circuit of downstream oxygen sensor heater is shorted to power
supply.

Downstream oxygen sensor harness connector

Downstream oxygen sensor
heater -
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the downstream oxygen sensor
harness connector EN05 and the ECM harness
connector FB46.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
3 of the downstream oxygen sensor harness
connector EN05 and the body ground.
Standard voltage: 0V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 9 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 1 End.
2.8.6.13 DTC: P008700, P008800......
DTC Description
P008700 High-Pressure Fuel Rail Pressure Low

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Maintenance Manual of 1.5GDI Engine 2-271Control system

P008800 High-Pressure Fuel Rail Pressure High

Too Large PID Control Deviation of High-pressure
P008985
Fuel Supply Pressure
Too Small PID Control Deviation of High-pressure
P008984
Fuel Supply Pressure
Short Circuit between Flow Control Valve High
P009000
Side and Low Side Control Circuits
Flow Control Valve High or Low Side Control
P025100
Circuit Open
Flow Control Valve High Side Control Circuit
P025300
Voltage Low
Flow Control Valve High Side Control Circuit
P025400
Voltage High
Flow Control Valve Low Side Control Circuit
P025800
Voltage Low
Flow Control Valve Low Side Control Circuit
P025900
Voltage High
1. Circuit diagram

(Main relay)

Engine Instrument
compart panel PDU
ment
PDU

ECM

Fuel rail High-

pressur pressur
e e fuel
sensor pump

2. Diagnostic procedure
GAC Motor 2019
Control system 2-272 Maintenance Manual of 1.5GDI Engine

Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

Step 2 Check whether the circuit between the high-pressure fuel pump and the ECM is open.

High-pressure fuel pump harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the high-pressure fuel pump
Fuel control - harness connector EN45 and the ECM harness
connector EN01.
C Measure the resistance of circuit between
terminal 1 of the high-pressure fuel pump harness
connector EN45 and terminal 4 of the ECM
harness connector EN01.
Fuel control + D Measure the resistance of circuit between
terminal 2 of the high-pressure fuel pump harness
connector EN45 and terminal 3 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
ECM harness connector the standard value.
Replace or repair the harness or
Fuel control - Fuel control + connector.
N

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Maintenance Manual of 1.5GDI Engine 2-273Control system

Step 3 Check whether the control circuit of high-pressure fuel pump is shorted to ground.

High-pressure fuel pump harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the high-pressure fuel pump
Fuel control - harness connector EN45 and the ECM harness
connector EN01.
C Measure the resistance of circuit between
terminal 1 of the high-pressure fuel pump harness
connector EN45 and the body ground.
D Measure the resistance of circuit between
Fuel control + terminal 2 of the high-pressure fuel pump harness
connector EN45 and the body ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check whether the control circuit of high-pressure fuel pump is shorted to power supply.

High-pressure fuel pump harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the high-pressure fuel pump
Fuel control -
harness connector EN45 and the ECM harness
connector EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the high-pressure fuel pump harness
Fuel control + connector EN45 and the body ground.
E Measure the voltage of circuit between terminal
2 of the high-pressure fuel pump harness
connector EN45 and the body ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Replace the high-pressure fuel pump.

A Replace the high-pressure fuel pump.

B Verify if the fault is eliminated after the high-
pressure fuel pump is replaced.

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Control system 2-274 Maintenance Manual of 1.5GDI Engine

Y The system is working normally.

Step 6 Replace the the ECM.

A Replace the ECM.

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Maintenance Manual of 1.5GDI Engine 2-275Control system

B Verify if the fault is eliminated after the ECM is

replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.14 DTC: P009700, P009800......
DTC Description
P009700 IAT Sensor 2 Circuit Voltage Low
P009800 IAT Sensor 2 Circuit Voltage High
P009900 IAT Sensor 2 Circuit Voltage Implausible
IAT Sensor 2 Cold Start Check Implausible
P138024
(Positive Deviation)
IAT Sensor 2 Cold Start Check Implausible
P138023
(Negative Deviation)

1. Circuit diagram

GAC Motor 2019

Control system 2-276 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine
compartment
PDU

Canist Wa Rel VCT VCT

er ste ief (intake) (exhaust)
solenoi gat val
d valve e ve

ECM

Pressure Temperat
sensor ure
sensor

Charge air temperature Phase sensor (intake) Phase sensor (exhaust) Speed sensor
and pressure sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

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Maintenance Manual of 1.5GDI Engine 2-277Control system

Step 2 Check whether the circuit between the charge air temperature and pressure sensor and the
ECM is open.

A Set the ENGINE START/STOP button to “OFF”

Charge air temperature and pressure sensor
harness connector position.
B Disconnect the charge air temperature and
Temperature signal of charge air
temperature and pressure sensor
pressure sensor harness connector EN32 and the
ECM harness connector FB46.
C Measure the resistance of circuit between
terminal 1 of the charge air temperature and
pressure sensor harness connector EN32 and
terminal 30 of the ECM harness connector FB46.
D Measure the resistance of circuit between
Charge air Charge air terminal 2 of the charge air temperature and
temperature and temperature and
pressure sensor pressure sensor pressure sensor harness connector EN32 and
ground power supply terminal 37 of the ECM harness connector FB46.
E Measure the resistance of circuit between
terminal 3 of the charge air temperature and
pressure sensor harness connector EN32 and
ECM harness connector
terminal 42 of the ECM harness connector FB46.
Sensor ground Sensor 5V Standard resistance: less than 1Ω
power supply
F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Temperature signal of charge air

temperature and pressure sensor

Step 3 Check whether the control circuit of charge air temperature and pressure sensor is shorted
to ground.

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Control system 2-278 Maintenance Manual of 1.5GDI Engine

Charge air temperature and pressure sensor A Set the ENGINE START/STOP button to “OFF”
harness connector position.
Temperature signal of charge air
B Disconnect the charge air temperature and
temperature and pressure sensor pressure sensor harness connector EN32 and the
ECM harness connector FB46.
C Measure the resistance of circuit between
terminal 1 of the charge air temperature and
pressure sensor harness connector EN32 and the
body ground.
D Measure the resistance of circuit between
Charge air Charge air
temperature and temperature and terminal 2 of the charge air temperature and
pressure sensor pressure sensor pressure sensor harness connector EN32 and the
ground power supply
body ground.
E Measure the resistance of circuit between
terminal 3 of the charge air temperature and
pressure sensor harness connector EN32 and the
body ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check whether the control circuit of charge air temperature and pressure sensor is shorted
to power supply.

Charge air temperature and pressure sensor

A Set the ENGINE START/STOP button to “OFF”
harness connector position.
B Disconnect the charge air temperature and
Temperature signal of charge air
temperature and pressure sensor pressure sensor harness connector EN32 and the
ECM harness connector FB46.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the charge air temperature and pressure
sensor harness connector EN32 and the body
Charge air Charge air
temperature and temperature and
ground.
pressure sensor pressure sensor E Measure the voltage of circuit between terminal
ground power supply
2 of the charge air temperature and pressure
sensor harness connector EN32 and the body
ground.
F Measure the voltage of circuit between terminal
3 of the charge air temperature and pressure
sensor harness connector EN32 and the body
ground.
Standard voltage: 0V
G Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

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Maintenance Manual of 1.5GDI Engine 2-279Control system

Step 5 Replace the charge air temperature and pressure sensor.

A Replace the charge air temperature and

pressure sensor.
B Verify if the fault is eliminated after the charge
air temperature and pressure sensor is replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

A Replace the ECM.

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Control system 2-280 Maintenance Manual of 1.5GDI Engine

B Verify if the fault is eliminated after the ECM is

replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.15 DTC: P00C721, P00C722......
DTC Description
Low Pressure Value of MAP Sensor Signal during
P00C721
Start
High Pressure Value of MAP Sensor Signal during
P00C722
Start
MAP Sensor Pressure Implausibly Higher Than
P010622
Model Pressure
MAP Sensor Pressure Implausibly Lower Than
P010621
Model Pressure
Abnormal Signal Value without Fluctuation of MAP
P01062A
sensor
P010700 MAP Sensor Shorted to Ground
P010800 MAP sensor Shorted to Power Supply
P120000 MAP Sensor Pressure above Upper Limit
P120100 MAP Sensor Pressure below Lower Limit
1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-281Control system

(Main relay)

Engine Instrument
compart panel PDU
ment
PDU

MAP / IAT
Temperat Pressure
ure sensor sensor
sensor

ECM

Throttle Coolant Knock

position temperat sensor
sensor ure
sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault.
Check whether there is any intermittent
N fault.

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Control system 2-282 Maintenance Manual of 1.5GDI Engine

Step 2 Check whether the circuit between the MAP/IAT sensor and the ECM is open.

MAP/IAT sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
MAP/IAT sensor MAP/IAT sensor B Disconnect the MAP/IAT sensor harness
ground pressure signal connector EN16 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of the MAP/IAT sensor harness
connector EN16 and terminal 6 of the ECM
harness connector EN01.
MAP/IAT sensor D Measure the resistance of circuit between
power supply terminal 3 of the MAP/IAT sensor harness
connector EN16 and terminal 44 of the ECM
harness connector EN01.
E Measure the resistance of circuit between
terminal 4 of the MAP/IAT sensor harness
ECM harness connector connector EN16 and terminal 12 of the ECM
harness connector EN01.
MAP/IAT sensor MAP/IAT sensor
ground pressure signal Standard resistance: less than 1Ω
F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Sensor power supply

Step 3 Check whether the control circuit of MAP/IAT sensor is shorted to ground.

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Maintenance Manual of 1.5GDI Engine 2-283Control system

MAP/IAT sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
MAP/IAT sensor MAP/IAT sensor B Disconnect the MAP/IAT sensor harness
ground pressure signal connector EN16 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of the MAP/IAT sensor harness
connector EN16 and the body ground.
D Measure the resistance of circuit between
MAP/IAT sensor terminal 3 of the MAP/IAT sensor harness
power supply connector EN16 and the body ground.
E Measure the resistance of circuit between
terminal 4 of the MAP/IAT sensor harness
connector EN16 and the body ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check whether the control circuit of MAP/IAT sensor is shorted to power supply.

MAP/IAT sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
MAP/IAT sensor MAP/IAT sensor B Disconnect the MAP/IAT sensor harness
ground pressure signal connector EN16 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the MAP/IAT sensor harness connector EN16
MAP/IAT sensor and the body ground.
power supply
E Measure the voltage of circuit between terminal
3 of the MAP/IAT sensor harness connector EN16
and the body ground.
F Measure the voltage of circuit between terminal
4 of the MAP/IAT sensor harness connector EN16
and the body ground.
Standard voltage: 0V
G Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Replace the MAP/IAT sensor.

A Replace the MAP/IAT sensor.

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Control system 2-284 Maintenance Manual of 1.5GDI Engine

B Verify if the fault is eliminated after the MAP/IAT

sensor is replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

A Replace the ECM.

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Maintenance Manual of 1.5GDI Engine 2-285Control system

B Verify if the fault is eliminated after the ECM is

replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.16 DTC: P00CE24, P00CE23......
DTC Description
IAT Sensor 1 Cold Start Check Implausible
P00CE24
(Positive Deviation)
IAT Sensor 1 Cold Start Check Implausible
P00CE23
(Negative Deviation)
P011200 IAT Sensor 1 Circuit Voltage Low
P011300 IAT Sensor 1 Circuit Voltage High
P011400 IAT Sensor 1 Circuit Voltage Implausible

1. Circuit diagram

GAC Motor 2019

Control system 2-286 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrument
compart panel PDU
ment
PDU

MAP / IAT
Temperat Pressure
ure sensor sensor
sensor

ECM

Throttle Coolant Knock

position temperat sensor
sensor ure
sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

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Maintenance Manual of 1.5GDI Engine 2-287Control system

Step 2 Check whether the circuit between the MAP/IAT sensor and the ECM is open.

MAP/IAT sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
MAP/IAT sensor MAP/IAT sensor B Disconnect the MAP/IAT sensor harness
ground power supply connector EN16 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of the MAP/IAT sensor harness
connector EN16 and terminal 6 of the ECM
harness connector EN01.
MAP/IAT sensor D Measure the resistance of circuit between
temperature signal terminal 2 of the MAP/IAT sensor harness
connector EN16 and terminal 11 of the ECM
harness connector EN01.
E Measure the resistance of circuit between
terminal 3 of the MAP/IAT sensor harness
connector EN16 and terminal 44 of the ECM
ECM harness connector
harness connector EN01.
MAP/IAT sensorMAP/IAT sensor
ground temperature signal
Standard resistance: less than 1Ω
F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N
connector.

Sensor power supply

Step 3 Check whether the control circuit of MAP/IAT sensor is shorted to ground.

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Control system 2-288 Maintenance Manual of 1.5GDI Engine

MAP/IAT sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
MAP/IAT sensor MAP/IAT sensor B Disconnect the MAP/IAT sensor harness
ground power supply connector EN16 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of the MAP/IAT sensor harness
connector EN16 and the body ground.
D Measure the resistance of circuit between
MAP/IAT sensor terminal 2 of the MAP/IAT sensor harness
temperature signal connector EN16 and the body ground.
E Measure the resistance of circuit between
terminal 3 of the MAP/IAT sensor harness
connector EN16 and the body ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check whether the control circuit of MAP/IAT sensor is shorted to power supply.

MAP/IAT sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
MAP/IAT sensor MAP/IAT sensor B Disconnect the MAP/IAT sensor harness
ground power supply connector EN16 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the MAP/IAT sensor harness connector EN16
MAP/IAT sensor and the body ground.
temperature signal
E Measure the voltage of circuit between terminal
2 of the MAP/IAT sensor harness connector EN16
and the body ground.
F Measure the voltage of circuit between terminal
3 of the MAP/IAT sensor harness connector EN16
and the body ground.
Standard voltage: 0V
G Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Replace the MAP/IAT sensor.

A Replace the MAP/IAT sensor.

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Maintenance Manual of 1.5GDI Engine 2-289Control system
B Verify if the fault is eliminated after the MAP/IAT
sensor is replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

A Replace the ECM.

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Control system 2-290 Maintenance Manual of 1.5GDI Engine

B Verify if the fault is eliminated after the ECM is

replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.17 DTC: P011623, P011626......
DTC Description
Coolant Temperature Sensor Signal Implausible
P011623
(Low Side)
Coolant Temperature Sensor Signal Implausible
P011626
(Stuck)
Coolant Temperature Sensor 1 Circuit Voltage
P011700
Low
Coolant Temperature Sensor 1 Circuit Voltage
P011800
High
Coolant Temperature Sensor 1 Circuit Voltage
P011900
Implausible
Coolant Temperature Sensor 1 Cold Start Check
P050C24
Implausible (Positive Deviation)
Coolant Temperature Sensor 1 Cold Start Check
P050C23
Implausible (Negative Deviation)

1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-291Control system

(Main relay)

Engine Instrument
compart panel PDU
ment
PDU

MAP / IAT
Temperat Pressure
ure sensor sensor
sensor

ECM

Throttle Coolant Knock

position temperat sensor
sensor ure
sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

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Control system 2-292 Maintenance Manual of 1.5GDI Engine

Step 2 Check the coolant temperature sensor.

Coolant temperature sensor A Set the ENGINE START/STOP button to “OFF”

position.
B Remove the coolant temperature sensor.
C Measure whether the resistance across the
coolant temperature sensor is normal.
Standard resistance: 2.4±2kΩ (@20℃)

N Replace the coolant temperature sensor.

Step 3 Check whether the circuit between the coolant temperature sensor and the ECM is open.

Coolant temperature sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Coolant temperature
sensor signal B Disconnect the coolant temperature sensor
harness connector EN15 and the ECM harness
connector EN01.
C Measure the resistance of circuit between
terminal 1 of the coolant temperature sensor
harness connector EN15 and terminal 57 of the
ECM harness connector EN01.
D Measure the resistance of circuit between
terminal 3 of the coolant temperature sensor
Coolant temperature harness connector EN15 and terminal 43 of the
sensor ground
ECM harness connector EN01.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

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Maintenance Manual of 1.5GDI Engine 2-293Control system

ECM harness connector

Coolant temperature
sensor ground

Coolant temperature
sensor signal

Step 4 Check whether the control circuit of coolant temperature sensor is shorted to ground.

Coolant temperature sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Coolant temperature
sensor signal B Disconnect the coolant temperature sensor
harness connector EN15 and the ECM harness
connector EN01.
C Measure the resistance of circuit between
terminal 1 of the coolant temperature sensor
harness connector EN15 and the body ground.
D Measure the resistance of circuit between
terminal 3 of the coolant temperature sensor
harness connector EN15 and the body ground.
Coolant temperature
sensor ground Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.

Replace or repair the harness or

N connector.

Step 5 Check whether the control circuit of coolant temperature sensor is shorted to power supply.

Coolant temperature sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Coolant temperature
sensor signal B Disconnect the coolant temperature sensor
harness connector EN15 and the ECM harness
connector EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the coolant temperature sensor harness
connector EN15 and the body ground.
Coolant temperature
E Measure the voltage of circuit between terminal
sensor ground 3 of the coolant temperature sensor harness
connector EN15 and the body ground.
GAC Motor 2019
Control system 2-294 Maintenance Manual of 1.5GDI Engine

Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

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Maintenance Manual of 1.5GDI Engine 2-295Control system

Step 6 Replace the coolant temperature sensor.

A Replace the coolant temperature sensor.

B Verify if the fault is eliminated after the coolant
temperature sensor is replaced.
Y The system is working normally.

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 8 End.
2.8.6.18 DTC: P012100, P012200......
DTC Description
Electronic Throttle Position Sensor 1 Signal
P012100
Implausible
Electronic Throttle Position Sensor 1 Signal Circuit
P012200
Voltage Low
Electronic Throttle Position Sensor 1 Signal Circuit
P012300
Voltage High

1. Circuit diagram

GAC Motor 2019

Control system 2-296 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrument
compart panel PDU
ment
PDU

MAP / IAT
Temperat Pressure
ure sensor sensor
sensor

ECM

Throttle Coolant Knock

position temperat sensor
sensor ure
sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

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Maintenance Manual of 1.5GDI Engine 2-297Control system

Step 2 Check whether the circuit between the electronic throttle position sensor 1 and the ECM is
open.

Electronic throttle position sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the electronic throttle position
Throttle position sensor Throttle position sensor sensor harness connector EN18 and the ECM
ground power supply
harness connector EN01.
C Measure the resistance of circuit between
terminal 2 of the electronic throttle position sensor
harness connector EN18 and terminal 51 of the
ECM harness connector EN01.
D Measure the resistance of circuit between
Throttle position sensor terminal 3 of the electronic throttle position sensor
signal 1
harness connector EN18 and terminal 8 of the
ECM harness connector EN01.
E Measure the resistance of circuit between
terminal 6 of the electronic throttle position sensor
harness connector EN18 and terminal 24 of the
ECM harness connector
ECM harness connector EN01.
Throttle position sensor Throttle position sensor Standard resistance: less than 1Ω
power supply signal 1
F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Throttle position sensor

ground

Step 3 Check whether the control circuit of electronic throttle position sensor 1 is shorted to
ground.

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Control system 2-298 Maintenance Manual of 1.5GDI Engine

Electronic throttle position sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the electronic throttle position
Throttle position sensor Throttle position sensor
ground power supply sensor harness connector EN18 and the ECM
harness connector EN01.
C Measure the resistance of circuit between
terminal 2 of the electronic throttle position sensor
harness connector EN18 and the body ground.
D Measure the resistance of circuit between
terminal 3 of the electronic throttle position sensor
Throttle position sensor harness connector EN18 and the body ground.
signal 1
E Measure the resistance of circuit between
terminal 6 of the electronic throttle position sensor
harness connector EN18 and the body ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check whether the control circuit of electronic throttle position sensor 1 is shorted to power
supply.

Electronic throttle position sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the electronic throttle position
Throttle position sensor Throttle position sensor
ground power supply
sensor harness connector EN18 and the ECM
harness connector EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
2 of the electronic throttle position sensor harness
connector EN18 and the body ground.
Throttle position sensor
signal 1 E Measure the voltage of circuit between terminal
3 of the electronic throttle position sensor harness
connector EN18 and the body ground.
F Measure the voltage of circuit between terminal
6 of the electronic throttle position sensor harness
connector EN18 and the body ground.
Standard voltage: 0V
G Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Replace the electronic throttle position sensor.

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Maintenance Manual of 1.5GDI Engine 2-299Control system

A Replace the electronic throttle position sensor.

B Verify if the fault is eliminated after the
electronic throttle position sensor is replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

A Replace the ECM.

GAC Motor 2019

Control system 2-300 Maintenance Manual of 1.5GDI Engine

B Verify if the fault is eliminated after the ECM is

replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.19 DTC: P013100, P013200......
DTC Description
Upstream Oxygen Sensor Signal Circuit Voltage
P013100
Low
Upstream Oxygen Sensor Signal Circuit Voltage
P013200
High
P013300 Upstream Oxygen Sensor Aging
P013400 Upstream Oxygen Sensor Signal Circuit Fault
P219500 Upstream Oxygen Sensor Signal Biased Lean
P219600 Upstream Oxygen Sensor Signal Biased Rich
Coupling of Upstream Oxygen Sensor Signal Wire
P223100
to Heater Wire

1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-301Control system

(Main relay)

Engine
compart
ment
PDU

Upstre Downs
am tream
oxygen oxygen
sensor sensor

ECM

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
N
intermittent fault. Check whether there is
any intermittent fault.

GAC Motor 2019

Control system 2-302 Maintenance Manual of 1.5GDI Engine

Step 2 Check whether the circuit between the upstream oxygen sensor and the ECM is open.

A Set the ENGINE START/STOP button to “OFF”

Upstream oxygen sensor harness connector
Upstream oxygen sensor
signal -
Upstream oxygen sensor
signal +
ECM harness connector
Upstream oxygen sensor
signal +
position.
B Disconnect the upstream oxygen sensor
harness connector EN04 and the ECM harness
connector FB46.
C Measure the resistance of circuit between
terminal 1 of the upstream oxygen sensor harness
connector EN04 and terminal 68 of the ECM
harness connector FB46.
D Measure the resistance of circuit between
terminal 2 of the upstream oxygen sensor harness
connector EN04 and terminal 17 of the ECM
harness connector FB46.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Upstream oxygen sensor

signal -

Step 3 Check whether the control circuit of upstream oxygen sensor is shorted to ground.

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Maintenance Manual of 1.5GDI Engine 2-303Control system

Upstream oxygen sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Upstream oxygen sensor
B Disconnect the upstream oxygen sensor
signal - harness connector EN04 and the ECM harness
connector FB46.
C Measure the resistance of circuit between
terminal 1 of the upstream oxygen sensor harness
connector EN04 and the body ground.
D Measure the resistance of circuit between
terminal 2 of the upstream oxygen sensor harness
Upstream oxygen sensor connector EN04 and the body ground.
signal +
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check whether the control circuit of upstream oxygen sensor is shorted to power supply.

Upstream oxygen sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Upstream oxygen sensor
B Disconnect the upstream oxygen sensor
signal - harness connector EN04 and the ECM harness
connector FB46.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the upstream oxygen sensor harness
connector EN04 and the body ground.
Upstream oxygen sensor E Measure the voltage of circuit between terminal
signal +
2 of the upstream oxygen sensor harness
connector EN04 and the body ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Check whether the status of the fuel pipeline is normal.

A Replace the upstream oxygen sensor.

B Verify if the fault is eliminated after the upstream
oxygen sensor is replaced.
Y The system is working normally.

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Control system 2-304 Maintenance Manual of 1.5GDI Engine

Step 6 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

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Maintenance Manual of 1.5GDI Engine 2-305Control system

Next step

Step 7 End.
2.8.6.20 DTC: P013600, P013700......
DTC Description
P013600 Downstream Oxygen Sensor Signal Open
Downstream Oxygen Sensor Signal Wire Shorted
P013700
to Ground
Downstream Oxygen Sensor Signal Wire Shorted
P013800
to Power Supply
Slow Rich-Lean Response Of Downstream
P013A00
Oxygen Sensor
Coupling of Downstream Oxygen Sensor Signal
P223200
Wire to Heater Wire
Downstream Oxygen Sensor Aging - Signal
P227000
Biased Lean Continuously
Downstream Oxygen Sensor Aging - Signal
P227100
Biased Rich Continuously

1. Circuit diagram

GAC Motor 2019

Control system 2-306 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine
compart
ment
PDU

Upstre Downs
am tream
oxygen oxygen
sensor sensor

ECM

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-307Control system
2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

Step 2 Check whether the circuit between the downstream oxygen sensor and the ECM is open.

Downstream oxygen sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Downstream oxygen
B Disconnect the downstream oxygen sensor
sensor signal + harness connector EN05 and the ECM harness
connector FB46.
C Measure the resistance of circuit between
terminal 1 of the downstream oxygen sensor
harness connector EN05 and terminal 39 of the
ECM harness connector FB46.
Downstream oxygen
D Measure the resistance of circuit between
sensor signal - terminal 2 of the downstream oxygen sensor
harness connector EN05 and terminal 67 of the
ECM harness connector FB46.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
ECM harness connector the standard value.
Replace or repair the harness or
Downstream oxygen
sensor signal + N connector.

Downstream oxygen
sensor signal -

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Control system 2-308 Maintenance Manual of 1.5GDI Engine

Step 3 Check whether the control circuit of downstream oxygen sensor is shorted to ground.

Downstream oxygen sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Downstream oxygen B Disconnect the downstream oxygen sensor
sensor signal + harness connector EN05 and the ECM harness
connector FB46.
C Measure the resistance of circuit between
terminal 1 of the downstream oxygen sensor
harness connector EN05 and the body ground.
D Measure the resistance of circuit between
Downstream oxygen terminal 2 of the downstream oxygen sensor
sensor signal - harness connector EN05 and the body ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check whether the control circuit of downstream oxygen sensor is shorted to power supply.

Downstream oxygen sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Downstream oxygen
B Disconnect the downstream oxygen sensor
sensor signal + harness connector EN05 and the ECM harness
connector FB46.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the downstream oxygen sensor harness
Downstream oxygen connector EN05 and the body ground.
sensor signal - E Measure the voltage of circuit between terminal
2 of the downstream oxygen sensor harness
connector EN05 and the body ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Replace the downstream oxygen sensor.

A Replace the downstream oxygen sensor.

B Verify if the fault is eliminated after the
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine 2-309Control system
downstream oxygen sensor is replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

GAC Motor 2019

Control system 2-310 Maintenance Manual of 1.5GDI Engine

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.21 DTC: P019000, P019128......
DTC Description
High-Pressure Fuel Rail Pressure Sensor Voltage
P019000
Signal Implausible
Negative Deviation of Characteristic Curve of
P019128
High-Pressure Fuel Rail Pressure Sensor
Positive Deviation of Characteristic Curve of High-
P019129
Pressure Fuel Rail Pressure Sensor
High-Pressure Fuel Rail Pressure Sensor Circuit
P019200
Voltage Low
High-Pressure Fuel Rail Pressure Sensor Circuit
P019300
Voltage High
High-Pressure Fuel Rail Pressure Sensor Signal
P019400
Stuck
High-Pressure Fuel Passage Pressure High
P053F22
during Catalytic Converter Heating
High-Pressure Fuel Passage Pressure Low during
P053F21
Catalytic Converter Heating

1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-311Control system

(Main relay)

Engine Instrument
compart panel PDU
ment
PDU

ECM

Fuel rail High-

pressur pressur
e e fuel
sensor pump

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

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Control system 2-312 Maintenance Manual of 1.5GDI Engine

Step 2 Check whether the circuit between the high-pressure common rail pressure sensor and the
ECM is open.

High-pressure common rail pressure sensor harness

A Set the ENGINE START/STOP button to “OFF”
connector position.
High-pressure common rail B Disconnect the high-pressure common rail
pressure sensor signal pressure sensor harness connector EN46 and the
ECM harness connector EN01.
C Measure the resistance of circuit between
terminal 1 of the high-pressure common rail
pressure sensor harness connector EN46 and
terminal 9 of the ECM harness connector EN01.
D Measure the resistance of circuit between
High-pressure common High-pressure
rail pressure sensor common rail pressure terminal 2 of the high-pressure common rail
ground sensor power supply pressure sensor harness connector EN46 and
terminal 14 of the ECM harness connector EN01.
E Measure the resistance of circuit between
terminal 3 of the high-pressure common rail
ECM harness connector pressure sensor harness connector EN46 and
terminal 44 of the ECM harness connector EN01.
High-pressure common High-pressure
rail pressure sensor common rail pressure Standard resistance: less than 1Ω
ground sensor power supply F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Sensor power supply

Step 3 Check whether the control circuit of high-pressure common rail pressure sensor is shorted
to ground.

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Maintenance Manual of 1.5GDI Engine 2-313Control system

High-pressure common rail pressure sensor harness

connector
High-pressure common
pressure sensor signal
High-pressure common High-pressure
rail pressure sensor common rail pressure
ground sensor power supply
A Set the ENGINE START/STOP button to “OFF”
position.
rail B Disconnect the high-pressure common rail
pressure sensor harness connector EN46 and the
ECM harness connector EN01.
C Measure the resistance of circuit between
terminal 1 of the high-pressure common rail
pressure sensor harness connector EN46 and the
body ground.
D Measure the resistance of circuit between
terminal 2 of the high-pressure common rail
pressure sensor harness connector EN46 and the
body ground.
E Measure the resistance of circuit between
terminal 3 of the high-pressure common rail
pressure sensor harness connector EN46 and the
body ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check whether the control circuit of high-pressure common rail pressure sensor is shorted
to power supply.

High-pressure common rail pressure sensor harness A Set the ENGINE START/STOP button to “OFF”
connector position.
High-pressure common rail B Disconnect the high-pressure common rail
pressure sensor signal pressure sensor harness connector EN46 and the
ECM harness connector EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the high-pressure common rail pressure
High-pressure common High-pressure sensor harness connector EN46 and the body
rail pressure sensor common rail pressure ground.
ground sensor power supply
E Measure the voltage of circuit between terminal
2 of the high-pressure common rail pressure
sensor harness connector EN46 and the body
ground.
F Measure the voltage of circuit between terminal
3 of the high-pressure common rail pressure
sensor harness connector EN46 and the body
ground.
Standard voltage: 0V
G Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

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Control system 2-314 Maintenance Manual of 1.5GDI Engine

Step 5 Replace the high-pressure common rail pressure sensor.

A Replace the high-pressure common rail

pressure sensor.
B Verify if the fault is eliminated after the high-
pressure common rail pressure sensor is
replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

A Replace the ECM.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-315Control system

B Verify if the fault is eliminated after the ECM is

replaced.
N The system is working normally.

Next step

Step 7 End.
2.8.6.22 DTC: P020100, P026100......
DTC Description
P020100 1# Cylinder Injector Control Circuit Open
1# Cylinder Injector High/Low Side Control Circuit
P026100
Voltage Low
1# Cylinder Injector Low Side Control Circuit
P026200
Voltage High
1# Cylinder Injector Control Circuit Current Rise
P026300
Time Implausible
Short Circuit between 1# Cylinder Injector High
P02EE00
Side and Low Side Control Circuits

1. Circuit diagram

GAC Motor 2019

Control system 2-316 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Injector Injector Injector Injector

4 3 2 1

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-317Control system

Step 2 Check the #1 cylinder injector.

Injector
A Set the ENGINE START/STOP button to “OFF”
position.
B Remove the #1 cylinder injector.
C Measure whether the resistance of #1 cylinder
injector is normal.
Standard resistance: 2±0.1Ω (@20℃)
N Replace the #1 cylinder injector.

Step 3 Check whether the circuit between the #1 cylinder injector and the ECM is open.

A Set the ENGINE START/STOP button to “OFF”

Injector 1 harness connector
position.
Injector 1-
B Disconnect the #1 cylinder injector harness
connector EN06 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of #1 cylinder injector harness
connector EN06 and terminal 33 of the ECM
harness connector EN01.
Injector 1+ D Measure the resistance of circuit between
terminal 2 of #1 cylinder injector harness
connector EN06 and terminal 31 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

GAC Motor 2019

Control system 2-318 Maintenance Manual of 1.5GDI Engine

ECM harness connector

Injector 1+

Injector 1-

Step 4 Check whether the control circuit of #1 cylinder injector is shorted to ground.

Injector 1 harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Injector 1-
B Disconnect the #1 cylinder injector harness
connector EN06 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of #1 cylinder injector harness
connector EN06 and the body ground.
D Measure the resistance of circuit between
Injector 1+ terminal 2 of #1 cylinder injector harness
connector EN06 and the body ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N
connector.

Step 5 Check whether the control circuit of #1 cylinder injector is shorted to power supply.

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Maintenance Manual of 1.5GDI Engine 2-319Control system

Injector 1 harness connector A Set the ENGINE START/STOP button to “OFF”

position.
Injector 1- B Disconnect the #1 cylinder injector harness
connector EN06 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of #1 cylinder injector harness connector EN06
Injector 1+ and the body ground.
E Measure the voltage of circuit between terminal
2 of #1 cylinder injector harness connector EN06
and the body ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

GAC Motor 2019

Control system 2-320 Maintenance Manual of 1.5GDI Engine

Step 6 Replace the #1 cylinder injector.

A Replace the #1 cylinder injector.

B Verify if the fault is eliminated after the #1
cylinder injector is replaced.
Y The system is working normally.

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 8 End.
2.8.6.23 DTC: P020200, P026400......
DTC Description
P020200 2# Cylinder Injector Control Circuit Open
2# Cylinder Injector High/Low Side Control Circuit
P026400
Voltage Low
2# Cylinder Injector Low Side Control Circuit
P026500
Voltage High
2# Cylinder Injector Control Circuit Current Rise
P026600
Time Implausible
Short Circuit between 2# Cylinder Injector High
P02EF00
Side and Low Side Control Circuits

1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-321Control system

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Injector Injector Injector Injector

4 3 2 1

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

GAC Motor 2019

Control system 2-322 Maintenance Manual of 1.5GDI Engine

Step 2 Check the #2 cylinder injector.

Injector A Set the ENGINE START/STOP button to “OFF”

position.
B Remove the #2 cylinder injector.
C Measure whether the resistance of #2 cylinder
injector is normal.
Standard resistance: 2±0.1Ω (@20℃)
N Replace the #2 cylinder injector.

Step 3 Check whether the circuit between the #2 cylinder injector and the ECM is open.

A Set the ENGINE START/STOP button to “OFF”

Injector 2 harness connector
position.
Injector 2-
B Disconnect the #2 cylinder injector harness
connector EN07 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of #2 cylinder injector harness
connector EN07 and terminal 49 of the ECM
harness connector EN01.
Injector 2+ D Measure the resistance of circuit between
terminal 2 of #2 cylinder injector harness
connector EN07 and terminal 47 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

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Maintenance Manual of 1.5GDI Engine 2-323Control system

ECM harness connector

Injector 2+ Injector 2-

Step 4 Check whether the control circuit of #2 cylinder injector is shorted to ground.

Injector 2 harness connector A Set the ENGINE START/STOP button to “OFF”

position.
Injector 2- B Disconnect the #2 cylinder injector harness
connector EN07 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of #2 cylinder injector harness
connector EN07 and the body ground.
D Measure the resistance of circuit between
Injector 2+ terminal 2 of #2 cylinder injector harness
connector EN07 and the body ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Check whether the control circuit of #2 cylinder injector is shorted to power supply.

Injector 2 harness connector A Set the ENGINE START/STOP button to “OFF”

position.
Injector 2- B Disconnect the #2 cylinder injector harness
connector EN07 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of #2 cylinder injector harness connector EN07
Injector 2+ and the body ground.
E Measure the voltage of circuit between terminal
2 of #2 cylinder injector harness connector EN07
and the body ground.
Standard voltage: 0V
GAC Motor 2019
Control system 2-324 Maintenance Manual of 1.5GDI Engine

F Verify if the voltage is consistent with the

standard value.
Replace or repair the harness or
N connector.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-325Control system

Step 6 Replace the #2 cylinder injector.

A Replace the #2 cylinder injector.

B Verify if the fault is eliminated after the #2
cylinder injector is replaced.
Y The system is working normally.

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 8 End.
2.8.6.24 DTC: P020300, P026700......
DTC Description
P020300 3# Cylinder Injector Control Circuit Open
3# Cylinder Injector High/Low Side Control Circuit
P026700
Voltage Low
3# Cylinder Injector Low Side Control Circuit
P026800
Voltage High
3# Cylinder Injector Control Circuit Current Rise
P026900
Time Implausible
Short Circuit between 3# Cylinder Injector High
P02F000
Side and Low Side Control Circuits

1. Circuit diagram

GAC Motor 2019

Control system 2-326 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Injector Injector Injector Injector

4 3 2 1

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-327Control system

Step 2 Check the #3 cylinder injector.

Injector A Set the ENGINE START/STOP button to “OFF”

position.
B Remove the #3 cylinder injector.
C Measure whether the resistance of #3 cylinder
injector is normal.
Standard resistance: 2±0.1Ω (@20℃)

N Replace the #3 cylinder injector.

Step 3 Check whether the circuit between the #3 cylinder injector and the ECM is open.

Injector 3 harness connector A Set the ENGINE START/STOP button to “OFF”

position.
Injector 3- B Disconnect the #3 cylinder injector harness
connector EN08 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of #3 cylinder injector harness
connector EN08 and terminal 34 of the ECM
harness connector EN01.
Injector 3+ D Measure the resistance of circuit between
terminal 2 of #2 cylinder injector harness
connector EN08 and terminal 46 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

GAC Motor 2019

Control system 2-328 Maintenance Manual of 1.5GDI Engine

ECM harness connector

Injector 3-

Injector 3+

Step 4 Check whether the control circuit of #3 cylinder injector is shorted to ground.

Injector 3 harness connector A Set the ENGINE START/STOP button to “OFF”

position.
Injector 3- B Disconnect the #3 cylinder injector harness
connector EN08 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of #3 cylinder injector harness
connector EN08 and the body ground.
D Measure the resistance of circuit between
Injector 3+ terminal 2 of #3 cylinder injector harness
connector EN08 and the body ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Check whether the control circuit of #3 cylinder injector is shorted to power supply.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-329Control system

Injector 3 harness connector A Set the ENGINE START/STOP button to “OFF”

position.
Injector 3- B Disconnect the #3 cylinder injector harness
connector EN08 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of #3 cylinder injector harness connector EN08
Injector 3+ and the body ground.
E Measure the voltage of circuit between terminal
2 of #3 cylinder injector harness connector EN08
and the body ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

GAC Motor 2019

Control system 2-330 Maintenance Manual of 1.5GDI Engine

Step 6 Replace the #3 cylinder injector.

A Replace the #3 cylinder injector.

B Verify if the fault is eliminated after the #3
cylinder injector is replaced.
Y The system is working normally.

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 8 End.
2.8.6.25 DTC: P020400, P027000......
DTC Description
P020400 4# Cylinder Injector Control Circuit Open
4# Cylinder Injector High/Low Side Control Circuit
P027000
Voltage Low
4# Cylinder Injector Low Side Control Circuit
P027100
Voltage High
4# Cylinder Injector Control Circuit Current Rise
P027200
Time Implausible
Short Circuit between 4# Cylinder Injector High
P02F100
Side and Low Side Control Circuits

1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-331Control system

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Injector Injector Injector Injector

4 3 2 1

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

GAC Motor 2019

Control system 2-332 Maintenance Manual of 1.5GDI Engine

Step 2 Check the #4 cylinder injector.

Injector
A Set the ENGINE START/STOP button to “OFF”
position.
B Remove the #4 cylinder injector.
C Measure whether the resistance of #4 cylinder
injector is normal.
Standard resistance: 2±0.1Ω (@20℃)
N Replace the #4 cylinder injector

Step 3 Check whether the circuit between the #4 cylinder injector and the ECM is open.

Injector 4 harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Injector 4- B Disconnect the #4 cylinder injector harness
connector EN09 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of #4 cylinder injector harness
connector EN09 and terminal 48 of the ECM
harness connector EN01.
Injector 4+ D Measure the resistance of circuit between
terminal 2 of #4 cylinder injector harness
connector EN09 and terminal 32 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-333Control system

ECM harness connector

Injector 4+

Injector 4-

Step 4 Check whether the control circuit of #4 cylinder injector is shorted to ground.

Injector 4 harness connector A Set the ENGINE START/STOP button to “OFF”

position.
Injector 4- B Disconnect the #4 cylinder injector harness
connector EN09 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of #4 cylinder injector harness
connector EN09 and the body ground.
D Measure the resistance of circuit between
Injector 4+ terminal 2 of #4 cylinder injector harness
connector EN09 and the body ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Check whether the control circuit of #4 cylinder injector is shorted to power supply.

GAC Motor 2019

Control system 2-334 Maintenance Manual of 1.5GDI Engine

A Set the ENGINE START/STOP button to “OFF”

Injector 4 harness connector
position.
Injector 4- B Disconnect the #4 cylinder injector harness
connector EN09 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of #4 cylinder injector harness connector EN09
Injector 4+ and the body ground.
E Measure the voltage of circuit between terminal
2 of #4 cylinder injector harness connector EN09
and the body ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-335Control system

Step 6 Replace the #4 cylinder injector

A Replace the #4 cylinder injector

B Verify if the fault is eliminated after the #4
cylinder injector is replaced.
Y The system is working normally.

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 8 End.
2.8.6.26 DTC: P021900
DTC Description
P021900 Engine Overspeed

1. Circuit diagram

GAC Motor 2019

Control system 2-336 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Refer to P-CAN
system circuit
diagram

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

Step 2 Check the power and ground wires of the ECM.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-337Control system

A Check whether the power and ground wires of

ECM are normal.
N Repair or replace the harness.

Step 3 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 4 End.
2.8.6.27 DTC: P022100, P022200......
DTC Description
Electronic Throttle Position Sensor 2 Signal
P022100
Implausible
Electronic Throttle Position Sensor 2 Signal Circuit
P022200
Voltage Low
Electronic Throttle Position Sensor 2 Signal Circuit
P022300
Voltage High

1. Circuit diagram

GAC Motor 2019

Control system 2-338 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrument
compart panel PDU
ment
PDU

MAP / IAT
Temperat Pressure
ure sensor sensor
sensor

ECM

Throttle Coolant Knock

position temperat sensor
sensor ure
sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-339Control system

Step 2 Check whether the circuit between the electronic throttle position sensor 2 and the ECM is
open.

Electronic throttle position sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Throttle position Throttle position
B Disconnect the electronic throttle position
sensor ground sensor power sensor harness connector EN18 and the ECM
supply harness connector EN01.
C Measure the resistance of circuit between
terminal 2 of the electronic throttle position sensor
harness connector EN18 and terminal 51 of the
ECM harness connector EN01.
D Measure the resistance of circuit between
Throttle position sensor terminal 3 of the electronic throttle position sensor
signal 2 harness connector EN18 and terminal 8 of the
ECM harness connector EN01.
E Measure the resistance of circuit between
terminal 5 of the electronic throttle position sensor
harness connector EN18 and terminal 41 of the
ECM harness connector
ECM harness connector EN01.
Throttle position sensor power Standard resistance: less than 1Ω
supply
F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Throttle position Throttle position

sensor ground sensor signal 2

Step 3 Check whether the control circuit of electronic throttle position sensor 2 is shorted to
ground.

GAC Motor 2019

Control system 2-340 Maintenance Manual of 1.5GDI Engine

Electronic throttle position sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Throttle position Throttle position
B Disconnect the electronic throttle position
sensor ground sensor power sensor harness connector EN18 and the ECM
supply harness connector EN01.
C Measure the resistance of circuit between
terminal 2 of the electronic throttle position sensor
harness connector EN18 and the body ground.
D Measure the resistance of circuit between
terminal 3 of the electronic throttle position sensor
Throttle position sensor harness connector EN18 and the body ground.
signal 2 E Measure the resistance of circuit between
terminal 5 of the electronic throttle position sensor
harness connector EN18 and the body ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check whether the control circuit of electronic throttle position sensor 2 is shorted to power
supply.

A Set the ENGINE START/STOP button to “OFF”

Electronic throttle position sensor harness connector
position.
B Disconnect the electronic throttle position
Throttle position Throttle position
sensor ground sensor power sensor harness connector EN18 and the ECM
supply harness connector EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
2 of the electronic throttle position sensor harness
connector EN18 and the body ground.
Throttle position sensor E Measure the voltage of circuit between terminal
signal 2 3 of the electronic throttle position sensor harness
connector EN18 and the body ground.
F Measure the voltage of circuit between terminal
5 of the electronic throttle position sensor harness
connector EN18 and the body ground.
Standard voltage: 0V
G Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Check whether the status of the fuel pipeline is normal.

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Maintenance Manual of 1.5GDI Engine 2-341Control system

A Replace the electronic throttle position sensor.

B Verify if the fault is eliminated after the
electronic throttle position sensor is replaced.
Replace the electronic throttle position
Y sensor.

Step 6 Replace the the ECM.

A Replace the ECM.

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Control system 2-342 Maintenance Manual of 1.5GDI Engine

B Verify if the fault is eliminated after the ECM is

replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.28 DTC: P023400, P029900......
DTC Description
P023400 High Charge Air Pressure Display of Turbocharger
P029900 Low Charge Air Pressure Display of Turbocharger
P023622 Charge Air Pressure Implausibly High
P023621 Charge Air Pressure Implausibly Low
P120500 Charge Air Pressure below Lower Limit

1. Circuit diagram

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Maintenance Manual of 1.5GDI Engine 2-343Control system

(Main relay)

Engine
compartment
PDU

Canist Wa Rel VCT VCT

er ste ief (intake) (exhaust)
solenoi gat val
d valve e ve

ECM

Pressure Temperat
sensor ure
sensor

Charge air temperature Phase sensor (intake) Phase sensor (exhaust) Speed sensor
and pressure sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

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Control system 2-344 Maintenance Manual of 1.5GDI Engine

Step 2 Check the turbocharger.

A Check whether the turbocharger pipeline is

clogged or leaks.
Repair or replace the turbocharger
N pipeline.

Step 3 Check the power supply circuit of waste gate.

A Set the ENGINE START/STOP button to “OFF”

Waste gate harness connector
position.
B Disconnect the waste gate harness connector
EN22.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
2 of the waste gate harness connector EN22 and
the body ground.
Standard voltage: 11~14V
Waste gate +
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check the circuit between the waste gate and the ECM.

A Set the ENGINE START/STOP button to “OFF”

Waste gate harness connector
position.
B Disconnect the waste gate harness connector
EN22 and the ECM harness connector FB46.
C Measure the resistance of circuit between
terminal 1 of the waste gate harness connector
EN22 and terminal 44 of the ECM harness
connector FB46.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
Waste gate - the standard value.
Replace or repair the harness or
N connector.

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Maintenance Manual of 1.5GDI Engine 2-345Control system

ECM harness connector

Waste gate
control signal

Step 5 Replace the waste gate.

A Replace the waste gate.

B Verify if the fault is eliminated after the waste
gate is replaced.
Y The system is working normally.

Step 6 Replace the turbocharger.

A Replace the turbocharger.

B Verify if the fault is eliminated after the
turbocharger is replaced.
Y The system is working normally.

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 8 End.

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Control system 2-346 Maintenance Manual of 1.5GDI Engine

2.8.6.29 DTC: P023700, P023800

DTC Description
P023700 Charge Air Pressure Sensor Shorted To Ground
Charge Air Pressure Sensor Shorted to Power
P023800
Supply
1. Circuit diagram

(Main relay)

Engine
compartment
PDU

Canist Wa Rel VCT VCT

er ste ief (intake) (exhaust)
solenoi gat val
d valve e ve

ECM

Pressure Temperat
sensor ure
sensor

Charge air temperature Phase sensor (intake) Phase sensor (exhaust) Speed sensor
and pressure sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.

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Maintenance Manual of 1.5GDI Engine 2-347Control system

E Read the DTC again.

F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

Step 2 Check whether the circuit between the charge air pressure sensor and the ECM is open.

Charge air temperature and pressure sensor

harness connector
Pressure signal of charge air
temperature and pressure sensor
Charge air temperature Charge air temperature
and pressure sensor and pressure sensor
ground power supply
ECM harness connector
Sensor ground Pressure signal of charge air
temperature and pressure sensor
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the charge air pressure sensor
harness connector EN32 and the ECM harness
connector FB46.
C Measure the resistance of circuit between
terminal 1 of the charge air pressure sensor
harness connector EN32 and terminal 30 of the
ECM harness connector FB46.
D Measure the resistance of circuit between
terminal 3 of the charge air pressure sensor
harness connector EN32 and terminal 42 of the
ECM harness connector FB46.
E Measure the resistance of circuit between
terminal 4 of the charge air pressure sensor
harness connector EN32 and terminal 38 of the
ECM harness connector FB46.
Standard resistance: less than 1Ω
F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Sensor 5V power
supply

Step 3 Check whether the control circuit of charge air pressure sensor is shorted to ground.

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Control system 2-348 Maintenance Manual of 1.5GDI Engine

Charge air temperature and pressure sensor A Set the ENGINE START/STOP button to “OFF”
harness connector position.
Pressure signal of charge air B Disconnect the charge air pressure sensor
temperature and pressure sensor
harness connector EN32 and the ECM harness
connector FB46.
C Measure the resistance of circuit between
terminal 1 of the charge air pressure sensor
harness connector EN32 and the body ground.
D Measure the resistance of circuit between
terminal 3 of the charge air pressure sensor
Charge air temperature Charge air temperature
and pressure sensor and pressure sensor
harness connector EN32 and the body ground.
ground power supply E Measure the resistance of circuit between
terminal 4 of the charge air pressure sensor
harness connector EN32 and the body ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
connector.
N

Step 4 Check whether the control circuit of charge air pressure sensor is shorted to power supply.

Charge air temperature and pressure sensor

harness connector
Pressure signal of charge air
temperature and pressure sensor
Charge air temperature Charge air temperature
and pressure sensor and pressure sensor
ground power supply
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the charge air pressure sensor
harness connector EN32 and the ECM harness
connector FB46.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the charge air pressure sensor harness
connector EN32 and the body ground.
E Measure the voltage of circuit between terminal
3 of the charge air pressure sensor harness
connector EN32 and the body ground.
F Measure the voltage of circuit between terminal
4 of the charge air pressure sensor harness
connector EN32 and the body ground.
Standard voltage: 0V
G Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Replace the charge air pressure sensor.

A Replace the charge air pressure sensor.

GAC Motor 2019
Maintenance Manual of 1.5GDI Engine 2-349Control system
B Verify if the fault is eliminated after the charge
air pressure sensor is replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

A Replace the ECM.

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Control system 2-350 Maintenance Manual of 1.5GDI Engine

B Verify if the fault is eliminated after the ECM is

replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.30 DTC: P024300, P024500......
DTC Description
P024300 Waste Gate Control Circuit Open
P024500 Waste Gate Control Circuit Voltage Low
P024600 Waste Gate Control Circuit Voltage High

1. Circuit diagram

(Main relay)

Engine
compartment
PDU

Canist Wa Rel VCT VCT

er ste ief (intake) (exhaust)
solenoi gat val
d valve e ve

ECM

Pressure Temperat
sensor ure
sensor

Charge air temperature Phase sensor (intake) Phase sensor (exhaust) Speed sensor
and pressure sensor

2. Diagnostic procedure

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-351Control system

Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault.
Check whether there is any intermittent
N fault.
Y

Step 2 Check the waste gate.

Waste gate
A Set the ENGINE START/STOP button to “OFF”
position.
B Remove the waste gate.
C Measure whether the resistance across the
waste gate is normal.
Standard resistance: 23±1.2Ω
N Replace the waste gate.

Step 3 Check the fuse EF30 of waste gate.

A Check whether the fuse EF30 is blown.

N Go to step 5.

Step 4 Check and repair the fuse EF30 circuit.

A Check whether the fuse EF30 circuit is shorted.

B Repair the circuit and check that there is no
short circuit.
C Replace the fuse with one with rated current.
GAC Motor 2019
Control system 2-352 Maintenance Manual of 1.5GDI Engine

The fuse is rated at EF30 10A

D Verify if the waste gate works normally.
Y The system is working normally.

Step 5 Check the power supply circuit of waste gate.

A Set the ENGINE START/STOP button to “OFF”

Waste gate harness connector
position.
B Disconnect the waste gate harness connector
EN22.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
2 of the waste gate harness connector EN22 and
the body ground.
Standard voltage: 11~14V
Waste gate +
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 6 Check whether the circuit between the waste gate and the ECM is open.

Waste gate harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the waste gate harness connector
EN22 and the ECM harness connector FB46.
C Measure the resistance of circuit between
terminal 1 of the waste gate harness connector
EN22 and terminal 44 of the ECM harness
connector FB46.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
Waste gate -
the standard value.
Replace or repair the harness or
N connector.

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Maintenance Manual of 1.5GDI Engine 2-353Control system

ECM harness connector

Waste gate
control signal

Step 7 Check whether the control circuit of waste gate is shorted to ground.

Waste gate harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the waste gate harness connector
EN22 and the ECM harness connector FB46.
C Measure the resistance of circuit between
terminal 1 of the waste gate harness connector
EN22 and the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
standard value.
Waste gate -
Replace or repair the harness or
N connector.

Step 8 Check whether the control circuit of waste gate is shorted to power supply.

Waste gate harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the waste gate harness connector
EN22 and the ECM harness connector FB46.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the waste gate harness connector EN22 and
the body ground.
Standard voltage: 0V
Waste gate - E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N
connector.

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Control system 2-354 Maintenance Manual of 1.5GDI Engine

Step 9 Replace the waste gate.

A Replace the waste gate.

B Verify if the fault is eliminated after the waste
gate is replaced.
Y The system is working normally.

Step 10 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 11 End.
2.8.6.31 DTC: P030000, P030100......
DTC Description
P030000 Random or Multi-cylinder Misfire
P030100 1# Cylinder Misfire Detected
P030200 2# Cylinder Misfire Detected
P030300 3# Cylinder Misfire Detected
P030400 4# Cylinder Misfire Detected
P036300 Misfire Detected – Fueling Disabled

1. Circuit diagram

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Maintenance Manual of 1.5GDI Engine 2-355Control system

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Refer to P-CAN
system circuit
diagram

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

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Control system 2-356 Maintenance Manual of 1.5GDI Engine

Step 2 Check the vacuum pipe and intake system.

A Check whether the vacuum pipe of activated

carbon canister solenoid valve is connected
incorrectly or leaks.
B Check whether the vacuum pipe of brake
vacuum booster is connected incorrectly or leaks.
C Check whether the vacuum pipe of MAP sensor
is connected incorrectly or leaks.
D Check whether the crankcase vent valve and
vent pipe are connected incorrectly or leak.
E Check whether the intake system leaks.
Y Handle the faulty part.

Step 3 Check the spark plug.

A Set the ENGINE START/STOP button to “OFF”

position.
B Remove the spark plug, and check whether the
spark plug gap (a) is normal.
Standard value of spark plug gap: 0.7~0.8mm
C Verify if the spark plug gap -a- is consistent with
the standard value.
N Replace the spark plug.

Step 4 Check the ignition coil.

A Check whether the jump spark of ignition coil is

normal.
N Replace the ignition coil.

Step 5 Check the compression pressure of misfire cylinder.

A Check whether the compression pressure of

misfire cylinder is too low.

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Maintenance Manual of 1.5GDI Engine 2-357Control system

Check the cause of low cylinder

N compression pressure.

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Control system 2-358 Maintenance Manual of 1.5GDI Engine

Step 6 Check the fuel and the fuel injector of misfire cylinder.

A Check whether the fuel injector is leaking or

stuck.
B Check whether the fuel quality is abnormal.
Y Handle the faulty part.

Step 7 Check the fuel system pressure.

A Check whether the fuel system pressure is

normal.
N Check and repair the fuel system.

Step 8 Check the valve timing system.

A Check whether the valve timing is correct.

N Re-adjust the valve timing.

Step 9 Check the power and ground wires of ECM.

A Check whether the power and ground wires of

ECM are normal.
N Repair or replace the harness.

Step 10 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 11 End.

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Maintenance Manual of 1.5GDI Engine 2-359Control system

2.8.6.32 DTC: P032500, P032700......

DTC Description
P032500 Knock Sensor Signal Circuit Voltage Low
P032700 Knock Sensor Signal Shorted to Ground (A side)
P032714 Knock Sensor Signal Shorted to Ground (B side)
Knock Sensor Signal Shorted to Power Supply (A
P032800
side)
Knock Sensor Signal Shorted to Power Supply (B
P032815
side)
P151000 Knock Sensor Signal Evaluation and Diagnosis
1. Circuit diagram

(Main relay)

Engine Instrument
compart panel PDU
ment
PDU

MAP / IAT
Temperat Pressure
ure sensor sensor
sensor

ECM

Throttle Coolant Knock

position temperat sensor
sensor ure
sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.

GAC Motor 2019

Control system 2-360 Maintenance Manual of 1.5GDI Engine

B Set the ENGINE START/STOP button to “ON”

position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

Step 2 Check whether the knock sensor circuit is open.

Knock sensor harness connector
Knock sensor signal -
Low
Knock sensor signal -
High
ECM harness connector
Knock sensor signal -
Low
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the knock sensor harness connector
EN14 and the ECM harness connector EN01.
C Measure the resistance of circuit between
terminal 1 of the knock sensor harness connector
EN14 and terminal 10 of the ECM harness
connector EN01.
D Measure the resistance of circuit between
terminal 2 of the knock sensor harness connector
EN14 and terminal 25 of the ECM harness
connector EN01.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Knock sensor signal -

High

Step 3 Check whether the control circuit of knock sensor is shorted to ground.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine
Knock sensor harness connector
Knock sensor signal -
Low
Knock sensor signal -
High
Step 4 Check whether the control circuit of knock sensor is shorted to power supply.
Knock sensor harness connector
Knock sensor signal -
Low
Knock sensor signal -
High
Step 5 Replace the knock sensor.
Step 6 Replace the the ECM.
2-361Control system
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the knock sensor harness connector
EN14 and the ECM harness connector EN01.
C Measure the resistance of circuit between
terminal 1 of the knock sensor harness connector
EN14 and the body ground.
D Measure the resistance of circuit between
terminal 2 of the knock sensor harness connector
EN14 and the body ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the knock sensor harness connector
EN14 and the ECM harness connector EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the knock sensor harness connector EN14
and the body ground.
E Measure the voltage of circuit between terminal
2 of the knock sensor harness connector EN14
and the body ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.
A Replace the knock sensor.
B Verify if the fault is eliminated after the knock
sensor is replaced.
Y The system is working normally.
GAC Motor 2019
Control system 2-362 Maintenance Manual of 1.5GDI Engine

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

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Maintenance Manual of 1.5GDI Engine 2-363Control system

Next step

Step 7 End.
2.8.6.33 DTC: P033500, P033900......
DTC Description
P033500 Speed Sensor Reverse Signal Implausible
P033900 Speed Sensor Signal Implausible
P261700 Speed Sensor Signal Lost

1. Circuit diagram

(Main relay)

Engine
compartment
PDU

Canist Wa Rel VCT VCT

er ste ief (intake) (exhaust)
solenoi gat val
d valve e ve

ECM

Pressure Temperat
sensor ure
sensor

Charge air temperature Phase sensor (intake) Phase sensor (exhaust) Speed sensor
and pressure sensor

2. Diagnostic procedure

GAC Motor 2019

Control system 2-364 Maintenance Manual of 1.5GDI Engine

Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

Step 2 Check whether the circuit between the speed sensor and the ECM is open.

A Set the ENGINE START/STOP button to “OFF”

Speed sensor harness connector
position.
B Disconnect the speed sensor harness connector
Speed sensor signal
EN19 and the ECM harness connector EN01.
C Measure the resistance of circuit between
terminal 1 of the speed sensor harness connector
EN19 and terminal 28 of the ECM harness
connector EN01.
D Measure the resistance of circuit between
terminal 2 of the speed sensor harness connector
Speed sensor ground Speedsensor power EN19 and terminal 23 of the ECM harness
supply
connector EN01.
E Measure the resistance of circuit between
terminal 3 of the speed sensor harness connector
EN19 and terminal 7 of the ECM harness
connector EN01.
ECM harness connector
Standard resistance: less than 1Ω
Speedsensor power F Verify if the measured value is consistent with
supply
the standard value.
Replace or repair the harness or
N connector.

Speed sensor
ground
Speed sensor signal

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Maintenance Manual of 1.5GDI Engine 2-365Control system

Step 3 Check whether the control circuit of speed sensor is shorted to ground.

Speed sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Speed sensor signal B Disconnect the speed sensor harness connector
EN19 and the ECM harness connector EN01.
C Measure the resistance of circuit between
terminal 1 of the speed sensor harness connector
EN19 and the body ground.
D Measure the resistance of circuit between
terminal 2 of the speed sensor harness connector
Speed sensor ground Speedsensor power
EN19 and the body ground.
supply E Measure the resistance of circuit between
terminal 3 of the speed sensor harness connector
EN19 and the body ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check whether the control circuit of speed sensor is shorted to power supply.

Speed sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Speed sensor signal B Disconnect the speed sensor harness connector
EN19 and the ECM harness connector EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the speed sensor harness connector EN19
and the body ground.
Speed sensor ground Speedsensor power E Measure the voltage of circuit between terminal
supply 2 of the speed sensor harness connector EN19
and the body ground.
F Measure the voltage of circuit between terminal
3 of the speed sensor harness connector EN19
and the body ground.
Standard voltage: 0V
G Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Replace the speed sensor.

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Control system 2-366 Maintenance Manual of 1.5GDI Engine

A Replace the speed sensor.

B Verify if the fault is eliminated after the speed
sensor is replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

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Maintenance Manual of 1.5GDI Engine 2-367Control system

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.34 DTC: P034100, P034200......
DTC Description
Intake Camshaft Sensor Signal Implausible
P034100
(Bank1)
Intake Camshaft Sensor Signal Shorted to Ground
P034200
(Bank1)
Intake Camshaft Sensor Signal Shorted to Power
P034300
Supply (Bank1)

1. Circuit diagram

(Main relay)

Engine
compartment
PDU

Canist Wa Rel VCT VCT

er ste ief (intake) (exhaust)
solenoi gat val
d valve e ve

ECM

Pressure Temperat
sensor ure
sensor

Charge air temperature Phase sensor (intake) Phase sensor (exhaust) Speed sensor
and pressure sensor

GAC Motor 2019

Control system 2-368 Maintenance Manual of 1.5GDI Engine

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

Step 2 Check whether the circuit between the intake phase sensor and the ECM is open.

Phase sensor (intake ) harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the intake phase sensor harness
Phase sensor (intake)
signal connector EN20 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of the intake phase sensor harness
connector EN20 and terminal 26 of the ECM
harness connector EN01.
D Measure the resistance of circuit between
Phase sensor (intake) Phase sensor (intake)
ground power supply terminal 2 of the intake phase sensor harness
connector EN20 and terminal 53 of the ECM
harness connector EN01.
E Measure the resistance of circuit between
terminal 3 of the intake phase sensor harness
connector EN20 and terminal 27 of the ECM
ECM harness connector
harness connector EN01.
Sensor ground Standard resistance: less than 1Ω
F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Phase sensor (intake) Sensor power supply

signal

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-369Control system

Step 3 Check whether the control circuit of intake phase sensor is shorted to ground.

Phase sensor (intake ) harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Phase sensor (intake)
B Disconnect the intake phase sensor harness
signal connector EN20 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 1 of the intake phase sensor harness
connector EN20 and the body ground.
D Measure the resistance of circuit between
terminal 2 of the intake phase sensor harness
Phase sensor (intake) Phase sensor (intake)
ground power supply connector EN20 and the body ground.
E Measure the resistance of circuit between
terminal 3 of the intake phase sensor harness
connector EN20 and the body ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check whether the control circuit of intake phase sensor is shorted to power supply.

Phase sensor (intake ) harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Phase sensor (intake)
B Disconnect the intake phase sensor harness
signal connector EN20 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of the intake phase sensor harness connector
EN20 and the body ground.
Phase sensor (intake) Phase sensor (intake)
ground power supply E Measure the voltage of circuit between terminal
2 of the intake phase sensor harness connector
EN20 and the body ground.
F Measure the voltage of circuit between terminal
3 of the intake phase sensor harness connector
EN20 and the body ground.
Standard voltage: 0V
G Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

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Control system 2-370 Maintenance Manual of 1.5GDI Engine

Step 5 Replace the intake phase sensor.

A Replace the intake phase sensor.

B Verify if the fault is eliminated after the intake
phase sensor is replaced.
Y The system is working normally.

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Maintenance Manual of 1.5GDI Engine 2-371Control system

Step 6 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.35 DTC: P035100, P230000......
DTC Description
P035100 1# Cylinder Ignition Coil Control Circuit Open
1# Cylinder Ignition Coil Control Circuit Voltage
P230000
Low
1# Cylinder Ignition Coil Control Circuit Voltage
P230100
High

1. Circuit diagram

GAC Motor 2019

Control system 2-372 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine
compart
ment
PDU

Ignition Ignition Ignition Ignition

coil 1 coil 2 coil 3 coil 4

ECM

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-373Control system

Step 2 Check the fuse EF33 of #1 cylinder ignition coil.

A Check whether the fuse EF33 is blown.

N Go to step 4.

Step 3 Check and repair the fuse EF33 circuit.

A Check whether the fuse EF33 circuit is shorted.

B Repair the circuit and check that there is no
short circuit.
C Replace the fuse with one with rated current.
The fuse is rated at EF33 15A
D Verify if the #1 cylinder ignition coil works
normally.
Y The system is working normally.

Step 4 Check the power supply circuit of #1 cylinder ignition coil.

Ignition coil 1 harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Ignition coil 1 power B Disconnect the #1 cylinder ignition coil harness
supply connector EN10.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of #1 cylinder ignition coil harness connector
EN10 and the body ground.
Standard voltage: 11~14V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Check the ground circuit of #1 cylinder ignition coil.

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Control system 2-374 Maintenance Manual of 1.5GDI Engine

Ignition coil 1 harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Ignition coil 1 ground B Disconnect the #1 cylinder ignition coil harness
connector EN10.
C Measure the resistance of circuit between
terminal 3 of #1 cylinder ignition coil harness
connector EN10 and the body ground.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Step 6 Check whether the circuit between the #1 cylinder ignition coil and the ECM is open.

Ignition coil 1 harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Ignition coil 1 control B Disconnect the #1 cylinder ignition coil harness
signal connector EN10 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 2 of #1 cylinder ignition coil harness
connector EN10 and terminal 37 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

ECM harness connector

Ignition coil 1 control

signal

Step 7 Check whether the control circuit of #1 cylinder ignition coil is shorted to ground.

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Maintenance Manual of 1.5GDI Engine 2-375Control system

Ignition coil 1 harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Ignition coil 1 control B Disconnect the #1 cylinder ignition coil harness
signal connector EN10 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 2 of #1 cylinder ignition coil harness
connector EN10 and the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 8 Check whether the control circuit of #1 cylinder ignition coil is shorted to power supply.

Ignition coil 1 harness connector
Ignition coil 1 control
signal
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the #1 cylinder ignition coil harness
connector EN10 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
2 of #1 cylinder ignition coil harness connector
EN10 and the body ground.
Standard voltage: 0V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 9 Replace the #1 cylinder ignition coil.

A Replace the #1 cylinder ignition coil.

B Verify if the fault is eliminated after the #1
cylinder ignition coil is replaced.
Y The system is working normally.

Step 10 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is

GAC Motor 2019

Control system 2-376 Maintenance Manual of 1.5GDI Engine

replaced.
Y The system is working normally.

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Maintenance Manual of 1.5GDI Engine 2-377Control system

Next step

Step 11 End.
2.8.6.36 DTC: P035200, P230300......
DTC Description
P035200 2# Cylinder Ignition Coil Control Circuit Open
2# Cylinder Ignition Coil Control Circuit Voltage
P230300
Low
2# Cylinder Ignition Coil Control Circuit Voltage
P230400
High
1. Circuit diagram

(Main relay)

Engine
compart
ment
PDU

Ignition Ignition Ignition Ignition

coil 1 coil 2 coil 3 coil 4

ECM

2. Diagnostic procedure

GAC Motor 2019

Control system 2-378 Maintenance Manual of 1.5GDI Engine

Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

Step 2 Check the fuse EF33 of #2 cylinder ignition coil.

A Check whether the fuse EF33 is blown.

N Go to step 4.

Step 3 Check and repair the fuse EF33 circuit.

A Check whether the fuse EF33 circuit is shorted.

B Repair the circuit and check that there is no
short circuit.
C Replace the fuse with one with rated current.
The fuse is rated at EF33 15A
D Verify if the #2 cylinder ignition coil works
normally.
Y The system is working normally.

Step 4 Check the power supply circuit of #2 cylinder ignition coil.

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Maintenance Manual of 1.5GDI Engine 2-379Control system

Ignition coil 2 harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Ignition coil 2 power B Disconnect the #2 cylinder ignition coil harness
supply
connector EN11.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of #2 cylinder ignition coil harness connector
EN11 and the body ground.
Standard voltage: 11~14V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.
Y

Step 5 Check the ground circuit of #2 cylinder ignition coil.

A Set the ENGINE START/STOP button to “OFF”

Ignition coil 2 harness connector
position.
Ignition coil 2 ground B Disconnect the #2 cylinder ignition coil harness
connector EN11.
C Measure the resistance of circuit between
terminal 3 of #2 cylinder ignition coil harness
connector EN11 and the body ground.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Step 6 Check whether the circuit between the #2 cylinder ignition coil and the ECM is open.

Ignition coil 2 harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Ignition coil 2 control B Disconnect the #2 cylinder ignition coil harness
signal
connector EN11 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 2 of #2 cylinder ignition coil harness
connector EN11 and terminal 40 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

GAC Motor 2019

Control system 2-380 Maintenance Manual of 1.5GDI Engine

ECM harness connector

Ignition coil 2 control

signal

Step 7 Check whether the control circuit of #2 cylinder ignition coil is shorted to ground.

Ignition coil 2 harness connector
Ignition coil 2 control
signal
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the #2 cylinder ignition coil harness
connector EN11 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 2 of #2 cylinder ignition coil harness
connector EN11 and the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.

Step 8 Check whether the control circuit of #2 cylinder ignition coil is shorted to power supply.

A Set the ENGINE START/STOP button to “OFF”

Ignition coil 2 harness connector
Ignition coil 2 control
signal
position.
B Disconnect the #2 cylinder ignition coil harness
connector EN11 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
2 of #2 cylinder ignition coil harness connector
EN11 and the body ground.
Standard voltage: 0V
E Verify if the voltage is consistent with the
standard value.

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Maintenance Manual of 1.5GDI Engine 2-381Control system

Replace or repair the harness or

N connector.

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Control system 2-382 Maintenance Manual of 1.5GDI Engine

Step 9 Replace the #2 cylinder ignition coil.

A Replace the #2 cylinder ignition coil.

B Verify if the fault is eliminated after the #2
cylinder ignition coil is replaced.
Y The system is working normally.

Step 10 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
N The system is working normally.

Next step

Step 11 End.
2.8.6.37 DTC: P230600, P230700......
DTC Description
3# Cylinder Ignition Coil Control Circuit Voltage
P230600
Low
3# Cylinder Ignition Coil Control Circuit Voltage
P230700
High
P035300 3# Cylinder Ignition Coil Control Circuit Open

1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-383Control system

(Main relay)

Engine
compart
ment
PDU

Ignition Ignition Ignition Ignition

coil 1 coil 2 coil 3 coil 4

ECM

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
N intermittent fault. Check whether there is
any intermittent fault.

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Control system 2-384 Maintenance Manual of 1.5GDI Engine

Step 2 Check the fuse EF33 of #3 cylinder ignition coil.

A Check whether the fuse EF33 is blown.

N Go to step 4.

Step 3 Check and repair the fuse EF33 circuit.

A Check whether the fuse EF33 circuit is shorted.

B Repair the circuit and check that there is no
short circuit.
C Replace the fuse with one with rated current.
The fuse is rated at EF33 15A
D Verify if the #3 cylinder ignition coil works
normally.
Y The system is working normally.

Step 4 Check the power supply circuit of #3 cylinder ignition coil.

Ignition coil 3 harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Ignition coil 3 power
B Disconnect the #3 cylinder ignition coil harness
supply connector EN12.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of #3 cylinder ignition coil harness connector
EN12 and the body ground.
Standard voltage: 11~14V
E Verify if the voltage is consistent with the
standard value.
N Replace or repair the harness or
connector.

Step 5 Check the ground circuit of #3 cylinder ignition coil.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-385Control system

Ignition coil 3 harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the #3 cylinder ignition coil harness
Ignition coil 3 ground
connector EN12.
C Measure the resistance of circuit between
terminal 3 of #3 cylinder ignition coil harness
connector EN12 and the body ground.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Step 6 Check whether the circuit between the #3 cylinder ignition coil and the ECM is open.

A Set the ENGINE START/STOP button to “OFF”

Ignition coil 3 harness connector
Ignition coil 3 control
signal
position.
B Disconnect the #3 cylinder ignition coil harness
connector EN12 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 2 of #3 cylinder ignition coil harness
connector EN12 and terminal 38 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

ECM harness connector

Ignition coil 3 control

signal

Step 7 Check whether the control circuit of #3 cylinder ignition coil is shorted to ground.

GAC Motor 2019

Control system 2-386 Maintenance Manual of 1.5GDI Engine

Ignition coil 3 harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Ignition coil 3 control B Disconnect the #3 cylinder ignition coil harness
signal connector EN12 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 2 of #3 cylinder ignition coil harness
connector EN12 and the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 8 Check whether the control circuit of #3 cylinder ignition coil is shorted to power supply.

Ignition coil 3 harness connector
Ignition coil 3 control
signal
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the #3 cylinder ignition coil harness
connector EN12 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
2 of #3 cylinder ignition coil harness connector
EN12 and the body ground.
Standard voltage: 0V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 9 Replace the #3 cylinder ignition coil.

A Replace the #3 cylinder ignition coil.

B Verify if the fault is eliminated after the #3
cylinder ignition coil is replaced.
Y The system is working normally.

Step 10 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine 2-387Control system
replaced.
Y The system is working normally.

GAC Motor 2019

Control system 2-388 Maintenance Manual of 1.5GDI Engine

Next step

Step 11 End.
2.8.6.38 DTC: P035400, P230900......
DTC Description
P035400 4# Cylinder Ignition Coil Control Circuit Open
4# Cylinder Ignition Coil Control Circuit Voltage
P230900
Low
4# Cylinder Ignition Coil Control Circuit Voltage
P231000
High

1. Circuit diagram

(Main relay)

Engine
compart
ment
PDU

Ignition Ignition Ignition Ignition

coil 1 coil 2 coil 3 coil 4

ECM

2. Diagnostic procedure

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-389Control system

Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

Step 2 Check the fuse EF33 of #4 cylinder ignition coil.

A Check whether the fuse EF33 is blown.

N Go to step 4.

Step 3 Check and repair the fuse EF33 circuit.

A Check whether the fuse EF33 circuit is shorted.

B Repair the circuit and check that there is no
short circuit.
C Replace the fuse with one with rated current.
The fuse is rated at EF33 15A
D Verify if the #4 cylinder ignition coil works
normally.
Y The system is working normally.

Step 4 Check the power supply circuit of #4 cylinder ignition coil.

GAC Motor 2019

Control system 2-390 Maintenance Manual of 1.5GDI Engine

Ignition coil 4 harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Ignition coil 4 power B Disconnect the #4 cylinder ignition coil harness
supply
connector EN13.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
1 of #4 cylinder ignition coil harness connector
EN13 and the body ground.
Standard voltage: 11~14V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Check the ground circuit of #4 cylinder ignition coil.

Ignition coil 4 harness connector

Ignition coil 4 ground
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the #4 cylinder ignition coil harness
connector EN13.
C Measure the resistance of circuit between
terminal 3 of #4 cylinder ignition coil harness
connector EN13 and the body ground.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Step 6 Check whether the circuit between the #4 cylinder ignition coil and the ECM is open.

Ignition coil 4 harness connector
Ignition coil 4 signal
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the #4 cylinder ignition coil harness
connector EN13 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 2 of #4 cylinder ignition coil harness
connector EN13 and terminal 39 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-391Control system

Replace or repair the harness or

N connector.

GAC Motor 2019

Control system 2-392 Maintenance Manual of 1.5GDI Engine

ECM harness connector

Ignition coil 4 control

signal

Step 7 Check whether the control circuit of #4 cylinder ignition coil is shorted to ground.

Ignition coil 4 harness connector
Ignition coil 4 control
signal
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the #4 cylinder ignition coil harness
connector EN13 and the ECM harness connector
EN01.
C Measure the resistance of circuit between
terminal 2 of #4 cylinder ignition coil harness
connector EN13 and the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 8 Check whether the control circuit of #4 cylinder ignition coil is shorted to power supply.

Ignition coil 4 harness connector
Ignition coil 4 control
signal
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the #4 cylinder ignition coil harness
connector EN13 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
2 of #4 cylinder ignition coil harness connector
EN13 and the body ground.
Standard voltage: 0V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-393Control system

Step 9 Replace the #4 cylinder ignition coil.

A Replace the #4 cylinder ignition coil.

B Verify if the fault is eliminated after the #4
cylinder ignition coil is replaced.
Y The system is working normally.

Step 10 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 11 End.
2.8.6.39 DTC: P036600, P036700......
DTC Description
Exhaust Camshaft Sensor Signal Implausible
P036600
(Bank1)
Exhaust Camshaft Sensor Signal Shorted to
P036700
Ground (Bank1)
Exhaust Camshaft Sensor Signal Shorted to
P036800
Power Supply (Bank1)

1. Circuit diagram

GAC Motor 2019

Control system 2-394 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine
compartment
PDU

Canist Wa Rel VCT VCT

er ste ief (intake) (exhaust)
solenoi gat val
d valve e ve

ECM

Pressure Temperat
sensor ure
sensor

Charge air temperature Phase sensor (intake) Phase sensor (exhaust) Speed sensor
and pressure sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-395Control system

Step 2 Check if the circuit between the exhaust phase sensor and the ECM is open.

Phase sensor (exhaust end) harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the exhaust phase sensor harness
Ground Power connector EN21 and the ECM harness connector
EN01.
C Measure the resistance of the circuit between
terminal 1 of the exhaust phase sensor harness
connector EN21 and terminal 26 of the ECM
harness connector EN01.
D Measure the resistance of the circuit between
Signal terminal 2 of the exhaust phase sensor harness
connector EN21 and terminal 54 of the ECM
harness connector EN01.
E Measure the resistance of the circuit between
terminal 3 of the exhaust phase sensor harness
ECM harness connector connector EN21 and terminal 27 of the ECM
harness connector EN01.
Sensor ground Sensor power Standard resistance: less than 1Ω
supply
F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Phase sensor (exhaust end) signal

Step 3 Check if the control circuit of exhaust phase sensor is shorted to ground.

GAC Motor 2019

Control system 2-396 Maintenance Manual of 1.5GDI Engine

Phase sensor (exhaust end) harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the exhaust phase sensor harness
Ground Power connector EN21 and the ECM harness connector
EN01.
C Measure the resistance of the circuit between
terminal 1 of the exhaust phase sensor harness
connector EN21 and the body ground.
D Measure the resistance of the circuit between
terminal 2 of the exhaust phase sensor harness
Signal connector EN21 and the body ground.
E Measure the resistance of the circuit between
terminal 3 of the exhaust phase sensor harness
connector EN21 and the body ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check if the control circuit of exhaust phase sensor is shorted to power supply.

Phase sensor (exhaust end) harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the exhaust phase sensor harness
Ground Power connector EN21 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of the circuit between
terminal 1 of the exhaust phase sensor harness
connector EN21 and the body ground.
Signal
E Measure the voltage of the circuit between
terminal 2 of the exhaust phase sensor harness
connector EN21 and the body ground.
F Measure the voltage of the circuit between
terminal 3 of the exhaust phase sensor harness
connector EN21 and the body ground.
Standard voltage: 0V
G Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Replace the exhaust phase sensor.

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Maintenance Manual of 1.5GDI Engine 2-397Control system

A Replace the exhaust phase sensor.

B Verify if the fault is eliminated after the exhaust
phase sensor is replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

A Replace the ECM.

GAC Motor 2019

Control system 2-398 Maintenance Manual of 1.5GDI Engine

B Verify if the fault is eliminated after the ECM is

replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.40 DTC: P042000
DTC Description
P042000 Three-way Catalytic Converter OSC Aging

1. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.
Y

Step 2 Check the three-way catalytic converter.

A Visually check the appearance of the three-way

catalytic converter for dents.
Y Replace the three-way catalytic converter.

Step 3 Check for exhaust leakage.

A Start the engine and run it at idle speed.

B Check if exhaust leakage occurs in the pipeline
before the downstream oxygen sensor.
Y Repair or replace the exhaust pipe.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-399Control system

Step 4 Check the color of the exhaust.

A Start the engine and run it to the operating

temperature.
B Check the color of the exhaust when the engine
is idling or when the accelerator pedal is
depressed quickly in neutral position.
C Check if the exhaust is blue.
Y Repair the internal faults of the engine.

Step 5 Check the oxygen sensor.

A Check if the upstream and downstream oxygen

sensors work normally
N Replace the oxygen sensor.

Step 6 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.41 DTC: P044200, P044400......
DTC Description
P044200 1.0mm Leaks in Evaporation System
P044400 Canister Control Valve Control Circuit Open
2.2mm Leaks in Evaporation System or Loose
P045500
Fuel Filler Cap
P045800 Canister Control Valve Circuit Voltage Low
P045900 Canister Control Valve Circuit Voltage High
Low-load Desorption Line Fault - Canister Valve
P049700
Fault
High-load Desorption Line Fault - Canister Valve
P04F000
Fault

1. Circuit diagram

GAC Motor 2019

Control system 2-400 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine
compart
ment
PDU

Canist Canister
er vent
soleno valve
id
valve

ECM

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-401Control system

Step 2 Check the tightness of the canister and related pipelines.

A Check the tightness of the canister and related

pipelines.
N Replace the leaking parts.

Step 3 Check the canister solenoid valve.

Canister solenoid valve A Set the ENGINE START/STOP button to “OFF”

position.
B Remove the canister solenoid valve.
C Measure if the resistance at both ends of the
canister solenoid valve is normal.
Standard resistance: 16±2Ω
N Replace the canister solenoid valve.

Step 4 Check the canister solenoid valve fuse EF30.

A Check whether the fuse EF30 is blown.

N Go to step 5.

Step 5 Check and repair the fuse EF30 circuit.

A Check whether the fuse EF30 circuit is shorted.

B Repair the circuit and check that there is no
short circuit.
C Replace the fuse with one with rated current.
The fuse is rated at EF30 10A
D Check if the canister solenoid valve works
normally.
Y The system is working normally.

Step 6 Check the power circuit of the canister solenoid valve.

GAC Motor 2019

Control system 2-402 Maintenance Manual of 1.5GDI Engine

Canister solenoid valve harness connector
Canister solenoid valve power
supply
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the canister solenoid valve harness
connector EN17.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of the circuit between
terminal 2 of the canister solenoid valve harness
connector EN17 and the body ground.
Standard voltage: 11~14V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 7 Check if the circuit between the canister solenoid valve and the ECM is open.

Canister solenoid valve harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the canister solenoid valve harness
Canister solenoid valve signal
connector EN17 and the ECM harness connector
EN01.
C Measure the resistance of the circuit between
terminal 1 of the canister solenoid valve harness
connector EN17 and terminal 18 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

ECM harness connector

Canister solenoid valve signal

Step 1 Check if the control circuit of canister solenoid valve is shorted to ground.
GAC Motor 2019
Maintenance Manual of 1.5GDI Engine 2-403Control system

Canister solenoid valve harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the canister solenoid valve harness
Canister solenoid valve signal
connector EN17 and the ECM harness connector
EN01.
C Measure the resistance of the circuit between
terminal 1 of the canister solenoid valve harness
connector EN17 and the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 9 Check if the control circuit of canister solenoid valve is shorted to power supply.

Canister solenoid valve harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the canister solenoid valve harness
Canister solenoid valve signal
connector EN17 and the ECM harness connector
EN01.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of the circuit between
terminal 1 of the canister solenoid valve harness
connector EN17 and the body ground.
Standard voltage: 0V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 10 Replace the canister solenoid valve.

A Replace the canister solenoid valve.

B Verify if the fault is eliminated after the canister
solenoid valve is replaced.

Y The system is working normally.

Step 11 Replace the the ECM.

A Replace the ECM.

GAC Motor 2019

Control system 2-404 Maintenance Manual of 1.5GDI Engine

B Verify if the fault is eliminated after the ECM is

replaced.
Y The system is working normally.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-405Control system

Next step

Step 12 End.
2.8.6.42 DTC: P044700, P049800......
DTC Description
P044700 Canister Vent Valve Control Circuit Open
P049800 Canister Vent Valve Control Circuit Voltage Low
P049900 Canister Vent Valve Control Circuit Voltage High
Crankcase Ventilation System High-Load Pipeline
P04DB00
Disconnected
P242200 Canister Vent Valve Stuck

1. Circuit diagram

(Main relay)

Engine
compart
ment
PDU

Canist Canister
er vent
soleno valve
id
valve

ECM

2. Diagnostic procedure

GAC Motor 2019

Control system 2-406 Maintenance Manual of 1.5GDI Engine

Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

Step 2 Check the canister vent valve.

Canister vent valve A Set the ENGINE START/STOP button to “OFF”

position.
B Remove the canister vent valve.
C Measure if the resistance at both ends of the
canister vent valve is normal.
Standard resistance: 16±2 Ω (at 20℃)
N Replace the canister vent valve.

Step 3 Check the canister vent valve fuse EF30.

A Check whether the fuse EF30 is blown.

N Go to step 5.

Step 4 Check and repair the fuse EF30 circuit.

A Check whether the fuse EF30 circuit is shorted.

B Repair the circuit and check that there is no
short circuit.
C Replace the fuse with one with rated current.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-407Control system

The fuse is rated at EF30 10A

D Check if the canister vent valve works normally.
Y The system is working normally.

Step 5 Check the power circuit of the canister vent valve.

Canister vent valve connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the canister vent valve harness
Canister vent valve+
connector BD69.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of the circuit between
terminal 1 of the canister vent valve harness
connector BD69 and the body ground.
Standard voltage: 11~14V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 6 Check if the circuit between the canister vent valve and the ECM is open.

Canister vent valve connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the canister vent valve harness
connector BD69 and the ECM harness connector
FB46.
C Measure the resistance of the circuit between
terminal 2 of the canister vent valve harness
connector BD69 and terminal 93 of the ECM
harness connector FB46.
Standard resistance: less than 1Ω
Canister vent valve- D Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

GAC Motor 2019

Control system 2-408 Maintenance Manual of 1.5GDI Engine

ECM harness connector

Canister vent valve signal

Step 7 Check if the control circuit of the canister vent valve is shorted to ground.

Canister vent valve connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the canister vent valve harness
connector BD69 and the ECM harness connector
FB46.
C Measure the resistance of the circuit between
terminal 2 of the canister vent valve harness
connector BD69 and the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
Canister vent valve- standard value.
Replace or repair the harness or
N connector.

Step 8 Check if the control circuit of the canister vent valve is shorted to power supply.

Canister vent valve connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the canister vent valve harness
connector BD69 and the ECM harness connector
FB46.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of the circuit between
terminal 2 of the canister vent valve harness
connector BD69 and the body ground.
Canister vent valve- Standard voltage: 0V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-409Control system

Step 9 Replace the canister vent valve.

A Replace the canister vent valve.

B Verify if the fault is eliminated after the canister
vent valve is replaced.
Y The system is working normally.

Step 10 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 11 End.
2.8.6.43 DTC: P045128, P04512A......
DTC Description
P045128 Fuel Tank Pressure Sensor Signal Deviation
P04512A Fuel Tank Pressure Sensor Signal Stuck
Fuel Tank Pressure Sensor Signal Oscillation
P045125
Implausible
P045200 Fuel Tank Pressure Sensor Circuit Voltage Low
P045300 Fuel Tank Pressure Sensor Circuit Voltage High
Fuel Tank Pressure Sensor Signal Out of Range
P128200
(Positive)
Fuel Tank Pressure Sensor Signal Out of Range
P128300
(Negative)

1. Circuit diagram

GAC Motor 2019

Control system 2-410 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

Oil
pump
soleno
id
valve

ECM

Canister Fuel tank PCV

desorption evaporatin pipeline
pressure g pressure
sensor pressure sensor
sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-411Control system

Step 2 Check if the circuit between the fuel tank evaporating pressure sensor and the ECM is
open.

A Set the ENGINE START/STOP button to “OFF”

Fuel tank evaporating pressure sensor harness
connector position.
5V power supply
B Disconnect the fuel tank evaporating pressure
sensor harness connector BD70 and the ECM
harness connector FB46.
C Measure the resistance of the circuit between
terminal 1 of fuel tank evaporating pressure
sensor harness connector BD70 and terminal 42
of ECM harness connector FB46.
Ground Signal D Measure the resistance of the circuit between
terminal 2 of fuel tank evaporating pressure
sensor harness connector BD70 and terminal 30
of ECM harness connector FB46.
E Measure the resistance of the circuit between
terminal 3 of fuel tank evaporating pressure
sensor harness connector BD70 and terminal 64
ECM harness connector
of ECM harness connector FB46.
Sensor 5V power Standard resistance: less than 1Ω
ground supply
F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Fuel tank evaporating

pressure sensor
signal

Step 3 Check if the control circuit of fuel tank evaporating pressure sensor is shorted to ground.

GAC Motor 2019

Control system 2-412 Maintenance Manual of 1.5GDI Engine

A Set the ENGINE START/STOP button to “OFF”

Fuel tank evaporating pressure sensor harness
connector position.
5V power supply
B Disconnect the fuel tank evaporating pressure
sensor harness connector BD70 and the ECM
harness connector FB46.
C Measure the resistance of the circuit between
terminal 1 of the fuel tank evaporating pressure
sensor harness connector BD70 and the body
ground.
Ground Signal D Measure the resistance of the circuit between
terminal 2 of the fuel tank evaporating pressure
sensor harness connector BD70 and the body
ground.
E Measure the resistance of the circuit between
terminal 3 of the fuel tank evaporating pressure
sensor harness connector BD70 and the body
ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check if the control circuit of fuel tank evaporating pressure sensor is shorted to power
supply.

A Set the ENGINE START/STOP button to “OFF”

Fuel tank evaporating pressure sensor harness position.
connector
B Disconnect the fuel tank evaporating pressure
5V power supply
sensor harness connector BD70 and the ECM
harness connector FB46.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of the circuit between
terminal 1 of fuel tank evaporating pressure
Ground Signal sensor harness connector BD70 and the body
ground.
E Measure the voltage of the circuit between
terminal 2 of fuel tank evaporating pressure
sensor harness connector BD70 and the body
ground.
F Measure the voltage of the circuit between
terminal 3 of fuel tank evaporating pressure
sensor harness connector BD70 and the body
ground.
Standard voltage: 0V
G Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-413Control system

Step 5 Replace the fuel tank evaporating pressure sensor.

A Replace the fuel tank evaporating pressure

sensor.
B Verify if the fault is eliminated after the fuel tank
evaporating pressure sensor is replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

A Replace the ECM.

GAC Motor 2019

Control system 2-414 Maintenance Manual of 1.5GDI Engine

B Verify if the fault is eliminated after the ECM is

replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.44 DTC: P046000, P046129......
DTC Description
P046000 Fuel Level Sensor Original Signal Out of Range
P046129 Fuel Level Signal Implausible
P046200 Fuel Level Sensor Circuit Voltage Low
P046300 Fuel Level Sensor Circuit Voltage High
P128400 Fuel Level Signal Out of Range
P25B000 Fuel Level Sensor Signal Stuck
U067600 Fuel Level Sensor Lost / Failure / Check Error

1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-415Control system

(Main relay)

Engine
compart
Fuel pump ment
relay PDU

Fuel level sensor

Fuel pump

ECM

Instrume
nt cluster

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

GAC Motor 2019

Control system 2-416 Maintenance Manual of 1.5GDI Engine

Step 2 Check if the circuit between the fuel level sensor and the ICM is open.

A Set the ENGINE START/STOP button to “OFF”

Fuel pump harness connector
position.
Fuel level Fuel level B Disconnect the fuel level sensor harness
sensor- sensor signal connector BD29 and the ICM harness connector
IP06.
C Measure the resistance of the circuit between
terminal 2 of the fuel level sensor harness
connector BD29 and terminal 7 of ICM harness
connector IP06.
D Measure the resistance of the circuit between
Fuel level sensor+ terminal 3 of the fuel level sensor harness
connector BD29 and terminal 30 of the ICM
harness connector IP06.
E Measure the resistance of the circuit between
terminal 4 of the fuel level sensor harness
connector BD29 and terminal 10 of the ICM
ICM harness connector
harness connector IP06.
Standard resistance: less than 1Ω
Fuel level Fuel level
sensor- sensor signal
F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Fuel level sensor+

Step 3 Check if the control circuit of fuel level sensor is shorted to ground.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-417Control system

A Set the ENGINE START/STOP button to “OFF”

Fuel pump harness connector
position.
Fuel level Fuel level
B Disconnect the fuel level sensor harness
sensor- sensor signal connector BD29 and the ICM harness connector
IP06.
C Measure the resistance of the circuit between
terminal 2 of the fuel level sensor harness
connector BD29 and the body ground.
D Measure the resistance of the circuit between
terminal 3 of the fuel level sensor harness
Fuel level sensor+ connector BD29 and the body ground.
E Measure the resistance of the circuit between
terminal 4 of the fuel level sensor harness
connector BD29 and the body ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check if the control circuit of fuel level sensor is shorted to power supply.

A Set the ENGINE START/STOP button to “OFF”

Fuel pump harness connector
position.
Fuel level Fuel level
B Disconnect the fuel level sensor harness
sensor- sensor signal connector BD29 and the ICM harness connector
IP06.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of the circuit between
terminal 2 of the fuel level sensor harness
connector BD29 and the body ground.
Fuel level sensor+
E Measure the voltage of the circuit between
terminal 3 of the fuel level sensor harness
connector BD29 and the body ground.
F Measure the voltage of the circuit between
terminal 4 of the fuel level sensor harness
connector BD29 and the body ground.
Standard voltage: 0V
G Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Replace the fuel level sensor.

A Replace the fuel level sensor.

B Verify if the fault is eliminated after the fuel level
GAC Motor 2019
Control system 2-418 Maintenance Manual of 1.5GDI Engine

sensor is replaced.
Y The system is working normally.

Step 6 Replace the ICM.

A Replace the ICM.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-419Control system

B Verify if the fault is eliminated after the ICM is

replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.45 DTC: P046700, P046800......
DTC Description
High-Load Desorption Pipeline Pressure Sensor
P046700
Circuit Voltage Low
High-Load Desorption Pipeline Pressure Sensor
P046800
Circuit Voltage High
High-load Desorption Pipeline Pressure Sensor
P128500
Signal above Upper Limit
High-load Desorption Pipeline Pressure Sensor
P128600
Signal below Lower Limit

1. Circuit diagram

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

Oil
pump
soleno
id
valve

ECM

Canister Fuel tank PCV

desorption evaporatin pipeline
pressure g pressure
sensor pressure sensor
sensor

GAC Motor 2019

Control system 2-420 Maintenance Manual of 1.5GDI Engine

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

Step 2 Check if the circuit between the canister desorption pressure sensor and the ECM is open.

A Set the ENGINE START/STOP button to “OFF”

Canister desorption pressure sensor harness
connector position.
B Disconnect the canister desorption pressure
Ground sensor harness connector EN49 and the ECM
harness connector FB46.
C Measure the resistance of the circuit between
terminal 1 of the canister desorption pressure
sensor harness connector EN49 and terminal 84
of the ECM harness connector FB46.
Power Signal D Measure the resistance of the circuit between
terminal 2 of the canister desorption pressure
sensor harness connector EN49 and terminal 90
of the ECM harness connector FB46.
E Measure the resistance of the circuit between
terminal 3 of the canister desorption pressure
sensor harness connector EN49 and terminal 91
ECM harness connector
of the ECM harness connector FB46.
Sensor 5V power Standard resistance: less than 1Ω
supply
F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Sensor ground Sensor grounding

Canister desorption
pressure sensor signal

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-421Control system

Step 3 Check if the control circuit of canister desorption pressure sensor is shorted to ground.

Canister desorption pressure sensor harness A Set the ENGINE START/STOP button to “OFF”
connector position.
B Disconnect the canister desorption pressure
Ground
sensor harness connector EN49 and the ECM
harness connector FB46.
C Measure the resistance of the circuit between
terminal 1 of the canister desorption pressure
sensor harness connector EN49 and the body
ground.
Power Signal D Measure the resistance of the circuit between
terminal 2 of the canister desorption pressure
sensor harness connector EN49 and the body
ground.
E Measure the resistance of the circuit between
terminal 3 of the canister desorption pressure
sensor harness connector EN49 and the body
ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check if the control circuit of canister desorption pressure sensor is shorted to power
supply.

Canister desorption pressure sensor harness A Set the ENGINE START/STOP button to “OFF”
connector position.
B Disconnect the canister desorption pressure
Ground
sensor harness connector EN49 and the ECM
harness connector FB46.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of the circuit between
terminal 1 of the canister desorption pressure
Power Signal sensor harness connector EN49 and the body
ground.
E Measure the voltage of the circuit between
terminal 2 of the canister desorption pressure
sensor harness connector EN49 and the body
ground.
F Measure the voltage of the circuit between
terminal 3 of the canister desorption pressure
sensor harness connector EN49 and the body
ground.
Standard voltage: 0V

GAC Motor 2019

Control system 2-422 Maintenance Manual of 1.5GDI Engine

G Verify if the voltage is consistent with the

standard value.
Replace or repair the harness or
N connector.

Step 5 Replace the canister desorption pressure sensor.

A Replace the canister desorption pressure

sensor.
B Verify if the fault is eliminated after the canister
desorption pressure sensor is replaced.
Y The system is working normally.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-423Control system

Step 6 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.46 DTC: P048000, P063400......
Diagnostic trouble code (DTC) Description
P048000 Cooling Fan Control Circuit Open
P063400 Cooling Fan Driver Chip Overheated
P069100 Cooling Fan Control Circuit Voltage Low
P069200 Cooling Fan Control Circuit Voltage High

1. Circuit diagram

GAC Motor 2019

Control system 2-424 Maintenance Manual of 1.5GDI Engine

Engine
Cooling fan compart
Main relay relay ment
PDU

Electronic fan module

Left Right
ECM electr electr
onic onic
fan fan

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

Step 2 Check the terminals of ECM and engine compartment PDU harness connector.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-425Control system

A Set the ENGINE START/STOP button to “OFF”

position.
B Disconnect the connectors of the ECM,
cooling fan relay and engine compartment PDU
harness.
C Check if the terminals in the harness connector
are damaged, bent, removed or corroded.
Y Repair the harness or connector.

Step 3 Check the cooling fan relay.

A Set the ENGINE START/STOP button to “OFF”

position.
B Remove the cooling fan relay ER05.
C Connect one end of the coil of the cooling fan
relay to the positive battery terminal, and connect
the other end to the ground. Then check the
continuity between the two ends of the relay
Fuse
switch contact.
N Replace the cooling fan relay.

Ground

Step 4 Check if the control circuit of cooling fan relay is open.

ECM harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the ECM harness connector FB46
and the cooling fan harness connector FB07.
C Remove the cooling fan relay ER05.
D Measure the resistance of the circuit between
terminal 52 of the ECM harness connector FB46
and terminal 1 of the cooling fan harness
connector FB07.
Electronic fan module Standard resistance: less than 1Ω
PWM E Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.

GAC Motor 2019

Control system 2-426 Maintenance Manual of 1.5GDI Engine

Electronic fan module harness connector

Electronic fan module

PWM

Step 5 Check if the control circuit of cooling fan relay is shorted to ground.

ECM harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the ECM harness connector FB46
and the cooling fan harness connector FB07.
C Measure the resistance of he circuit between
terminal 52 of ECM harness connector FB46 and
the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
Electronic fan module standard value.
PWM
Replace or repair the harness or
N connector.

Step 6 Check if the control circuit of cooling fan relay is shorted to power supply.

ECM harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the ECM harness connector FB46
and the cooling fan harness connector FB07.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the resistance of the circuit between
terminal 52 of ECM harness connector FB46 and
the body ground.
Electronic fan module E Verify if the voltage is consistent with the
PWM standard value.
Replace or repair the harness or
N connector.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-427Control system

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 8 End.
2.8.6.47 DTC: P050000, P050166......
DTC Description
P050000 Vehicle Speed Input Signal Failure
Road Speed Implausible - Low Road Speed under
P050166
Heavy Engine Load
Road Speed Implausible - Low Road Speed
P050165
during Vehicle Coasting and Fuel Cutoff
P050300 Speed Stuck
P121200 Road Speed above Upper Limit

1. Circuit diagram

GAC Motor 2019

Control system 2-428 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

ESPI

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N
any intermittent fault.

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Maintenance Manual of 1.5GDI Engine 2-429Control system

Step 2 Check the DTC of the BCS.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to the
“ON” position, read the DTC of the BCS, and
check if there is a DTC related to wheel speed
signal in the BCS.
N Give priority to troubleshooting of BCS.

Step 3 Check the CAN data communication cable between the ECM and the ESPI harness
connectors.

ECM harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the ECM harness connector FB46.
C Disconnect the ESPI harness connector FB04.
D Measure the resistance between terminal 56 of
the ECM harness connector FB46 and terminal 13
of the ESPI harness connector FB04.
E Measure the resistance between terminal 57 of
the ECM harness connector FB46 and terminal 27
of the ESPI harness connector FB04.
Standard resistance: less than 1 Ω
F Verify if the resistance is consistent with the
standard value.

ESPI harness connector

N Repair or replace the harness.

Step 4 Check the power and ground circuits of the ESPI.

A Check if the power and ground circuits of the

ESPI are normal.

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Control system 2-430 Maintenance Manual of 1.5GDI Engine

N Repair or replace the harness.

Step 5 Replace the ESPI.

A Replace the ESPI.

B Verify if the fault is eliminated after the
ESPI is replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.48 DTC: P050500, P050600
DTC Description
P050500 Engine Idle Speed Fluctuation Out of Range
P050600 Engine Idle Speed Low
P050700 Engine Idle Speed High
High Engine Idle Speed during Catalytic Converter
P050A22
Heating
Low Engine Idle Speed during Catalytic Converter
P050A21
Heating
Ignition Angle Efficiency Monitoring during
P050B00
Catalytic Converter Heating (Idle Speed)
Ignition Angle Efficiency Monitoring during
P050B20
Catalytic Converter Heating (Partial Load)
Parking Idle Speed Fluctuation Out of Range
P050D00 during Catalytic Converter Heating and without
Fuel Cutoff

1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-431Control system

(Main relay)

Engine Instrument
compart panel PDU
ment
PDU

MAP / IAT
Temperat Pressure
ure sensor sensor
sensor

ECM

Throttle Coolant Knock

position temperat sensor
sensor ure
sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check if there is any
N
intermittent fault.

GAC Motor 2019

Control system 2-432 Maintenance Manual of 1.5GDI Engine

Step 2 Check the electronic throttle body.

A Check if there are carbon deposits, oil stains,

etc. inside the electronic throttle body.
Y Clean the electronic throttle.

Step 3 Check the circuit between the electronic throttle position sensor 1 and the ECM.

Electronic throttle position sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the electronic throttle position
Throttle position sensorThrottle position sensor
ground power supply
sensor harness connector EN18 and the ECM
harness connector EN01.
C Measure the resistance of circuit between
terminal 2 of the electronic throttle position sensor
harness connector EN18 and terminal 51 of the
ECM harness connector EN01.
D Measure the resistance of circuit between
Throttle position sensor terminal 3 of the electronic throttle position sensor
signal 1
harness connector EN18 and terminal 8 of the
ECM harness connector EN01.
E Measure the resistance of circuit between
terminal 6 of the electronic throttle position sensor
ECM harness connector harness connector EN18 and terminal 24 of the
ECM harness connector EN01.
Throttle position sensor Throttle position sensor
power supply signal 1
Standard resistance: less than 1Ω
F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Throttle position sensor

ground

Step 4 Check the circuit between the electronic throttle position sensor 2 and the ECM.

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Maintenance Manual of 1.5GDI Engine 2-433Control system

Electronic throttle position sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the electronic throttle position
Throttle position sensorThrottle position sensor
ground power supply sensor harness connector EN18 and the ECM
harness connector EN01.
C Measure the resistance of circuit between
terminal 2 of the electronic throttle position sensor
harness connector EN18 and terminal 51 of the
ECM harness connector EN01.
D Measure the resistance of circuit between
Throttle position sensor terminal 3 of the electronic throttle position sensor
signal 2
harness connector EN18 and terminal 8 of the
ECM harness connector EN01.
E Measure the resistance of circuit between
terminal 5 of the electronic throttle position sensor
harness connector EN18 and terminal 41 of the
ECM harness connector
ECM harness connector EN01.
Throttle position sensor Standard resistance: less than 1Ω
power supply
F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Throttle position sensor Throttle position sensor

ground signal 2

Step 5 Check the circuit between the electronic throttle drive motor and the ECM.

Electronic throttle position sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Electronic throttle motor
B Disconnect the electronic throttle position
DCM sensor harness connector EN18 and the ECM
harness connector EN01.
C Measure the resistance of circuit between
terminal 1 of the electronic throttle position sensor
harness connector EN18 and terminal 2 of the
ECM harness connector EN01.
Electronic throttle motor D Measure the resistance of circuit between
DCP terminal 4 of the electronic throttle position sensor
harness connector EN18 and terminal 1 of the
ECM harness connector EN01.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

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Control system 2-434 Maintenance Manual of 1.5GDI Engine

ECM harness connector

Electronic throttle motor Electronic throttle motor

DCP DCM

Step 6 Check the intake system pipes.

A Set the ENGINE START/STOP button to “OFF”

position.
B Remove all intake system pipes and check if
any pipe is clogged or leaking.
Y Repair or replace related pipes.

Step 7 Replace the electronic throttle position sensor.

A Replace the electronic throttle position sensor.

B Verify if the fault is eliminated after the
electronic throttle position sensor is replaced.
Y The system is working normally.

Step 8 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 9 End.

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Maintenance Manual of 1.5GDI Engine 2-435Control system
2.8.6.49 DTC: P051300, P161000......
DTC Description
P063300 ECM Not Learn SecretKey
PEPS (or IMMO) Authentication Response
P051300
Incorrect
ECM Failure to Receive a PEPS (or IMMO)
P161000
Authentication Response
Last PEPS (or IMMO) Authentication Response
P161100
Busy
PEPS (or IMMO) Authentication Response Format
P161200
Invalid
P161300 PEPS (or IMMO) and Key Authentication Failed
1. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

Step 2 Perform the IMMO matching.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to the
“ON” position, and go to the main interface of the
diagnostic scan tool.
C Follow the prompts on the screen of the
diagnostic scan tool to perform the IMMO
matching.
D Clear the DTC.
E Read the DTC again.
F Check whether the same DTC appears.
N The system is working normally.

Step 3 Replace the IMMO key.

A Replace the IMMO key and match the new one.

GAC Motor 2019
Control system 2-436 Maintenance Manual of 1.5GDI Engine

B Verify if the fault is eliminated after the IMMO

key is replaced.
Y The system is working normally.

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Maintenance Manual of 1.5GDI Engine 2-437Control system

Step 4 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 5 End.
2.8.6.50 DTC: P051C00, P051D00......
DTC Description
Crankcase Vent Pipe Pressure Sensor Circuit
P051C00
Voltage Low
Crankcase Vent Pipe Pressure Sensor Circuit
P051D00
Voltage High
Crankcase Vent Pipe Pressure Sensor Zero
P051E00
Voltage Deviation
Crankcase Vent Pipe Pressure Sensor Pressure
P12C000
above Upper Limit
Crankcase Vent Pipe Pressure Sensor Pressure
P12C100
below Lower Limit

1. Circuit diagram

GAC Motor 2019

Control system 2-438 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

Oil
pump
soleno
id
valve

ECM

Canister Fuel tank PCV

desorption evaporatin pipeline
pressure g pressure
sensor pressure sensor
sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

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Maintenance Manual of 1.5GDI Engine 2-439Control system

Step 2 Check if the circuit between the PCV pipe pressure sensor and the ECM is open.

PCV pipe pressure sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Signal
B Disconnect the PCV pipe pressure sensor
harness connector EN48 and the ECM harness
connector FB46.
C Measure the resistance of the circuit between
terminal 1 of the PCV pipe pressure sensor
harness connector EN48 and terminal 58 of the
ECM harness connector FB46.
D Measure the resistance of the circuit between
Ground Power
terminal 2 of the PCV pipe pressure sensor
harness connector EN48 and terminal 53 of the
ECM harness connector FB46.
E Measure the resistance of the circuit between
terminal 3 of the PCV pipe pressure sensor
harness connector EN48 and terminal 43 of the
ECM harness connector ECM harness connector FB46.
PCV pipeline pressure PCV pipeline pressure Standard resistance: less than 1Ω
sensor signal sensor 5V power supply F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

PCV pipeline pressure

sensor ground

Step 3 Check if the control circuit of PCV pipe pressure sensor is shorted to ground.

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Control system 2-440 Maintenance Manual of 1.5GDI Engine

PCV pipe pressure sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the PCV pipe pressure sensor
Signal
harness connector EN48 and the ECM harness
connector FB46.
C Measure the resistance of the circuit between
terminal 1 of the PCV pipe pressure sensor
harness connector EN48 and the body ground.
D Measure the resistance of the circuit between
terminal 2 of the PCV pipe pressure sensor
Ground Power
harness connector EN48 and the body ground.
E Measure the resistance of the circuit between
terminal 3 of the PCV pipe pressure sensor
harness connector EN48 and the body ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check if the control circuit of PCV pipe pressure sensor is shorted to power supply.

A Set the ENGINE START/STOP button to “OFF”

PCV pipe pressure sensor harness connector
position.
B Disconnect the PCV pipe pressure sensor
Signal
harness connector EN48 and the ECM harness
connector FB46.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of the circuit between
terminal 1 of the PCV pipe pressure sensor
harness connector EN48 and the body ground.
Ground Power
E Measure the voltage of the circuit between
terminal 2 of the PCV pipe pressure sensor
harness connector EN48 and the body ground.
F Measure the voltage of the circuit between
terminal 3 of the PCV pipe pressure sensor
harness connector EN48 and the body ground.
Standard voltage: 0V
G Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Replace the PCV pipe pressure sensor.

A Replace the PCV pipe pressure sensor.

GAC Motor 2019
Maintenance Manual of 1.5GDI Engine 2-441Control system
B Verify if the fault is eliminated after the
PCV pipe pressure sensor is replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

A Replace the ECM.

GAC Motor 2019

Control system 2-442 Maintenance Manual of 1.5GDI Engine

B Verify if the fault is eliminated after the ECM is

replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.51 DTC: P055700, P055800
DTC Description
P055700 Brake Chamber Vacuum Sensor Voltage Low
P055800 Brake Chamber Vacuum Sensor Voltage High
1. Circuit diagram

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Clock
spring

Accelerator
pedal
position
sensor
Vacuum sensor Cruise control switch

2. Diagnostic procedure

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Maintenance Manual of 1.5GDI Engine 2-443Control system

Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

Step 2 Check if the circuit between the vacuum sensor and the ECM is open.

Vacuum sensor harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Vacuum sensor B Disconnect the vacuum sensor harness
signal connector FB19 and the ECM harness connector
FB46.
C Measure the resistance of the circuit between
terminal 1 of the vacuum sensor harness
connector FB19 and terminal 84 of the ECM
harness connector FB46.
D Measure the resistance of the circuit between
Vacuum sensor 5V Vacuum sensor terminal 2 of the vacuum sensor harness
power supply grounding
connector FB19 and terminal 88 of the ECM
harness connector FB46.
E Measure the resistance of the circuit between
terminal 3 of the vacuum sensor harness
connector FB19 and terminal 90 of the ECM
ECM harness connector
harness connector FB46.
Vacuum sensor 5V
Standard resistance: less than 1Ω
power supply F Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

Vacuum sensor Sensor

signal ground

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Control system 2-444 Maintenance Manual of 1.5GDI Engine

Step 3 Check if the vacuum sensor control circuit is shorted to ground.

Vacuum sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Vacuum sensor B Disconnect the vacuum sensor harness
signal connector FB19 and the ECM harness connector
FB46.
C Measure the resistance of the circuit between
terminal 1 of the vacuum sensor harness
connector FB19 and the body ground.
D Measure the resistance of the circuit between
terminal 2 of the vacuum sensor harness
Vacuum sensor 5V Vacuum sensor connector FB19 and the body ground.
power supply grounding
E Measure the resistance of the circuit between
terminal 3 of the vacuum sensor harness
connector FB19 and the body ground.
Standard resistance: 10kΩ or higher
F Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check if the control circuit of the vacuum sensor is shorted to power supply.

Vacuum sensor harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Vacuum sensor B Disconnect the vacuum sensor harness
signal connector FB19 and the ECM harness connector
FB46.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of the circuit between
terminal 1 of the vacuum sensor harness
connector FB19 and the body ground.
Vacuum sensor 5V Vacuum sensor
power supply grounding E Measure the voltage of the circuit between
terminal 2 of the vacuum sensor harness
connector FB19 and the body ground.
F Measure the voltage of the circuit between
terminal 3 of the vacuum sensor harness
connector FB19 and the body ground.
Standard voltage: 0V
G Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

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Maintenance Manual of 1.5GDI Engine 2-445Control system

Step 5 Replace the vacuum sensor.

A Replace the vacuum sensor.

B Verify if the fault is eliminated after the vacuum
sensor is replaced.
Y The system is working normally.

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Control system 2-446 Maintenance Manual of 1.5GDI Engine

Step 6 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.52 DTC: P056000, P056200......
DTC Description
P056000 Battery Voltage Implausible
P056200 Low Battery Voltage
P056300 Battery Voltage High

1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-447Control system

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Refer to P-CAN
system circuit
diagram

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

Step 2 Check the battery.

GAC Motor 2019

Control system 2-448 Maintenance Manual of 1.5GDI Engine

A Measure the battery voltage.

Standard voltage: 11~14V
B Verify if the voltage is consistent with the
standard value.
N Charge the battery or check the charging
system.

Step 3 Check the ECM fuses EF25, EF32 and IF30.

A Check if the fuses IF25, IF32 and IF30 are

blown.
N Go to step 5.

Step 4 Check and repair the circuits of the fuses EF25, EF32 and IF30.

A Check if the circuits of the fuses IF25, IF32 and

EF30 are short.
B Repair the circuit and check that there is no
short circuit.
C Replace the fuse with one with rated current.
Amperage rating of fuse: EF25: 7.5A, EF32: 15A,
IF30: 7.5A
D Verify if the ECM works normally.
Y The system is working normally.

Step 5 Check the power circuit of the ECM.

A Set the ENGINE START/STOP button to “OFF”

ECM harness connector
position.
IG1 power Power Power B Disconnect the ECM harness connector FB46.
supply supply supply
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of the circuit between
terminals 14, 71 of the ECM harness connector
FB46 and the body ground.
E Measure the voltage of the circuit between
Power
supply
terminals 1, 2, 4 of the ECM harness connector
Power FB46 and the body ground.
supply
Standard voltage: 11~14V
F Verify if the voltage is consistent with the
standard value.
N Repair or replace the harness.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-449Control system

Step 6 Check the ground circuit of the ECM.

GAC Motor 2019

Control system 2-450 Maintenance Manual of 1.5GDI Engine

ECM harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Ground
B Disconnect the ECM harness connector FB46.
C Measure the resistance of the circuit between
terminals 3, 5, 6 of the ECM harness connector
FB46 and body ground.
Standard resistance: less than 1Ω
D Verify if the resistance is consistent with the
standard value.
Ground Ground N Repair or replace the harness.

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 8 End.
2.8.6.53 DTC: P057100
DTC Description
P057100 Asynchronous Brake Signal

1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-451Control system

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

Nor Nor Brake

mall mall
y on y off switch

ECM

Left instrument panel switch

block
(ENGINE START/STOP button)

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
N any intermittent fault.

Step 2 Check whether the brake switch is installed correctly.

GAC Motor 2019

Control system 2-452 Maintenance Manual of 1.5GDI Engine

A Check whether the brake switch is installed in

correct position.
N Reinstall the brake switch.

Step 3 Check the brake switch.

A Set the ENGINE START/STOP button to “OFF”

Brake
switch position.
B Disconnect the brake switch harness connector
FB24.
C Depress the brake pedal, and check the
continuity of the internal circuit between terminals
3 and 4 of the brake switch component.
D Release the brake pedal, and check the
continuity of the internal circuit between terminals
1 and 2 of the brake switch component.
N Replace the brake switch.

Step 4 Check the circuit between the brake switch and the ECM.

A Set the ENGINE START/STOP button to “OFF”

Brake switch harness connector
position.
Brake switch N/O
signal
B Disconnect the brake switch harness connector
FB24 and the ECM harness connector FB46.
C Measure the resistance of circuit between
terminal 1 of the brake switch harness connector
FB24 and terminal 82 of the ECM harness
connector FB46.
D Measure the resistance of circuit between
terminal 4 of the brake switch harness connector
Brake switch N/C FB24 and terminal 77 of the ECM harness
signal
connector FB46.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
N connector.

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Maintenance Manual of 1.5GDI Engine 2-453Control system

ECM harness connector

Brake switch N/C

signal

Sensor 5V power
supply

Step 5 Check the power and ground circuits of the brake switch.

A Check whether the power and ground circuits of

the brake switch are normal.
N Repair or replace the harness.

Step 6 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.54 DTC: P057500, P057800......
DTC Description
P057500 ACC input voltage signal implausible
P057800 Cruise control button stuck
P058500 ACC AD conversion failure

1. Circuit diagram

GAC Motor 2019

Control system 2-454 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Clock
spring

Accelerator
pedal
position
sensor
Vacuum sensor Cruise control switch

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault. Check whether there is
Y any intermittent fault.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-455Control system

Step 2 Check whether the circuit between the cruise control switch and the ECM is open.

Clock spring harness connector

A Set the ENGINE START/STOP button to “OFF”
position.
Cruise control switch B Disconnect the clock spring harness connector
+ IP10 and the ECM harness connector FB46.
C Measure the resistance of circuit between
terminal 7 of the clock spring harness connector
IP10 and terminal 90 of the ECM harness
connector FB46.
D Measure the resistance of circuit between
terminal 8 of the clock spring harness connector
Cruise control switch -
IP10 and terminal 89 of the ECM harness
connector FB46.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
the standard value.
ECM harness connector Replace or repair the harness or
connector.
N
Cruise control signal

Sensor ground

Step 3 Check whether the control circuit of cruise control switch is shorted to the ground.

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Control system 2-456 Maintenance Manual of 1.5GDI Engine

Clock spring harness connector

Cruise control switch
+ IP10 and the ECM harness connector FB46.
Cruise control switch -
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the clock spring harness connector
C Measure the resistance of circuit between
terminal 7 of the clock spring harness connector
IP10 and the body ground.
D Measure the resistance of circuit between
terminal 8 of the clock spring harness connector
IP10 and the body ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check whether the control circuit of cruise control switch is shorted to the power supply.

Clock spring harness connector A Set the ENGINE START/STOP button to “OFF”
position.
Cruise control switch B Disconnect the clock spring harness connector
+
IP10 and the ECM harness connector FB46.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of circuit between terminal
7 of the clock spring harness connector IP10 and
the body ground.
Cruise control switch - E Measure the voltage of circuit between terminal
8 of the clock spring harness connector IP10 and
the body ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Replace the cruise control switch.

A Replace the cruise control switch.

B Verify if the fault is eliminated after the cruise
control switch is replaced.
Y The system is working normally.

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Maintenance Manual of 1.5GDI Engine 2-457Control system

Step 6 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

GAC Motor 2019

Control system 2-458 Maintenance Manual of 1.5GDI Engine

Next step

Step 7 End.
2.8.6.55 DTC: P05BD00
DTC Description
P05BD00 ENGINE START/STOP Button Stuck

1. Circuit diagram

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

Nor Nor Brake

mall mall
y on y off switch

ECM

Left instrument panel

switch block
(ENGINE
START/STOP button)

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to “ON”
position, read the DTC and record it.

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Maintenance Manual of 1.5GDI Engine 2-459Control system

C Clear the DTC.

D Start the engine, idle it for about 5 minutes, and
carry out the related triggering test by simulating
the fault symptom; if the engine cannot be started,
do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
The DTC may be triggered by an
intermittent fault.
Check whether there is any intermittent
N
fault.

Step 2 Check whether the circuit between the ENGINE START/STOP button (left instrument panel
switch block) and the ECM is open.

Left instrument panel switch block

A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the ENGINE START/STOP button
ENGINE (left instrument panel switch block) harness
START/STOP button connector IP18 and the ECM harness connector
FB46.
C Measure the resistance of the circuit between
terminal 6 of the ENGINE START/STOP button
(left instrument panel switch block) harness
connector IP18 and terminal 26 of the ECM
harness connector FB46.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
Replace or repair the harness or
connector.
ECM N

ENGINE START/STOP button

signal

Step 3 Check whether the control circuit of the ENGINE START/STOP button (left instrument panel
switch block) is shorted to the ground.

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Control system 2-460 Maintenance Manual of 1.5GDI Engine

ECM A Set the ENGINE START/STOP button to “OFF”

position.
B Disconnect the ENGINE START/STOP button
ENGINE START/STOP
button signal (left instrument panel switch block) harness
connector IP18 and the ECM harness connector
FB46.
C Measure the resistance of the circuit between
terminal 26 of the ECM harness connector FB46
and the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 4 Check whether the control circuit of the ENGINE START/STOP button (left instrument panel
switch block) is shorted to the power supply.

ECM
A Set the ENGINE START/STOP button to “OFF”
position.
B Disconnect the ENGINE START/STOP button
ENGINE START/STOP
button signal (left instrument panel switch block) harness
connector IP18 and the ECM harness connector
FB46.
C Set the ENGINE START/STOP button to “ON”
position.
D Measure the voltage of the circuit between
terminal 26 of the ECM harness connector FB46
and the body ground.
Standard voltage: 0V
E Verify if the voltage is consistent with the
standard value.
Replace or repair the harness or
N connector.

Step 5 Replace the ENGINE START/STOP button (left instrument panel switch block).

A Replace the ENGINE START/STOP button (left

instrument panel switch block).
B Verify if the fault is eliminated after the ENGINE
START/STOP button (left instrument panel switch
block) is replaced.
Y The system is working normally.

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Maintenance Manual of 1.5GDI Engine 2-461Control system

Step 6 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM is
replaced.
Y The system is working normally.

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Control system 2-462 Maintenance Manual of 1.5GDI Engine

Next step

Step 7 End.
2.8.6.56 DTC: P060D00, P061A00......
DTC Description
P060D00 2nd Layer Accelerator Pedal Signal Implausible
P061A00 2nd Layer Torque Monitoring Fault
P061C00 2nd Layer Engine Speed Monitoring Fault
P062F42 EEPROM Reading Failure
P062F43 EEPROM Writing Failure
P063442 Chip Power Supply Channel 1 Overtemperature
P063443 Chip Power Supply Channel 2 Overtemperature
P064100 Chip 5V Power Supply Voltage 1 Failure
P065100 Chip 5V Power Supply Voltage 2 Failure
P065900 Chip 6V Power Supply Voltage Failure
P152000 Load Forecasting Monitoring Fault
Fuel Passage Monitoring Fault in Fuel Cutoff
P152100
Mode
Fuel Passage Monitoring Fault in Fuel Supply
P152200
Mode
P152300 Gas Mixture Monitoring Fault
P152400 Working Mode Monitoring Fault
P152500 Load Comparison Monitoring Fault
P152600 Ignition Angle Signal, Harness or ECU Failure
P152700 1st Layer Safe Fuel Cutoff Monitoring Fault
P152800 2nd Layer Safe Fuel Cutoff Monitoring Fault
P152900 Starter Control Monitoring Fault
P153000 AD Converter Zero Test Monitoring Fault
P153100 AD Converter Set Voltage Test Monitoring Fault
Electronic Throttle Safety Monitoring Torque
P154000
Limited
P157000 Monitoring Module Feedback Fault
P157300 Monitoring Fault Response Fault
P157500 DVE Drive Cutoff Due To Overvoltage
P157600 ECU Fault (5V Overvoltage Monitoring Failure)
P157700 ECU Fault (5V Undervoltage Monitoring Failure)
P157800 Monitoring Module Inquiry Fault
P261000 Engine off Timer Implausible
Multiple Injection Monitoring Faults during
P05EC00
Catalytic Converter Heating
1. Circuit diagram

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Maintenance Manual of 1.5GDI Engine 2-463Control system

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Refer to P-CAN
system circuit
diagram

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the power and ground wires of the ECM.

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Control system 2-464 Maintenance Manual of 1.5GDI Engine

A Check whether the power and ground wires

of ECM are normal.
N Repair or replace the harness.

Step 3 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 4 End.
2.8.6.57 DTC: P061500, P061600......
Diagnostic trouble code (DTC) Description
P061500 Starter Relay Control Circuit Fault
P061600 Starter Relay Control Circuit Voltage Low
P061700 Starter Relay Control Circuit Voltage High
1. Circuit diagram

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Maintenance Manual of 1.5GDI Engine 2-465Control system

PFB

IG2 relay (Main relay)

Engine
compart Engine
Starter ment Starter compart
relay 1 PDU relay 2 ment
PDU

TCM ECM DCDC

converte
r
ECM

Starter

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the terminals of ECM and engine compartment PDU harness connector.

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Control system 2-466 Maintenance Manual of 1.5GDI Engine

A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM, the starter relay and the
engine compartment PDU harness connectors.
C Check whether the terminals in the harness
connectors are damaged, bent, withdrawn or
corroded.
Y Repair the harness or connector.

Step 3 Check the starter relay.

A Set the ENGINE START/STOP button to

“OFF” position.
B Remove the starter relay ER15.
C Connect one end of the coil of the starter
relay to the positive battery terminal, and connect
the other end to the ground. Then check the
continuity between the two ends of the relay switch
Fuse
contact.
N Replace the starter relay.

Step 4 Check whether the control circuit of starter relay is open.

FB46 ECM harness connector

A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Remove the starter relay ER15.
D Measure the resistance between terminal 70
of the ECM harness connector FB46 and terminal
1 of the starter relay ER15.
Standard resistance: less than 1Ω
Starter relay 1 control
E Verify if the resistance is consistent with the
signal standard value.
N Replace or repair the harness or
connector.
Y

Step 5 Check whether the control circuit of starter relay is shorted to the ground.

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Maintenance Manual of 1.5GDI Engine 2-467Control system

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Remove the starter relay ER15.
D Measure the resistance between terminal 70
of the ECM harness connector FB46 and the body
ground.
Standard resistance: 10kΩ or higher
Starter relay 1 control E Verify if the resistance is consistent with the
signal standard value.
N Replace or repair the harness or
connector.
Y

Step 6 Check whether the control circuit of starter relay is shorted to the power supply.

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Remove the starter relay ER15.
D Set the ENGINE START/STOP button to “ON”
position.
E Measure the voltage between terminal 70 of
the ECM harness connector FB46 and the body
ground.
Starter relay 1 control
signal Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 8 End.
2.8.6.58 DTC: P062700, P062800......
Diagnostic trouble code (DTC) Description
P062700 Fuel Pump Enabling Control Circuit Open

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Control system 2-468 Maintenance Manual of 1.5GDI Engine

P062800 Fuel Pump Enabling Control Circuit Voltage Low

P062900 Fuel Pump Enabling Control Circuit Voltage High
1. Circuit diagram

(Main relay)

Engine
compart
Fuel pump ment
relay PDU

Fuel level sensor

Fuel pump

ECM

Instrume
nt cluster

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.

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Maintenance Manual of 1.5GDI Engine 2-469Control system

N The DTC may be triggered by an

intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the terminals of ECM and engine compartment PDU harness connector.

A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM, fuel pump relay and
engine compartment PDU harness connectors.
C Check whether the terminals in the harness
connectors are damaged, bent, withdrawn or
corroded.
Y Repair the harness or connector.

Step 3 Check the fuel pump relay.

A Set the ENGINE START/STOP button to

“OFF” position.
B Remove the fuel pump relay ER03.
C Connect one end of the coil of the fuel pump
relay to the positive battery terminal, and connect
the other end to the ground. Then check the
continuity between the two ends of the relay switch
Fuse
contact.
N Replace the fuel pump relay.

Step 4 Check whether the control circuit of fuel pump relay is open.

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Control system 2-470 Maintenance Manual of 1.5GDI Engine

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Remove the fuel pump relay ER03.
D Measure the resistance between terminal 86
of the ECM harness connector FB46 and terminal
1 of the fuel pump relay ER03.
Standard resistance: less than 1Ω
Fuel pump relay control
E Verify if the resistance is consistent with the
signal standard value.
N Replace or repair the harness or
connector.
Y

Step 5 Check whether the control circuit of fuel pump relay is shorted to the ground.

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Remove the fuel pump relay ER03.
D Measure the resistance between terminal 86
of the ECM harness connector FB46 and the body
ground.
Standard resistance: 10kΩ or higher
Fuel pump relay control E Verify if the resistance is consistent with the
signal standard value.
N Replace or repair the harness or
connector.
Y

Step 6 Check whether the control circuit of fuel pump relay is shorted to the power supply.

FB46 ECM harness connector

A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Remove the fuel pump relay ER03.
D Set the ENGINE START/STOP button to “ON”
position.
E Measure the voltage between terminal 86 of
the ECM harness connector FB46 and the body
ground.
Fuel pump relay control
signal Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
N Replace or repair the harness or
connector.

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Maintenance Manual of 1.5GDI Engine 2-471Control system

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 8 End.
2.8.6.59 DTC: P064500, P064600......
Diagnostic trouble code (DTC) Description
P064500 A/C Compressor Relay Control Circuit Open
P064600 A/C Compressor Relay Control Circuit Voltage Low
A/C Compressor Relay Control Circuit Voltage
P064700
High
1. Circuit diagram

GAC Motor 2019

Control system 2-472 Maintenance Manual of 1.5GDI Engine

(Main relay)

Compressor
relay

Electro Sol Compre

magne eno ssor
tic id
clutch valv
e

ECM HVAC control unit

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the terminals of ECM and engine compartment PDU harness connector.

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Maintenance Manual of 1.5GDI Engine 2-473Control system

A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM, compressor relay and
engine compartment PDU harness connectors.
C Check whether the terminals in the harness
connectors are damaged, bent, withdrawn or
corroded.
Y Repair the harness or connector.

Step 3 Check the compressor relay.

A Set the ENGINE START/STOP button to

“OFF” position.
B Remove the compressor relay ER13.
C Connect one end of the coil of the
compressor relay to the positive battery terminal,
and connect the other end to the ground. Then
Fuse
check the continuity between the two ends of the
relay switch contact.
N Replace the compressor relay.

Step 4 Check whether the control circuit of compressor relay is open.

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
Compressor relay
control signal
FB46.
C Remove the compressor relay ER13.
D Measure the resistance between terminal 51
of the ECM harness connector FB46 and terminal
1 of the compressor relay ER13.
Standard resistance: less than 1Ω
E Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 5 Check whether the control circuit of compressor relay is shorted to the ground.

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Control system 2-474 Maintenance Manual of 1.5GDI Engine

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
Compressor relay
control signal
FB46.
C Remove the compressor relay ER13.
D Measure the resistance between terminal 51
of the ECM harness connector FB46 and the body
ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 6 Check whether the control circuit of compressor relay is shorted to the power supply.

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
Compressor relay
control signal FB46.
C Remove the compressor relay ER13.
D Set the ENGINE START/STOP button to “ON”
position.
E Measure the voltage between terminal 51 of
the ECM harness connector FB46 and the body
ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 8 End.
2.8.6.60 DTC: P068600, P069000......
Diagnostic trouble code (DTC) Description
P068600 ECM/PCM Main Relay Stuck or Shorted to Ground

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Maintenance Manual of 1.5GDI Engine 2-475Control system

P069000 ECM/PCM Main Relay Voltage High

P06AA00 Main Relay Temperature High
1. Circuit diagram

Engine
Instrume
compart
nt panel
ment
Main relay PDU
PDU

ECM

Refer to P-CAN
system circuit
diagram

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.

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Control system 2-476 Maintenance Manual of 1.5GDI Engine

N The DTC may be triggered by an

intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the terminals of ECM and engine compartment PDU harness connector.

A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM, main relay and engine
compartment PDU harness connectors.
C Check whether the terminals in the harness
connectors are damaged, bent, withdrawn or
corroded.
Y Repair the harness or connector.

Step 3 Check the main relay.

A Set the ENGINE START/STOP button to

“OFF” position.
B Remove the main relay ER12.
C Connect one end of the coil of the main relay
to the positive battery terminal, and connect the
other end to the ground. Then check the continuity
between the two ends of the relay switch contact.
Fuse
N Replace the main relay.

Step 4 Check whether the control circuit of main relay is open.

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Maintenance Manual of 1.5GDI Engine 2-477Control system

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
Main relay control signal B Disconnect the ECM harness connector
FB46.
C Remove the main relay ER12.
D Measure the resistance between terminal 32
of the ECM harness connector FB46 and terminal
2 of main relay ER12
.
Standard resistance: less than 1Ω
E Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 5 Check whether the control circuit of main relay is shorted to the ground.

FB46 ECM harness connector A Set the ENGINE START/STOP button to

Main relay control signal
“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Remove the main relay ER12.
D Measure the resistance between terminal 32
of the ECM harness connector FB46 and the body
ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.

Step 6 Check whether the control circuit of main relay is shorted to the power supply.

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
Main relay control signal B Disconnect the ECM harness connector
FB46.
C Remove the main relay ER12.
D Set the ENGINE START/STOP button to “ON”
position.
E Measure the voltage between terminal 32 of
the ECM harness connector FB46 and the body
ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
N Replace or repair the harness or
connector.
GAC Motor 2019
Control system 2-478 Maintenance Manual of 1.5GDI Engine

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 8 End.
2.8.6.61 DTC: P06DA00, P06DB00......
Diagnostic trouble code (DTC) Description
P06DA00 Two-stage Oil Pump Control Circuit Open
P06DB00 Two-stage Oil Pump Control Circuit Voltage Low
P06DC00 Two-stage Oil Pump Control Circuit Voltage High
1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-479Control system

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

Oil pump
solenoid
valve

ECM

Canister Fuel tank PCV

desorption evaporatin pipeline
pressure g pressure pressure
sensor sensor sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes,
and carry out the related triggering test by
simulating the fault symptom; if the engine cannot
be started, do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.

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Control system 2-480 Maintenance Manual of 1.5GDI Engine

Step 2 Check the oil pump solenoid valve.

Oil pump solenoid valve A Set the ENGINE START/STOP button to

“OFF” position.
B Remove the oil pump solenoid valve.
C Measure whether the resistance across the oil
pump solenoid valve is normal.
Standard resistance: 17±1.7Ω (@20°C)
N Replace the oil pump solenoid
valve.

Step 3 Check the oil pump solenoid valve fuse EF30.

A Check whether the fuse EF30 is blown.

N Go to step 5.

Step 4 Check and repair the fuse EF30 circuit.

A Check whether the fuse EF30 circuit is

shorted.
B Repair the circuit and check that there is no
short circuit.
C Replace the fuse with one with rated current.
The fuse EF30 is rated at 10A.
D Check whether the oil pump solenoid valve
works normally.
Y The system is working normally.

Step 5 Check the power circuit of the oil pump solenoid valve.

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Maintenance Manual of 1.5GDI Engine 2-481Control system

EN47 oil pump solenoid valve harness connector A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the oil pump solenoid valve
Power supply of oil harness connector EN47.
pump solenoid valve
C Set the ENGINE START/STOP button to
“ON” position.
D Measure the voltage of circuit between
terminal 2 of the oil pump solenoid valve harness
connector EN47 and the body ground.
Standard voltage: 11~14V
E Verify if the voltage is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 6 Check whether the circuit between the oil pump solenoid valve and the ECM is open.

EN47 oil pump solenoid valve harness connector A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the oil pump solenoid valve
Grounding of oil pump harness connector EN47 and the ECM harness
solenoid valve connector EN01.
C Measure the resistance of circuit between
terminal 1 of the oil pump solenoid valve harness
connector EN47 and terminal 16 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
D Verify if the measured value is consistent with
the standard value.
N Replace or repair the harness or
connector.
EN01 ECM harness connector

Grounding of oil pump

solenoid valve

Step 7 Check whether the control circuit of oil pump solenoid valve is shorted to the ground.

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Control system 2-482 Maintenance Manual of 1.5GDI Engine

EN47 oil pump solenoid valve harness connector A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the oil pump solenoid valve
Grounding of oil pump harness connector EN47 and the ECM harness
solenoid valve connector EN01.
C Measure the resistance of circuit between
terminal 1 of the oil pump solenoid valve harness
connector EN47 and the body ground.
Standard resistance: 10kΩ or higher
D Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 8 Check whether the control circuit of oil pump solenoid valve is shorted to the power supply.

EN47 oil pump solenoid valve harness connector A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the oil pump solenoid valve
Grounding of oil pump harness connector EN47 and the ECM harness
solenoid valve connector EN01.
C Set the ENGINE START/STOP button to
“ON” position.
D Measure the voltage of circuit between
terminal 1 of the oil pump solenoid valve harness
connector EN47 and the body ground.
Standard voltage: 0V
E Verify if the voltage is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 9 Replace the oil pump solenoid valve.

A Replace the oil pump solenoid valve.

B Verify if the fault is eliminated after the oil
pump solenoid valve is replaced.
Y The system is working normally.

Step 10 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

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Maintenance Manual of 1.5GDI Engine 2-483Control system

Next step

Step 11 End.
2.8.6.62 DTC: P070000
DTC Description
Transmission Control Fault and Request to Turn on
P070000
MIL
1. Circuit diagram

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

6AT TCM

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.

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Control system 2-484 Maintenance Manual of 1.5GDI Engine

C Clear the DTC.

D Start the engine, idle it for about 5 minutes,
and carry out the related triggering test by
simulating the fault symptom; if the engine cannot
be started, do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the DTC of automatic transmission system.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC of automatic
transmission system, and check whether there is a
relevant DTC in the automatic transmission
system.
Y Give priority to troubleshooting
of automatic transmission
system.
N

Step 3 Check the CAN data communication cable between the ECM and the TCM harness
connectors.

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Disconnect the TCM harness connector
EN37.
D Measure the resistance between terminal 56
of the ECM harness connector FB46 and terminal
11 of the TCM harness connector EN37.
E Measure the resistance between terminal 57
of ECM harness connector FB46 and terminal 3 of
TCM harness connector EN37.
Standard resistance: less than 1Ω
F Verify if the resistance is consistent with the
standard value.
N Repair or replace the harness.

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Maintenance Manual of 1.5GDI Engine 2-485Control system

EN37 TCM harness connector

Step 4 Check the power and ground circuits of TCM.

A Check whether the power and ground circuits

of TCM are normal.
N Repair or replace the harness.

Step 5 Replace the TCM.

A Replace the TCM.

B Verify if the fault is eliminated after the TCM is
replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 7 End.

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Control system 2-486 Maintenance Manual of 1.5GDI Engine

2.8.6.63 DTC: P0A9400, P141800......

DTC Description
P0A9400 DC/DC Voltage Regulator Unit State Abnormal
P141800 DC/DC LIN Message Readback Time Error
DC/DC LIN Message Receiving Response Time
P141900
Out of Limit
P141A00 DC/DC LIN Message Frame Error
P141B00 DC/DC LIN Message Check Error
P141C00 DC/DC LIN Message 2 Readback Time Error
DC/DC LIN Message 2 Receiving Response Time
P141D00
Out of Limit
P141E00 DC/DC LIN Message 2 Frame Error
P141F00 DC/DC LIN Message 2 Check Error
1. Circuit diagram

Instrume
nt panel
PDU

Junction
box 3

Power input 2 Power input 1

DCDC converter

ECM

2. Diagnostic procedure

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Maintenance Manual of 1.5GDI Engine 2-487Control system

Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the LIN communication cable between the DC-DC converter and the ECM.

IP37 DCDC converter A Set the ENGINE START/STOP button to

“OFF” position.
LIN B Disconnect the DC-DC converter harness
communication connector IP37.
C Disconnect the ECM harness connector
FB46.
D Measure the resistance of circuit between
terminal 5 of the DC-DC converter harness
connector IP37 and terminal 36 of the ECM
harness connector FB46.
Standard resistance: less than 1Ω
E Verify if the resistance is consistent with the
standard value.
N Repair or replace the harness.

FB46 ECM harness connector

LIN
communication

Step 3 Check the power and ground wires of the DC-DC converter.

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Control system 2-488 Maintenance Manual of 1.5GDI Engine

A Check whether the power and ground wires

of DC-DC converter are normal.
N Repair or replace the harness.

Step 4 Replace the DC-DC converter.

A Replace the DC-DC converter.

B Verify if the fault is eliminated after the
DC-DC converter is replaced.
Y The system is working normally.

Step 5 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 6 End.
2.8.6.64 DTC: P120200, P120300......
DTC Description
P120200 Ambient Pressure Sensor Pressure above Upper
Limit
P120300 Low Pressure of Ambient Pressure Sensor
P222722 Ambient Pressure Sensor Pressure Implausibly
High
P222721 Ambient Pressure Sensor Pressure Implausibly
Low
P222800 Ambient Pressure Sensor Shorted to Ground
P222900 Ambient Pressure Sensor Shorted to Power Supply
1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-489Control system

(Main relay)

Engine Instrume
compa nt panel
rtment PDU
PDU

ECM BCM

GWM

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes,
and carry out the related triggering test by
simulating the fault symptom; if the engine cannot
be started, do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.

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Control system 2-490 Maintenance Manual of 1.5GDI Engine

Step 2 Check the CAN data communication cable between the HVAC control unit and the GWM.

IP19 GWM harness connector

A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the GWM harness connector
IP19.
C Disconnect the HVAC control unit harness
connector IP27.
D Measure the resistance between terminal 10
of GWM harness connector IP19 and terminal 17
of HVAC control unit harness connector IP27.
E Measure the resistance between terminal 20
of GWM harness connector IP19 and terminal 18
of HVAC control unit harness connector IP27.
Standard resistance: less than 1Ω
F Verify if the resistance is consistent with the
standard value.
IP27 HVAC control unit N Repair or replace the harness.

Step 3 Check the CAN data communication cable between the ECM and the GWM harness
connectors.

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Maintenance Manual of 1.5GDI Engine 2-491Control system

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Disconnect the GWM harness connector
IP19.
D Measure the resistance between terminal 56
of the ECM harness connector FB46 and terminal
9 of the GWM harness connector IP19.
E Measure the resistance between terminal 57
of the ECM harness connector FB46 and terminal
19 of the GWM harness connector IP19.
Standard resistance: less than 1Ω
F Verify if the resistance is consistent with the
standard value.
IP19 GWM harness connector N Repair or replace the harness.

Step 4 Check the power and ground wires of the HVAC control unit.

A Check whether the power and ground wires

of the HVAC control unit are normal.
N Repair or replace the harness.

Step 5 Replace the HVAC control unit.

A Replace the HVAC control unit.

B Verify if the fault is eliminated after the HVAC
control unit is replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

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Control system 2-492 Maintenance Manual of 1.5GDI Engine

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.65 DTC: P140000, P140100......
DTC Description
Readback Error of LIN Bus for Communication
P140000
between EMS and EBS
Response Timeout of LIN Bus for Communication
P140100
between EMS and EBS
Frame Error of LIN Bus for Communication
P140200
between EMS and EBS
Checksum Error of LIN Bus for Communication
P140300
between EMS and EBS
P143000 Battery Type Changed
P143100 EBS or Battery Fault
P143200 EBS Communication Load Rate High
1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-493Control system

(Main relay)

Engine Instrume
compa nt panel
rtment PDU
PDU

ECM

Alternator EBS OBD DLC

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the EBS type.

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Control system 2-494 Maintenance Manual of 1.5GDI Engine

A Check whether the EBS is wrong type or the

matching program is not executed after
replacement of EBS.
Y Replace the EBS of the correct
type or execute the EBS
matching program.
N

Step 3 Check the LIN communication cable between the EBS and the ECM.

EN02 EBS harness connector

EBS LIN communication
A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the EBS harness connector
EN02.
C Disconnect the ECM harness connector
FB46.
D Measure the resistance between terminal 2 of
the EBS harness connector EN02 and terminal 36
of the ECM harness connector FB46.
Standard resistance: less than 1Ω
E Verify if the resistance is consistent with the
standard value.
N Repair or replace the harness.

FB46 ECM harness connector

LIN communication

Step 4 Check the power and ground wires of the EBS.

A Check whether the power and ground wires

of the EBS are normal.
N Repair or replace the harness.

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Maintenance Manual of 1.5GDI Engine 2-495Control system

Step 5 Replace the EBS.

A Replace the EBS.

B Verify if the fault is eliminated after the EBS is
replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.66 DTC: P141400, P141500......
DTC Description
Readback Error of LIN Bus for Communication
P141400
between EMS and Intelligent Alternator
Response Timeout of LIN Bus for Communication
P141500
between EMS and Intelligent Alternator
Frame Error of LIN Bus for Communication
P141600
between EMS and Intelligent Alternator
Checksum Error of LIN Bus for Communication
P141700
between EMS and Intelligent Alternator
P144000 Intelligent Alternator Circuit Fault
P144100 Intelligent Alternator Mechanical Fault
P144200 Intelligent Alternator Communication Fault
1. Circuit diagram

GAC Motor 2019

Control system 2-496 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrume
compa nt panel
rtment PDU
PDU

ECM

Alternator EBS OBD DLC

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the LIN communication cable between the alternator and the ECM.

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Maintenance Manual of 1.5GDI Engine 2-497Control system

EN28 alternator harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the alternator harness connector
Alternator LIN EN28.
communication
C Disconnect the ECM harness connector
FB46.
D Measure the resistance between terminal 2 of
the alternator harness connector EN28 and
terminal 36 of the ECM harness connector FB46.
Standard resistance: less than 1Ω
E Verify if the resistance is consistent with the
standard value.
N Repair or replace the harness.

FB46 ECM harness connector

LIN communication

Step 3 Check the power and ground wires of the alternator.

A Check whether the power and ground wires

of alternator are normal.
N Repair or replace the harness.

Step 4 Replace the alternator.

A Replace the alternator.

B Verify if the fault is eliminated after the
alternator is replaced.
Y The system is working normally.

Step 5 Replace the the ECM.

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Control system 2-498 Maintenance Manual of 1.5GDI Engine

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 6 End.
2.8.6.67 DTC: P14AC00, P14AD00
Diagnostic trouble code (DTC) Description
P14AC00 Starter Damaged or Its Power Circuit Interrupted
Engine Stalling or Non-engagement between
P14AD00
Starter and Flywheel
1. Circuit diagram

PFB

IG2 relay (Main relay)

Engine
compart Engine
Starter ment Starter compart
relay 1 PDU relay 2 ment
PDU

TCM ECM DCDC

converte
r
ECM

Starter

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-499Control system
2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the circuit between the starter and the positive battery terminal.

A Set the ENGINE START/STOP button to

“OFF” position.
B Check whether the wire between the starter
and the positive battery terminal is open-circuited
or shorted.
Y Repair the harness or connector.

Step 3 Check the circuit between the starter and the starter relay.

A Set the ENGINE START/STOP button to

“OFF” position.
B Check whether the wire between the starter
and the starter relay is open-circuited or shorted.
Y Repair the harness or connector.

Step 4 Replace the starter.

A Replace the starter.

B Verify if the fault is eliminated after the starter
is replaced.
Y The system is working normally.

Step 5 Replace the the ECM.

A Replace the ECM.

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Control system 2-500 Maintenance Manual of 1.5GDI Engine

B Verify if the fault is eliminated after the ECM

is replaced.
Y The system is working normally.

Next step

Step 6 End.
2.8.6.68 DTC: P14AE00, P14AF00
Diagnostic trouble code (DTC) Description
Starter Feedback Voltage Signal Wire (KL50r)
P14AE00
Shorted to Power Supply
Starter Feedback Voltage Signal Wire (KL50r)
P14AF00
Shorted to Ground
1. Circuit diagram

PFB

IG2 relay (Main relay)

Engine
compart Engine
Starter ment Starter compart
relay 1 PDU relay 2 ment
PDU

TCM ECM DCDC

converte
r
ECM

Starter

2. Diagnostic procedure

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Maintenance Manual of 1.5GDI Engine 2-501Control system

Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the terminals of the ECM harness connector.

A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector.
C Check whether the terminals in the harness
connectors are damaged, bent, withdrawn or
corroded.
Y Repair the harness or connector.

Step 3 Check the engine starter relay.

A Set the ENGINE START/STOP button to

“OFF” position.
B Remove the engine starter relay ER15.
C Connect one end of the coil of the starter
relay to the positive battery terminal, and connect
the other end to the ground. Then check the
continuity between the two ends of the relay switch
Fuse
contact.
N Replace the starter relay of the
engine.

Step 4 Check whether the status feedback control circuit of the engine is open-circuited.

GAC Motor 2019

Control system 2-502 Maintenance Manual of 1.5GDI Engine

FB46 ECM harness connector

A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the ECM harness connector
Start feedback signal
FB46.
C Remove the starter relay ER15. of the
engine.
D Measure the resistance between terminal 31
of the ECM harness connector FB46 and slot 5 of
the starter relay ER15 of the engine.
Standard resistance: less than 1Ω
E Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 5 Check whether the status feedback control circuit of the engine is shorted to the ground.

FB46 ECM harness connector

A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the ECM harness connector
Start feedback signal
FB46.
C Remove the starter relay ER15. of the
engine.
D Measure the resistance between terminal 31
of the ECM harness connector FB46 and the body
ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 6 Check whether the status feedback control circuit of the engine is shorted to the power
supply.

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
Start feedback signal B Disconnect the ECM harness connector
FB46.
C Remove the starter relay ER15. of the
engine.
D Set the ENGINE START/STOP button to “ON”
position.
E Measure the voltage between terminal 31 of
the ECM harness connector FB46 and the body
ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
N Replace or repair the harness or
connector.

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Maintenance Manual of 1.5GDI Engine 2-503Control system

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 8 End.
2.8.6.69 DTC: P150000, P150100......
DTC Description
Collision and Fuel Cutoff Signal Received by
P150000
Vehicle
P150100 Airbag Communication Information Implausible
U015100 Lost Communication with SRS Module
1. Circuit diagram

(Main relay)

Engine Instrume
compa nt panel
rtment PDU
PDU

ECM

SRS ECU

GAC Motor 2019

Control system 2-504 Maintenance Manual of 1.5GDI Engine
2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the CAN data communication cable between the ECM and SRS ECU.

FB46 ECM harness connector

A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Disconnect the SRS ECU harness connector
BD05.
D Measure the resistance between terminal 56
of the ECM harness connector FB46 and terminal
12 of the SRS ECU harness connector BD05.
E Measure the resistance between terminal 57
of ECM harness connector FB46 and terminal 11
of SRS ECU harness connector BD05.
Standard resistance: less than 1Ω
F Verify if the resistance is consistent with the
standard value.
BD05 SRS ECU harness connector N Repair or replace the harness.

Step 3 Check the power and ground wires of SRS ECU.

A Check whether the power and ground wires

of the SRS ECU are normal.

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Maintenance Manual of 1.5GDI Engine 2-505Control system

N Repair or replace the harness.

Y

Step 4 Replace the SRS ECU.

A Replace the SRS ECU.

B Verify if the fault is eliminated after the SRS
ECU is replaced.
Y The system is working normally.

Step 5 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.
Next step

Step 6 End.
2.8.6.70 DTC: P155000, P155100......
DTC Description
P155000 Electronic Throttle Self-learning Condition Not Met
Electronic Throttle Lower Limit Position Initialized
P155100
Self-Learning Error
P155400 Return Spring Stuck in Maximum Position
P155500 Return Spring Stuck in Minimum Position
P155C00 Throttle Limp Position Self-learning Error
P155D00 Maximum PID Adjustment Fault of Throttle Body
P155E00 Minimum PID Adjustment Fault of Throttle Body
System Voltage in Nonconformity with
P155F00
Self-learning Condition of Electronic Throttle
P156100 DVE Position Control Offset
P156600 Throttle Mechanical BDC Re-self-learning Error
P210000 Electronic Throttle Drive Stage Fault (Open Circuit)
P210300 Electronic Throttle Drive Stage Fault (Short Circuit)
P210600 Electronic Throttle Drive Stage Fault (Implausible)
Electronic Throttle Drive Stage Fault (Overheat or
P211800
Overcurrent)

GAC Motor 2019

Control system 2-506 Maintenance Manual of 1.5GDI Engine

1. Circuit diagram

(Main relay)

Engine Instrument
compart panel PDU
ment
PDU

MAP / IAT
Temperat Pressure
ure sensor sensor sensor

ECM

Throttle Coolant Knock

position temperat sensor
sensor ure
sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes,
and carry out the related triggering test by
simulating the fault symptom; if the engine cannot
be started, do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.

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Maintenance Manual of 1.5GDI Engine 2-507Control system

Step 2 Execute the throttle self-learning program.

A After executing the throttle self-learning

program, read the DTC again and check whether
the same DTC appears.
N The system is working normally.

Step 3 Check the circuit between the electronic throttle position sensor 1 and the ECM.

EN18 electronic throttle position sensor harness connector A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the electronic throttle position
Throttle position sensor Throttle position sensor sensor harness connector EN18 and the ECM
ground power supply
harness connector EN01.
C Measure the resistance of circuit between
terminal 2 of the electronic throttle position sensor
harness connector EN18 and terminal 51 of the
ECM harness connector EN01.
D Measure the resistance of circuit between
Throttle position sensor terminal 3 of the electronic throttle position sensor
signal 1
harness connector EN18 and terminal 8 of the
ECM harness connector EN01.
E Measure the resistance of circuit between
terminal 6 of the electronic throttle position sensor
harness connector EN18 and terminal 24 of the
EN01 ECM harness connector ECM harness connector EN01.
Throttle position sensor Throttle position sensor Standard resistance: less than 1Ω
power supply signal 1 F Verify if the measured value is consistent with
the standard value.
N Replace or repair the harness or
connector.

Throttle position sensor

ground

Step 4 Check the circuit between the electronic throttle position sensor 2 and the ECM.

GAC Motor 2019

Control system 2-508 Maintenance Manual of 1.5GDI Engine

EN18 electronic throttle position sensor harness connector
Throttle position sensor Throttle position sensor
ground power supply
Throttle position sensor
signal 2
EN01 ECM harness connector
Throttle position sensor
power supply
A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the electronic throttle position
sensor harness connector EN18 and the ECM
harness connector EN01.
C Measure the resistance of circuit between
terminal 2 of the electronic throttle position sensor
harness connector EN18 and terminal 51 of the
ECM harness connector EN01.
D Measure the resistance of circuit between
terminal 3 of the electronic throttle position sensor
harness connector EN18 and terminal 8 of the
ECM harness connector EN01.
E Measure the resistance of circuit between
terminal 5 of the electronic throttle position sensor
harness connector EN18 and terminal 41 of the
ECM harness connector EN01.
Standard resistance: less than 1Ω
F Verify if the measured value is consistent with
the standard value.
N Replace or repair the harness or
connector.

Throttle position sensor Throttle position sensor

ground signal 2

Step 5 Check the circuit between the electronic throttle drive motor and the ECM.

EN18 electronic throttle position sensor harness connector
Electronic throttle motor
DCM
Electronic throttle motor
DCP
A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the electronic throttle position
sensor harness connector EN18 and the ECM
harness connector EN01.
C Measure the resistance of circuit between
terminal 1 of the electronic throttle position sensor
harness connector EN18 and terminal 2 of the
ECM harness connector EN01.
D Measure the resistance of circuit between
terminal 4 of the electronic throttle position sensor
harness connector EN18 and terminal 1 of the
ECM harness connector EN01.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
the standard value.
N Replace or repair the harness or
connector.

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Maintenance Manual of 1.5GDI Engine 2-509Control system

EN01 ECM harness connector

Electronic throttle motor Electronic throttle motor

DCP DCM

Step 6 Replace the electronic throttle position sensor.

A Replace the electronic throttle position

sensor.
B Verify if the fault is eliminated after the
electronic throttle position sensor is replaced.
Y The system is working normally.

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 8 End.
2.8.6.71 DTC: P161400
DTC Description
P161400 PIN input error
1. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.

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Control system 2-510 Maintenance Manual of 1.5GDI Engine

D Read the DTC again.

E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Execute the PIN input program.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, and enter the main interface of
diagnostic scan tool.
C Follow the prompts on the screen of the
diagnostic scan tool to execute the PIN input
program.
D Clear the DTC.
E Read the DTC again.
F Check whether the same DTC appears.
Y The system is working normally.

Step 3 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 4 End.
2.8.6.72 DTC: P217700, P217800......
DTC Description
Air/fuel Ratio Closed-loop Control Self-learning
P217700
Value Above Upper Limit (Medium Load Area)
Air/fuel Ratio Closed-loop Control Self-learning
P217800
Value Below Lower Limit (Medium Load Area)
Air/fuel Ratio Closed-loop Control Self-learning
P218700
Value Above Upper Limit (Idle Speed)
Air/fuel Ratio Closed-loop Control Self-learning
P218800
Value Below Lower Limit (Idle Speed)
Closed-loop Correction Value Based on
P209600 Downstream Oxygen Sensor Above Upper Limit -
Continuous Lean
Closed-loop Correction Value Based on
P209700 Downstream Oxygen Sensor Below Lower Limit -
Continuous Rich
1. Circuit diagram

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-511Control system

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Refer to P-CAN
system circuit
diagram

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes,
and carry out the related triggering test by
simulating the fault symptom; if the engine cannot
be started, do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.

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Control system 2-512 Maintenance Manual of 1.5GDI Engine

Step 2 Check the air cleaner.

A Check whether the air cleaner is blocked.

Y Replace the air cleaner
assembly.
N

Step 3 Check the intake system pipeline.

A Check whether there is any air leakage in the

intake system pipeline.
Y Repair the leaking pipeline.

Step 4 Check the spark plug.

A Set the ENGINE START/STOP button to

“OFF” position.
B Remove the spark plug, and check whether
the spark plug gap (a) is normal.
Standard value of spark plug gap: 0.7~0.8mm
C Verify if the spark plug gap (a) is consistent
with the standard value.
N Replace the spark plug.

Step 5 Check the ignition coil.

A Check whether the jump spark of ignition coil

is normal.
N Replace the ignition coil.

Step 6 Check the exhaust system pipeline.

A Check whether the exhaust system pipeline

leaks.

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Maintenance Manual of 1.5GDI Engine 2-513Control system

Y Repair the leaking pipeline.

N

Step 7 Check the fuel system pressure.

A Check whether the fuel system pressure is

normal.
N Check and repair the fuel
system.
Y

Step 8 Check the fuel injector.

A Set the ENGINE START/STOP button to

“OFF” position.
B Remove the fuel injector, connect it to the fuel
injector tester, and check whether the performance
of fuel injector is normal.
N Replace the fuel injector.

Step 9 Check the oxygen sensor.

A Check whether the oxygen sensor works

normally.
N Replace the oxygen sensor.

Step 10 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 11 End.
2.8.6.73 DTC: P227900
DTC Description
P227900 Intake System Leakage
1. Circuit diagram

GAC Motor 2019

Control system 2-514 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Refer to P-CAN
system circuit
diagram

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes,
and carry out the related triggering test by
simulating the fault symptom; if the engine cannot
be started, do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.

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Maintenance Manual of 1.5GDI Engine 2-515Control system

Step 2 Check the DTCs of engine system.

A Use the diagnostic scan tool to read the

DTCs of engine system, and check whether the
engine has DTCs of other sensors or actuators.
Y Give priority to other sensor or
actuator DTCs related faults.
N

Step 3 Check the intake system pipeline.

A Check whether there is any air leakage in the

intake system pipeline.
Y Repair the leaking pipeline.

Step 4 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 5 End.
2.8.6.74 DTC: P212200, P212300......
DTC Description
Electronic Accelerator Pedal Position Sensor 1
P212200
Signal Voltage Low
Electronic Accelerator Pedal Position Sensor 1
P212300
Signal Voltage High
Electronic Accelerator Pedal Position Sensor 2
P212700
Signal Voltage Low
Electronic Accelerator Pedal Position Sensor 2
P212800
Signal Voltage High
Electronic Accelerator Pedal Position Sensor
P213800
Signal Implausible
1. Circuit diagram

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Control system 2-516 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Clock spring

Accelerator
pedal
position
sensor
Vacuum sensor Cruise control switch

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check whether the circuit between the accelerator pedal position sensor 1 and the ECM is
open.

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Maintenance Manual of 1.5GDI Engine 2-517Control system

FB41 accelerator pedal position sensor harness connector A Set the ENGINE START/STOP button to
“OFF” position.
Accelerator pedal position B Disconnect the accelerator pedal position
sensor signal 1 sensor harness connector FB41 and the ECM
harness connector FB46.
C Measure the resistance of circuit between
terminal 3 of the accelerator pedal position sensor
harness connector FB41 and terminal 19 of the
ECM harness connector FB46.
Accelerator pedal position Accelerator pedal position
D Measure the resistance of circuit between
sensor 5V power supply 1 sensor ground 1 terminal 4 of the accelerator pedal position sensor
harness connector FB41 and terminal 18 of the
ECM harness connector FB46.
E Measure the resistance of circuit between
terminal 5 of the accelerator pedal position sensor
harness connector FB41 and terminal 21 of the
FB46 ECM harness connector
ECM harness connector FB46.
Standard resistance: less than 1Ω
Accelerator pedal position Accelerator pedal position F Verify if the measured value is consistent with
sensor signal 1 sensor 5V power supply 1
the standard value.
N Replace or repair the harness or
connector.

Accelerator pedal position

sensor ground 1

Step 3 Check whether the circuit between the accelerator pedal position sensor 2 and the ECM is
open.

FB41 accelerator pedal position sensor harness connector
Accelerator pedal position
sensor signal 2
Accelerator pedal position Accelerator pedal position
sensor 5V power supply 2 sensor ground 2
A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the accelerator pedal position
sensor harness connector FB41 and the ECM
harness connector FB46.
C Measure the resistance of circuit between
terminal 1 of the accelerator pedal position sensor
harness connector FB41 and terminal 40 of the
ECM harness connector FB46.
D Measure the resistance of circuit between
terminal 2 of the accelerator pedal position sensor
harness connector FB41 and terminal 20 of the
ECM harness connector FB46.
E Measure the resistance of circuit between
terminal 6 of the accelerator pedal position sensor
harness connector FB41 and terminal 49 of the
ECM harness connector FB46.
Standard resistance: less than 1Ω
F Verify if the measured value is consistent with

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Control system 2-518 Maintenance Manual of 1.5GDI Engine
the standard value.
N Replace or repair the harness or
connector.

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Maintenance Manual of 1.5GDI Engine 2-519Control system

FB41 accelerator pedal position sensor harness connector

Accelerator pedal position

sensor 5V power supply 2

Accelerator pedal positionAccelerator pedal position

sensor signal 2 sensor ground 2

Step 4 Check whether the accelerator pedal position sensor circuit is shorted to the ground.

FB41 accelerator pedal position sensor harness connector
Accelerator pedal position
sensor signal 1
Accelerator pedal position Accelerator pedal position
sensor 5V power supply 1 sensor ground 1
FB41 accelerator pedal position sensor harness connector
Accelerator pedal position
sensor signal 2
A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the accelerator pedal position
sensor harness connector FB41 and the ECM
harness connector FB46.
C Measure the resistance of circuit between
terminals 3, 4, 5 of the accelerator pedal position
sensor harness connector FB41 and the body
ground.
D Measure the resistance of circuit between
terminals 1, 2, 6 of the accelerator pedal position
sensor harness connector FB41 and the body
ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.

Accelerator pedal position Accelerator pedal position

sensor 5V power supply 2 sensor ground 2

Step 5 Check whether the accelerator pedal position sensor circuit is shorted to the power supply.

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Control system 2-520 Maintenance Manual of 1.5GDI Engine

FB41 accelerator pedal position sensor harness connector
Accelerator pedal position
sensor signal 1
Accelerator pedal position Accelerator pedal position
sensor 5V power supply 1 sensor ground 1
FB41 accelerator pedal position sensor harness connector
Accelerator pedal position
sensor signal 1
A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the accelerator pedal position
sensor harness connector FB41 and the ECM
harness connector FB46.
C Set the ENGINE START/STOP button to
“ON” position.
D Measure the voltage of circuit between
terminals 3, 4, 5 of the accelerator pedal position
sensor harness connector FB41 and the body
ground.
E Measure the voltage of circuit between
terminals 1, 2, 6 of the accelerator pedal position
sensor harness connector FB41 and the body
ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
N Replace or repair the harness or
connector.

Accelerator pedal position Accelerator pedal position

sensor 5V power supply 2 sensor ground 2

Step 6 Replace the accelerator pedal position sensor.

A Replace the accelerator pedal position

sensor.
B Verify if the fault is eliminated after the
accelerator pedal position sensor is replaced.
Y The system is working normally.

Step 7 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

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Maintenance Manual of 1.5GDI Engine 2-521Control system

Next step

Step 8 End.
2.8.6.75 DTC: P214700, P214800......
DTC Description
Cylinder 1 and 4 Fuel Injector High Side Control
P214700
Circuit Voltage Low
Cylinder 1 and 4 Fuel Injector High Side Control
P214800
Circuit Voltage High
1. Circuit diagram

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Injector Injector Injector Injector

4 3 2 1

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.

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Control system 2-522 Maintenance Manual of 1.5GDI Engine

B Set the ENGINE START/STOP button to

“ON” position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes,
and carry out the related triggering test by
simulating the fault symptom; if the engine cannot
be started, do not try again.
E Read the DTC again.
F Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the fuel injector.

Injector A Set the ENGINE START/STOP button to

“OFF” position.
B Remove the fuel injector.
C Measure whether the resistance of fuel
injector is normal.
Standard resistance: 2±0.1Ω (@20°C)
N Replace the fuel injector.

Injector
Y

Step 3 Check whether the circuit between the #1 cylinder injector and the ECM is open.

EN06 Fuel injector 1 harness connector A Set the ENGINE START/STOP button to
“OFF” position.
Fuel injector 1- B Disconnect the #1 cylinder fuel injector
harness connector EN06 and the ECM harness
connector EN01.
C Measure the resistance of circuit between
terminal 1 of #1 cylinder fuel injector harness
connector EN06 and terminal 33 of the ECM
harness connector EN01.
Fuel injector 1+
D Measure the resistance of circuit between
terminal 2 of #1 cylinder fuel injector harness
connector EN06 and terminal 31 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
the standard value.

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Maintenance Manual of 1.5GDI Engine 2-523Control system

N Replace or repair the harness or

connector.

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Control system 2-524 Maintenance Manual of 1.5GDI Engine

EN01 ECM harness connector

Fuel injector 1+

Fuel injector 1-

Step 4 Check whether the control circuit of #1 cylinder injector is shorted to ground.

EN06 Fuel injector 1 harness connector A Set the ENGINE START/STOP button to
“OFF” position.
Fuel injector 1- B Disconnect the #1 cylinder fuel injector
harness connector EN06 and the ECM harness
connector EN01.
C Measure the resistance of circuit between
terminal 1 of #1 cylinder fuel injector harness
connector EN06 and the body ground.
D Measure the resistance of circuit between
Fuel injector 1+ terminal 2 of #1 cylinder fuel injector harness
connector EN06 and the body ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 5 Check whether the control circuit of #1 cylinder injector is shorted to power supply.

EN06 Fuel injector 1 harness connector A Set the ENGINE START/STOP button to
“OFF” position.
Fuel injector 1- B Disconnect the #1 cylinder fuel injector
harness connector EN06 and the ECM harness
connector EN01.
C Set the ENGINE START/STOP button to
“ON” position.
D Measure the voltage of circuit between
terminal 1 of #1 cylinder fuel injector harness
Fuel injector 1+ connector EN06 and the body ground.
E Measure the voltage of circuit between
terminal 2 of #1 cylinder fuel injector harness
connector EN06 and the body ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
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Maintenance Manual of 1.5GDI Engine 2-525Control system

N Replace or repair the harness or

connector.

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Control system 2-526 Maintenance Manual of 1.5GDI Engine

Step 6 Check whether the circuit between the #4 cylinder injector and the ECM is open.

EN09 Fuel injector 4 harness connector A Set the ENGINE START/STOP button to
“OFF” position.
Fuel injector 4- B Disconnect the #4 cylinder fuel injector
harness connector EN09 and the ECM harness
connector EN01.
C Measure the resistance of circuit between
terminal 1 of #4 cylinder fuel injector harness
connector EN09 and terminal 48 of the ECM
harness connector EN01.
D Measure the resistance of circuit between
Fuel injector 4+
terminal 2 of #4 cylinder fuel injector harness
connector EN09 and terminal 32 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
the standard value.
EN01 ECM harness connector
N Replace or repair the harness or
Fuel injector 4+
connector.

Fuel injector 4-

Step 7 Check whether the control circuit of #4 cylinder injector is shorted to ground.

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Maintenance Manual of 1.5GDI Engine 2-527Control system

EN09 Fuel injector 4 harness connector A Set the ENGINE START/STOP button to
“OFF” position.
Fuel injector 4- B Disconnect the #4 cylinder fuel injector
harness connector EN09 and the ECM harness
connector EN01.
C Measure the resistance of circuit between
terminal 1 of #4 cylinder fuel injector harness
connector EN09 and the body ground.
D Measure the resistance of circuit between
terminal 2 of #4 cylinder fuel injector harness
Fuel injector 4+
connector EN09 and the body ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 8 Check whether the control circuit of #4 cylinder injector is shorted to power supply.

EN09 Fuel injector 4 harness connector A Set the ENGINE START/STOP button to
“OFF” position.
Fuel injector 4- B Disconnect the #4 cylinder fuel injector
harness connector EN09 and the ECM harness
connector EN01.
C Set the ENGINE START/STOP button to
“ON” position.
D Measure the voltage of circuit between
terminal 1 of #4 cylinder fuel injector harness
connector EN09 and the body ground.
Fuel injector 4+
E Measure the voltage of circuit between
terminal 2 of #4 cylinder fuel injector harness
connector EN09 and the body ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 9 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 10 End.

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Control system 2-528 Maintenance Manual of 1.5GDI Engine

2.8.6.76 DTC: P215000, P215100......

DTC Description
Cylinder 2 and 3 Fuel Injector High Side Control
P215000
Circuit Voltage Low
Cylinder 2 and 3 Fuel Injector High Side Control
P215100
Circuit Voltage Low
1. Circuit diagram

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Injector Injector Injector Injector

4 3 2 1

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Start the engine, idle it for about 5 minutes,
and carry out the related triggering test by
simulating the fault symptom; if the engine cannot
be started, do not try again.

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Maintenance Manual of 1.5GDI Engine 2-529Control system

E Read the DTC again.

F Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the fuel injector.

Injector A Set the ENGINE START/STOP button to

“OFF” position.
B Remove the fuel injector.
C Measure whether the resistance of fuel
injector is normal.
Standard resistance: 2±0.1Ω (@20°C)
N Replace the fuel injector.

Injector
Y

Step 3 Check whether the circuit between the #2 cylinder injector and the ECM is open.

EN07 Fuel injector 2 harness connector

A Set the ENGINE START/STOP button to
“OFF” position.
Fuel injector 2- B Disconnect the #2 cylinder fuel injector
harness connector EN07 and the ECM harness
connector EN01.
C Measure the resistance of circuit between
terminal 1 of #2 cylinder fuel injector harness
connector EN07 and terminal 49 of the ECM
harness connector EN01.
D Measure the resistance of circuit between
Fuel injector 2+ terminal 2 of #2 cylinder fuel injector harness
connector EN07 and terminal 47 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
the standard value.
N Replace or repair the harness or
connector.

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Control system 2-530 Maintenance Manual of 1.5GDI Engine

EN01 ECM harness connector

Fuel injector 2+ Fuel injector 2-

Step 4 Check whether the control circuit of #2 cylinder injector is shorted to ground.

EN07 Fuel injector 2 harness connector A Set the ENGINE START/STOP button to
“OFF” position.
Fuel injector 2-
B Disconnect the #2 cylinder fuel injector
harness connector EN07 and the ECM harness
connector EN01.
C Measure the resistance of circuit between
terminal 1 of #2 cylinder fuel injector harness
connector EN07 and the body ground.
D Measure the resistance of circuit between
terminal 2 of #2 cylinder fuel injector harness
Fuel injector 2+
connector EN07 and the body ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 5 Check whether the control circuit of #2 cylinder injector is shorted to power supply.

EN07 Fuel injector 2 harness connector A Set the ENGINE START/STOP button to
“OFF” position.
Fuel injector 2- B Disconnect the #2 cylinder fuel injector
harness connector EN07 and the ECM harness
connector EN01.
C Set the ENGINE START/STOP button to
“ON” position.
D Measure the voltage of circuit between
terminal 1 of #2 cylinder fuel injector harness
connector EN07 and the body ground.
Fuel injector 2+
E Measure the voltage of circuit between
terminal 2 of #2 cylinder fuel injector harness
connector EN07 and the body ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
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Maintenance Manual of 1.5GDI Engine 2-531Control system

N Replace or repair the harness or

connector.

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Control system 2-532 Maintenance Manual of 1.5GDI Engine

Step 6 Check whether the circuit between the #3 cylinder injector and the ECM is open.

EN08 Fuel injector 3 harness connector A Set the ENGINE START/STOP button to
“OFF” position.
Fuel injector 3- B Disconnect the #3 cylinder fuel injector
harness connector EN08 and the ECM harness
connector EN01.
C Measure the resistance of circuit between
terminal 1 of #3 cylinder fuel injector harness
connector EN08 and terminal 34 of the ECM
harness connector EN01.
D Measure the resistance of circuit between
Fuel injector 3+
terminal 2 of #3 cylinder fuel injector harness
connector EN08 and terminal 46 of the ECM
harness connector EN01.
Standard resistance: less than 1Ω
E Verify if the measured value is consistent with
EN01 ECM harness connector
the standard value.
N Replace or repair the harness or
Fuel injector 3- connector.

Fuel injector 3+

Step 7 Check whether the control circuit of #3 cylinder injector is shorted to ground.

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Maintenance Manual of 1.5GDI Engine 2-533Control system

EN08 Fuel injector 3 harness connector A Set the ENGINE START/STOP button to
“OFF” position.
Fuel injector 3- B Disconnect the #3 cylinder fuel injector
harness connector EN08 and the ECM harness
connector EN01.
C Measure the resistance of circuit between
terminal 1 of #3 cylinder fuel injector harness
connector EN08 and the body ground.
D Measure the resistance of circuit between
terminal 2 of #3 cylinder fuel injector harness
Fuel injector 3+
connector EN08 and the body ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 8 Check whether the control circuit of #3 cylinder injector is shorted to power supply.

EN08 Fuel injector 3 harness connector A Set the ENGINE START/STOP button to
“OFF” position.
Fuel injector 3- B Disconnect the #3 cylinder fuel injector
harness connector EN08 and the ECM harness
connector EN01.
C Set the ENGINE START/STOP button to
“ON” position.
D Measure the voltage of circuit between
terminal 1 of #3 cylinder fuel injector harness
connector EN08 and the body ground.
Fuel injector 3+
E Measure the voltage of circuit between
terminal 2 of #3 cylinder fuel injector harness
connector EN08 and the body ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 9 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 10 End.

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Control system 2-534 Maintenance Manual of 1.5GDI Engine

EN08 Fuel injector 3 harness connector A Set the ENGINE START/STOP button to
“OFF” position.
Fuel injector 3- B Disconnect the #3 cylinder fuel injector
harness connector EN08 and the ECM harness
connector EN01.
C Measure the resistance of circuit between
terminal 1 of #3 cylinder fuel injector harness
connector EN08 and the body ground.
D Measure the resistance of circuit between
terminal 2 of #3 cylinder fuel injector harness
Fuel injector 3+
connector EN08 and the body ground.
Standard resistance: 10kΩ or higher
E Verify if the resistance is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 8 Check whether the control circuit of #3 cylinder injector is shorted to power supply.

EN08 Fuel injector 3 harness connector A Set the ENGINE START/STOP button to
“OFF” position.
Fuel injector 3- B Disconnect the #3 cylinder fuel injector
harness connector EN08 and the ECM harness
connector EN01.
C Set the ENGINE START/STOP button to
“ON” position.
D Measure the voltage of circuit between
terminal 1 of #3 cylinder fuel injector harness
connector EN08 and the body ground.
Fuel injector 3+
E Measure the voltage of circuit between
terminal 2 of #3 cylinder fuel injector harness
connector EN08 and the body ground.
Standard voltage: 0V
F Verify if the voltage is consistent with the
standard value.
N Replace or repair the harness or
connector.
Y

Step 9 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 10 End.

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Maintenance Manual of 1.5GDI Engine 2-535Control system

2.8.6.77 DTC: P26F000, P26F100

Diagnostic trouble code (DTC) Description
P26F000 Starter Relay R1 Stuck Closed
Starter Relay R1 or Powertrain State Relay R2
P26F100
Stuck Open
1. Circuit diagram

PFB

IG2 relay (Main relay)

Engine
compart Engine
Starter ment Starter compart
relay 1 PDU relay 2 ment
PDU

TCM ECM DCDC

converte
r
ECM

Starter

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.

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Control system 2-536 Maintenance Manual of 1.5GDI Engine

E Check whether the same DTC appears.

N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the terminals of ECM and engine compartment PDU harness connector.

A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM, the starter relay and the
engine compartment PDU harness connectors.
C Check whether the terminals in the harness
connectors are damaged, bent, withdrawn or
corroded.
Y Repair the harness or connector.

Step 3 Check the starter relay ER15.

A Set the ENGINE START/STOP button to

“OFF” position.
B Remove the starter relay ER15.
C Connect one end of the coil of the starter
relay to the positive battery terminal, and connect
the other end to the ground. Then check the
Fuse continuity between the two ends of the relay switch
contact.
N Replace the starter relay ER15.

Step 4 Check the starter relay ER16.

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Maintenance Manual of 1.5GDI Engine 2-537Control system

A Set the ENGINE START/STOP button to

“OFF” position.
B Remove the starter relay ER16.
C Connect one end of the coil of the starter
relay to the positive battery terminal, and connect
the other end to the ground. Then check the
continuity between the two ends of the relay switch
Fuse
contact.
N Replace the starter relay ER16.

Step 5 Check the control circuit of starter relay.

A Check whether the control circuit of starter

relay is normal.
N Replace or repair the harness or
connector.
Y

Step 6 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.
Next step

Step 7 End.
2.8.6.78 DTC: U007300, U350100......
DTC Description
U007300 CAN Bus OFF
U350100 CAN Module Input Voltage Low
U350200 CAN Module Input Voltage High
1. Circuit diagram

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Control system 2-538 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

Refer to P-CAN
system circuit
diagram

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the resistance between terminals.

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Maintenance Manual of 1.5GDI Engine 2-539Control system

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Measure the resistance of circuit between
terminals 56 and 57 of the ECM harness connector
FB46.
D Standard resistance: about 120Ω
E Verify if the resistance is consistent with the
standard value.
N Repair or replace the harness.

Step 3 Check the power and ground wires of the ECM.

A Check whether the power and ground wires

of ECM are normal.
N Repair or replace the harness.

Step 4 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.
Next step

Step 5 End.
2.8.6.79 DTC: U010100
DTC Description
U010100 Lost Communication with TCM Module
1. Circuit diagram

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Control system 2-540 Maintenance Manual of 1.5GDI Engine

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

6AT TCM

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the CAN data communication cable between the ECM and the TCM harness
connectors.

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Maintenance Manual of 1.5GDI Engine 2-541Control system

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Disconnect the TCM harness connector
EN37.
D Measure the resistance between terminal 56
of the ECM harness connector FB46 and terminal
11 of the TCM harness connector EN37.
E Measure the resistance between terminal 57
of ECM harness connector FB46 and terminal 3 of
TCM harness connector EN37.
Standard resistance: less than 1Ω
F Verify if the resistance is consistent with the
standard value.
EN37 TCM harness connector N Repair or replace the harness.

Step 3 Check the power and ground circuits of TCM.

A Check whether the power and ground circuits

of TCM are normal.
N Repair or replace the harness.
Y

Step 4 Replace the TCM.

A Replace the TCM.

B Verify if the fault is eliminated after the TCM is
replaced.
Y The system is working normally.

Step 5 Replace the the ECM.

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Control system 2-542 Maintenance Manual of 1.5GDI Engine

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 6 End.
2.8.6.80 DTC: U012200
DTC Description
U012200 Lost Communication with ESP Module
1. Circuit diagram

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

ESPI

2. Diagnostic procedure

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Maintenance Manual of 1.5GDI Engine 2-543Control system

Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the CAN data communication cable between the ECM and the ESPI harness
connectors.

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Disconnect the ESPI harness connector
FB04.
D Measure the resistance between terminal 56
of the ECM harness connector FB46 and terminal
13 of the ESPI harness connector FB04.
E Measure the resistance between terminal 57
of the ECM harness connector FB46 and terminal
27 of the ESPI harness connector FB04.
Standard resistance: less than 1Ω
F Verify if the resistance is consistent with the
standard value.
FB04 ESPI harness connector N Repair or replace the harness.

Step 3 Check the power and ground circuits of the ESPI.

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Control system 2-544 Maintenance Manual of 1.5GDI Engine

A Check whether the power and ground circuits

of the ESPI are normal.
N Repair or replace the harness.

Step 4 Replace the ESPI.

A Replace the ESPI.

B Verify if the fault is eliminated after the ESPI
is replaced.
Y The system is working normally.

Step 5 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 6 End.
2.8.6.81 DTC: U012600
DTC Description
Signal Lost or Abnormal in Communication with
U012600
SAS
1. Circuit diagram

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Maintenance Manual of 1.5GDI Engine 2-545Control system

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

SAS

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the CAN data communication cable between the ECM and the SAS harness
connectors.

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Control system 2-546 Maintenance Manual of 1.5GDI Engine

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Disconnect the SAS harness connector IP17.
D Measure the resistance between terminal 56
of the ECM harness connector FB46 and terminal
2 of the SAS harness connector IP17.
E Measure the resistance between terminal 57
of ECM harness connector FB46 and terminal 1 of
SAS harness connector IP17.
Standard resistance: less than 1Ω
F Verify if the resistance is consistent with the
standard value.
N Repair or replace the harness.
IP17 SAS harness connector

Step 3 Check the power and ground circuits of SAS.

A Check whether the power and ground circuits

of SAS are normal.
N Repair or replace the harness.
Y

Step 4 Replace the SAS.

A Replace the SAS.

B Verify if the fault is eliminated after the SAS is
replaced.
Y The system is working normally.

Step 5 Replace the the ECM.

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Maintenance Manual of 1.5GDI Engine 2-547Control system

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 6 End.
2.8.6.82 DTC: U014000
DTC Description
U014000 Lost Communication with BCM Module
1. Circuit diagram

(Main relay)

Engine Instrume
compa nt panel
rtment PDU
PDU

ECM BCM

GWM

2. Diagnostic procedure

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Control system 2-548 Maintenance Manual of 1.5GDI Engine

Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the CAN data communication cable between the BCM and the GWM.

IP19 GWM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the GWM harness connector
IP19.
C Disconnect the BCM harness connector IP02.
D Measure the resistance between terminal 10
of GWM harness connector IP19 and terminal 43
of BCM harness connector IP02.
E Measure the resistance between terminal 20
of GWM harness connector IP19 and terminal 42
of BCM harness connector IP02.
Standard resistance: less than 1Ω
F Verify if the resistance is consistent with the
standard value.
N Repair or replace the harness.
IP02 BCM harness connector

Step 3 Check the CAN data communication cable between the ECM and the GWM harness
connectors.

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Maintenance Manual of 1.5GDI Engine 2-549Control system

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Disconnect the GWM harness connector
IP19.
D Measure the resistance between terminal 56
of the ECM harness connector FB46 and terminal
9 of the GWM harness connector IP19.
E Measure the resistance between terminal 57
of the ECM harness connector FB46 and terminal
19 of the GWM harness connector IP19.
Standard resistance: less than 1Ω
F Verify if the resistance is consistent with the
standard value.
IP19 GWM harness connector N Repair or replace the harness.

Step 4 Check the power and ground wires of the BCM.

A Check whether the power and ground wires

of the BCM are normal.
N Repair or replace the harness.

Step 5 Replace the BCM.

A Replace the BCM.

B Verify if the fault is eliminated after the BCM
is replaced.
Y The system is working normally.

Step 6 Replace the the ECM.

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Control system 2-550 Maintenance Manual of 1.5GDI Engine

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 7 End.
2.8.6.83 DTC: U100100
DTC Description
U100100 Lost Communication with MRR Module
1. Circuit diagram

(Main relay)

Engine Instrume
compart nt panel
ment PDU
PDU

ECM

MRR module

2. Diagnostic procedure

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Maintenance Manual of 1.5GDI Engine 2-551Control system

Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the CAN data communication cable between the ECM and the MRR module harness
connector.

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Disconnect the MRR module harness
connector FB35.
D Measure the resistance between terminal 56
of the ECM harness connector FB46 and terminal
2 of the MRR module harness connector FB35.
E Measure the resistance between terminal 57
of ECM harness connector FB46 and terminal 3 of
MRR module harness connector FB35.
Standard resistance: less than 1Ω
F Verify if the resistance is consistent with the
standard value.
FB35 MRR module harness connector N Repair or replace the harness.

Step 3 Check the power and ground circuits of the MRR.

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Control system 2-552 Maintenance Manual of 1.5GDI Engine

A Check whether the power and ground circuits

of the MRR are normal.
N Repair or replace the harness.

Step 4 Replace the MRR module.

A Replace the MRR module.

B Verify if the fault is eliminated after the MRR
module is replaced.
Y The system is working normally.

Step 5 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 6 End.
2.8.6.84 DTC: U015500
DTC Description
Signal Lost or Abnormal in Communication with
U015500
ICM
1. Circuit diagram

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Maintenance Manual of 1.5GDI Engine 2-553Control system

(Main relay)

Engine Instrume
compa nt panel
rtment PDU
PDU

ECM Instrument cluster

GWM

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.
Y

Step 2 Check the CAN data communication cable between the instrument cluster and the GWM.

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Control system 2-554 Maintenance Manual of 1.5GDI Engine

IP19 GWM harness connector

A Set the ENGINE START/STOP button to
“OFF” position.
B Disconnect the GWM harness connector
IP19.
C Disconnect the instrument cluster harness
connector IP06.
D Measure the resistance between terminal 10
of GWM harness connector IP19 and terminal 2 of
the instrument cluster harness connector IP06.
E Measure the resistance between terminal 20
of GWM harness connector IP19 and terminal 1 of
the instrument cluster harness connector IP06.
Standard resistance: less than 1Ω
F Verify if the resistance is consistent with the
standard value.
IP06 Instrument cluster harness connector N Repair or replace the harness.

Step 3 Check the CAN data communication cable between the ECM and the GWM harness
connectors.

FB46 ECM harness connector A Set the ENGINE START/STOP button to

“OFF” position.
B Disconnect the ECM harness connector
FB46.
C Disconnect the GWM harness connector
IP19.
D Measure the resistance between terminal 56
of the ECM harness connector FB46 and terminal
9 of the GWM harness connector IP19.
E Measure the resistance between terminal 57
of the ECM harness connector FB46 and terminal
19 of the GWM harness connector IP19.
Standard resistance: less than 1Ω
F Verify if the resistance is consistent with the
standard value.
N Repair or replace the harness.

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Maintenance Manual of 1.5GDI Engine 2-555Control system

IP19 GWM harness connector

Step 4 Check the power and ground wires of instrument cluster.

A
A Check whether the power and ground wires
of instrument cluster are normal.
N Repair or replace the harness.

Step 5 Replace the ICM.

A Replace the instrument cluster.

B Verify if the fault is eliminated after the
instrument cluster is replaced.
Y The system is working normally.
N

Step 6 Replace the the ECM.

A Replace the ECM.

B Verify if the fault is eliminated after the ECM
is replaced.
Y The system is working normally.

Next step

Step 7 End.

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Control system 2-556 Maintenance Manual of 1.5GDI Engine

2.8.6.85 DTC:P129000,P12B100......
DTC Description
Particulate Filter Differential Pressure Sensor
P129000
Post-Operation Offset Check Value Implausible
P12B100 Particulate Filter Backpressure High
Particulate Filter Removed/Pressure Sensor or
P226D00
Pipeline Abnormal
LSU Oxygen Sensor Characteristic Deviation (Thin
P219500
Side)
LSU Oxygen Sensor Characteristic Deviation (Rich
P219600
Side)
Particulate Filter Differential Pressure Sensor GPF
P129100 Dynamic Response Implausible or Pipeline
Abnormal
Particulate Filter Differential Pressure Sensor
P245500
Circuit Voltage High
Particulate Filter Differential Pressure Sensor
P245400
Circuit Voltage Low
Particulate Filter Differential Pressure Sensor Sent
U060100
Communication Fault
Particulate Filter Differential Pressure Sensor Data
U060141
Check Implausible
Particulate Filter Differential Pressure Sensor
P129300 Channel 1 Digital Signal Implausible (SENT Signal
High or Low)
Particulate Filter Differential Pressure Sensor
P129400 Channel 2 Digital Signal Implausible (SENT Signal
High or Low)
Particulate Filter Differential Pressure Sensor
P12A200
Pipeline Connection Error
Particulate Filter Differential Pressure Sensor Rear
P12A300 Pipe Connecting Pipeline Abnormal/Completely
Blocked/Sensor Signal Abnormal
Particulate Filter Differential Pressure Sensor
P129600
Signal Stuck
1. Circuit diagram

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Maintenance Manual of 1.5GDI Engine 2-557Control system

Engine
Instrument compartment
panel PDU ER15 starter ER16 starter PDU
relay 1 relay 2

ECM

Differential
pressure sensor

2. Diagnostic procedure
Step 1 Check the DTC status.

A Connect the diagnostic scan tool to the OBD

DLC.
B Set the ENGINE START/STOP button to
“ON” position, read the DTC and record it.
C Clear the DTC.
D Read the DTC again.
E Check whether the same DTC appears.
N The DTC may be triggered by an
intermittent fault. Check whether
there is any intermittent fault.

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Control system 2-558 Maintenance Manual of 1.5GDI Engine

Step 2 Check whether the connector of the differential pressure sensor is connected normally.

A Turn off all electrical consumers, and

FB35 differential pressure sensor disconnect the negative battery terminal.
B Check whether the pins of the harness
connector of the differential pressure sensor are
bent, corroded, or withdrawn.
C Check whether the inspection result is
normal.
N Re-connect the differential
pressure sensor, and replace the
harness or differential pressure
sensor if necessary.
Power Ground Signal
supply

Step 3 Check whether the connecting pipeline of the particulate filter is normal.

A Turn off all electrical consumers, and

disconnect the negative battery terminal.
B Check whether the pipeline of the particulate
filter is blocked, cracked or damaged.
C Check whether the inspection result is
normal.
N Replace the damaged
connecting pipeline of the
particulate filter.
Y

Step 4 Check whether the harness between the differential pressure sensor and the ECM is
connected normally.

A Turn off all electrical consumers, and

FB35 differential pressure sensor disconnect the negative battery terminal.
B Disconnect the ECM harness connector
EN01 and the differential pressure sensor harness
connector FB35.
C Measure the resistance between terminal 7 of
the ECM harness connector EN01 and terminal 1
of the differential pressure sensor harness
connector FB35.
D Measure the resistance between terminal 17
of the ECM harness connector FB46 and terminal
Power Ground Signal 2 of the differential pressure sensor harness
supply connector FB35.
E Measure the resistance between terminal 36
of ECM harness connector EN01 and terminal 3 of
the differential pressure sensor harness connector
FB35.

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Maintenance Manual of 1.5GDI Engine 2-559Control system
Standard resistance: less than 1Ω
F Verify if the resistance is consistent with the
standard value.

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Control system 2-560 Maintenance Manual of 1.5GDI Engine

EN01 ECM
To the differential N Repair or replace the harness.
pressure sensor +

To the differential
Signal
pressure sensor -

Step 5 Replace the differential pressure sensor.

A Replace the differential pressure sensor.

B Verify if the fault is eliminated after the
differential pressure sensor is replaced.
Y The system is working normally.

Step 6 Replace the particulate filter.

A Replace the particulate filter.

B Verify if the fault is eliminated after the
particulate filter is replaced.
Y The system is working normally.

Next step

Step 7 End.

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Maintenance Manual of 1.5GDI Engine 2-561Control system

2.8.7 Removal and installation

2.8.7.1 Removing and installing MAP/IAT
sensor
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery.
3 Remove the MAP/IAT sensor
a. Remove the engine upper guard plate assembly
①.

b. Disconnect the MAP/IAT sensor connector as

arrowed.

c. Unscrew the fixing bolt as arrowed, and remove

the MAP/IAT sensor ①.
• Tightening torque of bolt: 5±0.5Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.

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Control system 2-562 Maintenance Manual of 1.5GDI Engine

2.8.7.2 Removing and installing water

temperature sensor
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.
3 Drain the coolant. Refer to 1.8.4.5 Changing
coolant.
4 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly.
5 Remove the electronic throttle body. Refer to
2.6.7.6 Removing and installing electronic throttle
body.
6 Remove the water temperature sensor.
a. Disconnect the water temperature sensor
connector as arrowed.

b. Unscrew the water temperature sensor ①.

• Tightening torque of water temperature sensor:
15±1.5Nm
Tip:
Before unscrewing the water temperature sensor,
place a suitable container below to collect the
coolant.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- As shown in the figure, apply sealant in area a of
the sensor during installation.
• Standard width: about 3±1mm.

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Maintenance Manual of 1.5GDI Engine 2-563Control system

2.8.7.3 Removing and installing oil control

valve
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting battery.
3 Remove the oil control valve.
a. Remove the engine upper guard plate assembly
①.

b. Disconnect the oil control valve connector as

arrowed.

c. Unscrew the fixing bolt as arrowed, and remove

the oil control valve ①.
• Tightening torque of bolt: 6±0.9Nm
Tip:
The oil control valve is a precision part and must be
properly placed after removal to prevent scratches,
impacts and contamination.

Installation procedure

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Control system 2-564 Maintenance Manual of 1.5GDI Engine

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
- During installation, replace the O-ring ①, and
apply a little oil to the surface of new O-ring.

2.8.7.4 Removing and installing electronic

accelerator pedal assembly
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.
3 Remove the electronic accelerator pedal
assembly a, and disengage the fixing clips (arrows
A and B) of the left assembly of the front extension
plate. b. Remove the left assembly of the front
extension plate ①.

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Maintenance Manual of 1.5GDI Engine 2-565Control system

c. Disconnect the electronic accelerator pedal

assembly connector as arrowed.

d. Unscrew the fixing nut as arrowed, and take off

the electronic accelerator pedal assembly ①.
• Tightening torque of nut: 8±1Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.8.7.5 Removing and installing ECM
Removal procedure
Note:
The ECM is located next to the air cleaner
assembly in the engine compartment. The ECM
shall be removed and installed with care to avoid
impact and prevent moisture. During removal and
installation, do not touch the connector pins with
hands or forcibly disassemble the housing, for fear
of damaging the internal electrical components.
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.

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Control system 2-566 Maintenance Manual of 1.5GDI Engine

3 Remove the ECM

a. Disconnect the ECM connectors (arrows A and
B).

b. Unscrew the fixing bolt (arrow A).

c. Unscrew the fixing clip as arrowed, and take off
the ECM with bracket ①.
• Tightening torque of bolt (arrow A): 8±2Nm

d. Unscrew the fixing nut as arrowed, and take off

the ECM ①.
• Tightening torque of nut: 8±2Nm

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- After installation, it is required to program the
ECM.

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Maintenance Manual of 1.5GDI Engine 2-567Cooling system

2.9 Cooling system

2.9.1 Specifications
2.9.1.1 Fastener specifications
Location Specification Tightening torque, N.m
Engine compartment lower guard Hexagon bolt and extra large
6±2
plate washer assembly M6×20
Hexagon flange bolt M6×16 8±2
Expansion tank assembly
Hexagon flange bolt M6×30 8±2
Hexagon socket bolt and plain
Thermostat assembly 9±0.9
washer assembly M6×28
Hexagon flange bolt M6×20 9±0.9
Water pump assembly
Hexagon flange bolt M6×30 9±0.9
A/C high- and low-pressure pipe
Hexagon flange bolt M6×16 8±2
assembly II
All-metal hexagon flange lock nut
A/C exhaust pipe assembly I 8±2
M6
Hexagon head bolt, spring
Radiator and fan assembly (for
washer and plain washer 8±2
outside pipeline connection)
assembly M6×25
Hexagon head bolt and plain
Condenser assembly 8±2
washer assembly M6×20

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Cooling system 2-568 Maintenance Manual of 1.5GDI Engine

2.9.2 Description and operation

2.9.2.1 Overview and precautions for operation
Overview
Because the mixture is burned in the cylinder's combustion chamber to produce high temperature when
the engine is working, and heat is transmitted through the cylinder block, the engine will fail to work if
cooling is unavailable. Thus, the coolant passages are arranged in the cylinder block to allow heat
exchange with the outside by the circulation of coolant. In this way, the operating temperature of the
engine can be kept within a certain range, so that the engine can work efficiently under all working
conditions. When the engine is in cold state, the cooling system controls the amount of circulating
coolant through the thermostat assembly, so the engine can be warmed up quickly. The cooling system
consists of the radiator, expansion tank assembly, cooling fan assembly, thermostat assembly, water
pump assembly and V-ribbed belt. The cooling system can work normally only when all the above
components function well. When the engine coolant reaches the operating temperature of the thermostat
assembly, the thermostat assembly is turned on, and at this time, the coolant flows to the engine after
cooled down by the radiator. The cooling system leads some engine coolant into the heater core
assembly through the water pipe for heating and defrosting. The expansion tank assembly is connected
to the radiator for recovering the engine coolant discharged due to thermal expansion.
The expansion tank assembly is connected to the radiator, turbocharger assembly and engine cooling
system through three water pipes respectively. As the vehicle is running, the engine coolant heats up
and expands gradually. Some engine coolant flows into the expansion tank assembly from the radiator
and engine due to expansion. The air trapped in the radiator and engine is also discharged into the
expansion tank assembly. When the engine stops, the engine coolant automatically cools down and
shrinks, and the coolant discharged previously is sucked back to the radiator and engine. Thus, the
engine coolant in the radiator can be kept at a proper level, and the cooling efficiency is improved. When
the cooling system is cold, the engine coolant level shall be maintained between the MIN and MAX
marks of the expansion tank assembly.
The cooling fan assembly adopts the dual-fan and high/low speed control mode, and drives the fan
blades through two different motors. The cooling fan is controlled directly by ECM using the cooling fan
low-speed and high-speed relays; the fan speed is changed by series connection mode in the low-speed
circuit. When the engine coolant reaches 95°C
(203°F), ECM runs the cooling fan assembly at low speed. However, when the engine coolant reaches
98°C (208.4ºF), ECM runs the cooling fan assembly at high speed
. When the temperature drops to 95°C (203ºF), ECM switches the cooling fan to low speed from high
speed. When the temperature is 92°C (203ºF), ECM turns off the cooling fan.
Precautions for operation
Even when the engine is not running, the cooling fan under the engine compartment may start. Keep
hands, clothes and tools away from the cooling fan blades under the engine compartment.
If the fan blades are bent or damaged to any degree, do not repair or reuse the damaged components. In
this case, the cooling fan assembly must be replaced. The damaged fan blades cannot guarantee normal
balance, and may fail and fly off during continuous operation, which is very dangerous.
Do not open the expansion tank cap when the engine is hot. It can be opened when the engine is cooled
to room temperature. Otherwise, the high-temperature coolant or steam comes out, causing personal
injury.

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Maintenance Manual of 1.5GDI Engine 2-569Cooling system
2.9.3 System working principles
2.9.3.1 System working principles
Engine is cold
The normal operating temperature of the engine is generally about 95°C. In this temperature range, all
parts of the engine are in the most ideal fitting status. If the engine cannot reach the ideal operating
temperature for a long time, the wear of engine block will be exacerbated. Because of low temperature,
the gas mixture is not fully burned in the combustion chamber, which will cause severe carbon deposits.
Therefore, when the engine is at low temperature, it is required that the engine reach the normal
operating temperature as soon as possible, and that the heat generated by the engine exchange with
the outside as little as possible. In this case, the thermostat assembly restricts the engine coolant in the
engine block to circulate only inside the engine block, bringing the heat generated around the cylinder
wall to other parts of the engine, so that the engine temperature rises quickly. The water pump circulates
the engine coolant in the cylinder block, and then the engine coolant circulates in the water jacket and
cylinder head of the engine block. This status is called “simple circulation”.
Engine reaches normal operating temperature
As the engine runs, the coolant in the engine block heats up quickly. When reaching the enabling
temperature (82°C) of the thermostat assembly, the engine coolant is pumped by the water pump to the
water jacket and cylinder head of engine block and the radiator. This status is called "full circulation".
Thermostat assembly
The thermostat assembly is wax type. When the cooling temperature is lower than the specified value,
the fine paraffin in the thermostat thermal pellet is solid, and the thermostat valve closes the passage
between the engine and the radiator under the action of the spring. Then the coolant flows back to the
engine through the water pump for simple circulation inside the engine. When the coolant temperature
reaches the specified value, the paraffin begins to melt and gradually becomes a liquid, and then the
paraffin increases in volume accordingly and compresses the rubber hose to contract it. While the rubber
hose is contracted, upward thrust is applied to the push rod, and the later applies downward reaction
thrust to the valve to open it. At this time, the coolant flows through the radiator and the thermostat valve,
and then flows back to the engine through the water pump for full circulation.

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Cooling system 2-570 Maintenance Manual of 1.5GDI Engine
Engine cooling diagram

Heater core assembly

Turbocharger assembly

Engine

Expansion
tank
assembly

Oil cooler
Water pump
assembly
Oil cooler
Thermostat assembly

Cooling fan assembly

Coolant in cold state Coolant in hot state Radiator

Tip:
Do not open the expansion tank cap when the engine is hot. It shall be opened when the engine is cooled
down to room temperature. Otherwise, the high-temperature coolant or steam comes out, causing
personal injury.
The cooling system can be repaired only when the engine is cooled down to room temperature.
To avoid damaging circuits and pipes of the cooling system and other systems, there shall be sufficient
distance between the circuits/pipes and all moving and heating components.
The coolant must be changed in accordance with relevant requirements. Otherwise, the cooling system
will have faults such as blockage, high temperature, and water leakage.
Please use the DF-6, -35°C coolant designated by the manufacturer. Filling volume of coolant: 7.2L.
After repair, check all pipelines (e.g., fuel, canister, coolant, refrigerant, brake fluid and vacuum
pipelines), and confirm that the electrical wires are restored to their original positions.
When the engine is running, the cooling fan assembly will start at any time. In this case, do not touch the
cooling fan assembly.
Do not take in coolant because it is toxic. If it comes in contact with the skin, clean it timely.

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Maintenance Manual of 1.5GDI Engine 2-571Cooling system
Clean the outside of the radiator frequently to prevent impurities such as dust and leaves from affecting its
heat dissipation function.

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Cooling system 2-572 Maintenance Manual of 1.5GDI Engine
2.9.4 Location of components
2.9.4.1 Location of components

Expansion tank
assembly

Cooling fan
assembly

Radiator

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Maintenance Manual of 1.5GDI Engine 2-573Cooling system
2.9.5 Exploded view
2.9.5.1 Exploded view

Expansion tank
cover

Expansion
Radiator tank
overflow hose assembly

Radiator water
inlet hose

Expansion tank
water outlet
hose
Expansion tank
mounting
cushion

Cooling fan Expansion tank

assembly mounting
bracket
Radiator water
outlet hose

Automatic
transmission water
outlet hose Turbocharger
overflow hose

Expansion tank water

return hose I

Expansion tank water

return tube

Radiator end cooling

water pipe assembly

Expansion tank water

return hose II

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Cooling system 2-574 Maintenance Manual of 1.5GDI Engine
2.9.6 Electrical schematic diagram
2.9.6.1 Electrical schematic diagram

Engine
compartment
PDU

Right cooling High speed Left Engine

fan relay cooling fan cooling fan compartment
relay relay PDU

ECM ECM
Right cooling Left cooling fan
fan

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Maintenance Manual of 1.5GDI Engine 2-575Cooling system
2.9.7 Diagnostic information and procedure
2.9.7.1 Diagnostic instructions
Familiarize yourself with the system functions and operations before starting the system diagnosis. This
helps you correctly determine the fault cause when a fault occurs, and more importantly, helps
determine whether the situation described by the customer is normal.
2.9.7.2 Visual inspection
• Check the aftermarket parts that may affect the operation of the cooling system.
• Check the accessible or visible system components for obvious damage or external leakage.
2.9.7.3 High engine water temperature
Diagnostic procedure
Step 1 Check whether the volume of coolant in the expansion tank is normal.

N Add the coolant to the normal

level, check the tightness of the
cooling system, and repair the
leaking parts.
Y

Step 2 Check whether the cooling fan assembly works normally.

N Check and repair the engine

cooling fan assembly.
Y

Step 3 Check whether the radiator is blocked or damaged.

Y Clean or replace the radiator.

Step 4 Check whether the water temperature sensor works normally.

N Check and repair the control

circuit of water temperature
sensor or replace the water
temperature sensor.
Y

Step 5 Check whether the thermostat assembly is stuck or the lift amount is insufficient for opening.

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Cooling system 2-576 Maintenance Manual of 1.5GDI Engine

Y Replace the thermostat assembly.

Step 6 Check whether the water pump assembly works normally.

N Replace the water pump

assembly.
Y

Step 7 Check whether the internal water passages of the cylinder block and cylinder head are
blocked with excessive dirt or foreign objects.

Y Clean the engine water passages,

and change the coolant.
Next step

Step 8 End.
2.9.7.4 Cooling fan fails to work
1. Diagnostic procedure
Step 1 Check whether the fuse of the cooling fan assembly is normal.

N Replace the fuse.

Step 2 Check whether the relay of the cooling fan assembly is normal.

N Replace the relay of the cooling

fan assembly.
Y

Step 3 Check whether the cooling fan assembly is normal.

N Check and repair the cooling fan

assembly.

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Maintenance Manual of 1.5GDI Engine 2-577Cooling system

Step 4 Check whether the cooling fan assembly is at normal voltage when it is working.

N Repair or replace the harness.

Step 5 Check whether the ECM is normal.

N Replace and program the ECM.

Next step

Step 6 End.

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Cooling system 2-578 Maintenance Manual of 1.5GDI Engine

2.9.8 Removal and installation

2.9.8.1 Changing coolant
Draining
Tip:
Before draining the coolant, wait till the coolant
cools down completely.
1 Turn off all electrical consumers, and turn off
the ENGINE START/STOP button.
2 Drain the coolant
a. Unscrew the expansion tank cap ① as arrowed.

b. Lift the vehicle.

c. Unscrew the fixing screws (arrow A) and fixing
bolts (arrow B), and remove the engine
compartment lower guard plate ①.
• Tightening torque of bolt (arrow B): 6±2Nm

d. Place a container for collecting the coolant

under the vehicle.
e. Loosen the fixing clamp as arrowed, disconnect
the radiator water outlet hose ① from the radiator,
and drain the coolant.

Filling

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Maintenance Manual of 1.5GDI Engine 2-579Cooling system

Adding coolant
- Connect the radiator water outlet hose to the
radiator, and install the fixing clamp in its original
position.
- Slowly add the coolant until it reaches the MAX
mark of the expansion tank assembly.
- Install the expansion tank cap.
- Turn off the A/C, start the engine and increase
the engine speed to 2000r/min, keep the cooling
fan assembly on, observe the coolant level, and
add the coolant if necessary, so that its level is
between the marks MAX and MIN.

2.9.8.2 Removing and installing expansion tank

assembly
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Drain the coolant. Refer to 1.8.4.5 Changing
coolant.
3 Remove the expansion tank assembly
a. Undo the fixing clamp (arrow A), and disconnect
the expansion tank water return hose II ① from
the expansion tank assembly.
b. Undo the fixing clamp (arrow B), and disconnect
the radiator overflow hose ② from the expansion
tank assembly.

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Cooling system 2-580 Maintenance Manual of 1.5GDI Engine

c. Unscrew the fixing bolt of expansion tank

assembly ① as arrowed.
• Tightening torque of bolt: 8±2Nm

d. Loosen the fixing clamp as arrowed, and

disconnect the expansion tank water outlet hose
①.
e. Take off the expansion tank assembly ②.

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.9.8.3 Removing and installing thermostat
assembly
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.
3 Drain the coolant. Refer to 1.8.4.5 Changing
coolant.
4 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly.
5 Remove the intercooler air outlet tube. Refer to
2.10.8.6 Removing and installing intercooler air
outlet tube .

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Maintenance Manual of 1.5GDI Engine 2-581Cooling system

6 Remove the thermostat assembly.

a. Undo the fixing clamp (arrow A), and disconnect
the radiator water inlet hose ① from the
thermostat assembly.
b. Undo the fixing clamp (arrow B), and disconnect
the radiator water outlet hose ① from the
thermostat assembly.
Tip:
Before disconnecting the hose from the thermostat
assembly, place the container for collecting the
coolant under the vehicle.

c. Unscrew the fixing bolt as arrowed, and take off

the thermostat assembly ①.
• Tightening torque of bolt: 9±0.9Nm
Tip: The thermostat assembly and the water inlet
and outlet hose joints of the radiator are integrated
together, and the internal components of the
thermostat assembly cannot be replaced
separately.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- The O-ring ① must be replaced every time the
thermostat assembly is removed and reinstalled.
- Soak the new O-ring ① in the coolant.

2.9.8.4 Removing and installing water pump

assembly
Removal procedure
1 Drain the coolant. Refer to 1.8.4.5 Changing
coolant.
2 Remove the front right wheel assembly. Refer
to 5.2.7.1 Removing and installing wheel
assembly.
3 Remove the front right wheel mudguard
assembly. Refer to 11.4.1.4 Removing and
installing front wheel mudguard.
4 Remove the V-ribbed belt. Refer to 2.13.9.1
Removing and installing V-ribbed belt.
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Cooling system 2-582 Maintenance Manual of 1.5GDI Engine

5 Remove the water pump assembly.

a. Undo the fixing clamp as arrowed, and remove
the intercooler air outlet hose I ①.

b. Unscrew the fixing bolts as arrowed, and take off

the water pump assembly ①.
• Tightening torque of bolt: 9±0.9Nm

Installation procedure

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Maintenance Manual of 1.5GDI Engine 2-583Cooling system

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
- Replace the seal ring ① of the water pump.
- Before installing the water pump assembly, apply
a coat of coolant to the seal ring ① of the water
pump to prevent the seal ring form breakage.

- Tighten the fixing bolts of water pump assembly

in the order of ① to ⑥ as shown in the figure.
• Tightening torque of bolt: 9±0.9Nm

2.9.8.5 Removing and installing radiator

Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.
3 Recover the refrigerant. Refer to 8.4.7.1
Recovering/adding refrigerant.
4 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly.
5 Remove the cooling fan assembly. Refer to
2.9.8.6 Removing and installing cooling fan
assembly.
6 Drain the coolant. Refer to 1.8.4.5 Changing
coolant.
7 Remove the front bumper assembly. Refer to
10.6.2.1 Removing and installing front bumper
assembly.

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Cooling system 2-584 Maintenance Manual of 1.5GDI Engine

8 Remove the radiator.

a. Undo the fixing clamp as arrowed, and
disconnect the radiator water outlet hose ① from
the radiator.

b. Unscrew the fixing bolt of the A/C high- and

low-pressure pipe assembly IⅠ as arrowed.
• Tightening torque of bolt: 8±2Nm

c. Loosen the fixing clamp (arrow A), and

disconnect the radiator overflow hose ① from the
radiator.
d. Loosen the fixing clamp (arrow B), and
disconnect the water inlet hose ② from the
radiator.
e. Unscrew the fixing nut (arrow C), and
disconnect the A/C exhaust pipe assembly I ③
and the A/C high- and low-pressure pipe assembly
Ⅱ④.
• Tightening torque of nut (arrow C): 8±2Nm

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Maintenance Manual of 1.5GDI Engine 2-585Cooling system

f. Unscrew the fixing bolt as arrowed, and take off

the left mounting bracket ① of radiator.
• Tightening torque of bolt: 8±2Nm

g. Unscrew the fixing bolt as arrowed, and take off

the right mounting bracket ① of radiator.
h. Remove the radiator with condenser assembly.
• Tightening torque of bolt: 8±2Nm

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Cooling system 2-586 Maintenance Manual of 1.5GDI Engine

i. Unscrew the fixing bolt (arrows A and B), and

take off the condenser assembly ① and the
radiator ②.
• Tightening torque of bolt (arrow A): 8±2Nm
• Tightening torque of bolt (arrow B): 8±2Nm

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- When taking off the condenser assembly, avoid
scratching or damaging the cooling fins of the
condenser assembly.
- After installation, vacuumize the HVAC system. Refer to
8.4.7.3 Vacuumizing A/C system.
- Add compressor lubricating oil. Refer to 8.4.7.2
Recovering/adding compressor lubricating oil.
- Add the refrigerant. Refer to 8.4.7.1
Recovering/adding refrigerant.
- Add the coolant. Refer to 1.8.4.5 Changing
coolant.
2.9.8.6 Removing and installing cooling fan
assembly
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.
3 Remove the intake pipe assembly. Refer to
2.6.7.3 Removing and installing intake pipe
assembly.
4 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly.

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Maintenance Manual of 1.5GDI Engine 2-587Cooling system

5 Remove the cooling fan assembly.

a. Unscrew the fixing screw as arrowed, and take
off the air cleaner fixing bracket II ①.

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Cooling system 2-588 Maintenance Manual of 1.5GDI Engine

b. Disconnect the cooling fan assembly connector

as arrowed.

c. Unscrew the fixing nut as arrowed, and take off

the cooling fan assembly ①.

Installation procedure
The installation procedure is in reverse of removal
procedure.

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Maintenance Manual of 1.5GDI Engine 2-589Turbocharger system

2.10 Turbocharger system

2.10.1 Specifications
2.10.1.1 Fastener specifications
Location Specification Tightening torque, N.m
Expansion tank water return tube Hexagon flange bolt M6×12 8±2
Turbocharger oil inlet pipe and Hollow hexagon socket bolt
25±2.5
turbocharger connection M10×1×25
Turbocharger oil inlet pipe and Hollow hexagon socket bolt
30±2
cylinder block connection M12X1.5X26
Hollow hexagon socket bolt
Turbocharger water inlet pipe 30±2
M12X1.5X26
Water inlet pipe Hexagon flange bolt M8×16 25±2.5
Turbocharger oil return pipe Hexagon flange bolt M6×14 9±0.9
Turbocharger vortex end inlet Heat-resistant hexagon flange
25±2
and outlet nut M8
Turbocharger vortex end inlet Heat-resistant stud M8×30 14.5±1.5
Hollow hexagon socket bolt
Turbocharger water return pipe 30±2
M12X1.5X30
Electronic intake air recirculation Hexagon socket head bolt
8±2
valve M6×18
Upper mounting brackets of
intercooler fixed on both sides of Hexagon flange bolt M6×25 8±2
front-end module
MAP/IAT sensor (charge air
Hexagon flange bolt M5×16 5±0.5
pressure)
Intercooler air outlet tube fixed on
Hexagon flange bolt M6×25 8±2
its fixing bracket
Intercooler air outlet tube fixed on
fixing bracket of heater water Hexagon flange bolt M6×25 8±2
outlet pipe
Intercooler air outlet tube fixed on
fixing bracket of intercooler Hexagon flange bolt M6×25 8±2
intake tube

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Turbocharger system 2-590 Maintenance Manual of 1.5GDI Engine

2.10.2 Description and operation

2.10.2.1 Overview
Overview
1.5TGDI engine adopts a low-inertia turbocharger assembly. It combines high-speed power and
low-speed torque through the precise matching of the turbocharger and the engine, providing continuous
surging power for the vehicle. With the turbocharging technology, the vehicle's adaptability to plateau is
greatly improved.
The turbocharger assembly is actually a combination of turbine and compressor. The cast exhaust
manifold is connected to the turbine, and the air intake pipe is connected to the compressor. The turbine
and compressor have one impeller respectively, and the two impellers are connected by a full floating
turbine shaft. When the exhaust gas is discharged, it flows through the turbine and drives its impeller.
Because the turbine impeller and the compressor impeller are directly connected by a full floating turbine
shaft, once the turbine impeller rotates, the compressor impeller rotates synchronously to compress the
intake air.
The turbocharger system is composed of turbocharging and cooling parts. Their main components are
turbocharger and intercooler respectively. The turbocharger drives the turbine blade with the emission of
exhaust gas to compress the intake air, improving the charging efficiency. As the engine adopts the
turbocharging technology, its maximum power and torque are increased significantly, the fuel economy
is improved, and the exhaust emissions are reduced. The intercooler is a vane type radiator. The
turbocharger itself is hot and likely to heat the air. Besides, air also heats up after compressed, and
expands after overheated, affecting the charging efficiency. Therefore, an intercooler is needed to cool
the air.
The turbocharger assembly is of high precision. Its working environment is harsh, so it needs to be
lubricated and cooled. The turbocharger assembly is provided with oil inlet and outlet, as well as water
inlet and outlet.

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Maintenance Manual of 1.5GDI Engine 2-591Turbocharger system
2.10.3 System working principles
2.10.3.1 System working principles
Operating principle
The turbocharger pushes the turbine in the turbine chamber by using the inertial impulse of exhaust gas
discharged from the engine, and the turbine drives the coaxial impeller to compress the air from the air
cleaner pipe to the cylinder, thus increasing the amount of intake air. ECM can control the charge air
pressure in real time by controlling the wastegate to meet the demands under various working
conditions; after the accelerator pedal is suddenly released, to avoid airflow fluctuations in the intake
system caused by intake inertia, the turbocharger system achieves the backflow of compressed air
through the electronic intake air recirculation valve to ensure stable flow in the intake system.
The hot air pressurized by the turbocharger flows through the intercooler assembly for cooling down to
decrease own temperature and increase the intake air density, and then enters the cylinder, thus
increasing the engine power and reducing the fuel consumption and harmful emissions.
When the engine speed increases, the exhaust gas discharging speed and the turbine speed increase
simultaneously, and the impeller compresses more air into the cylinder. Higher air pressure and density
can cause more fuel to be burned, and the fuel quantity increases and the engine speed is adjusted
accordingly, increasing the output power of the engine.

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Turbocharger system 2-592 Maintenance Manual of 1.5GDI Engine
2.10.4 Location of components
2.10.4.1 Location of components

Intercooler air outlet hose

II
Intercooler air inlet hose I

Electronic intake air

MAP/IAT sensor (charge air recirculation valve
pressure)

Intercooler air outlet Intercooler air inlet tube

hose I

Intercooler air outlet tube

Intercooler air inlet hose II

Intercooler assembly

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Maintenance Manual of 1.5GDI Engine 2-593Turbocharger system

Turbocharger assembly

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Turbocharger system 2-594 Maintenance Manual of 1.5GDI Engine
2.10.5 Exploded view
2.10.5.1 Exploded view

(3 in total)
Turbocharger oil inlet pipe
assembly

Turbocharger water inlet

pipe assembly

(3 in total)

Turbine outlet
gasket

Turbocharger
assembly

Turbocharger water
(7 in total) return pipe assembly

Turbine inlet gasket

(4 in total)

Turbocharger oil return

pipe assembly

Turbocharger oil return pipe

(4 in total) gasket
(2 in total)

Disposable part:
Tightening torque is represented in N•m

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Maintenance Manual of 1.5GDI Engine 2-595Turbocharger system

MAP/IAT sensor (charge air Intercooler air outlet hose

pressure) II

Intercooler air outlet hose I

Intercooler air outlet tube fixing

bracket
Intercooler air outlet tube

Intercooler air inlet

hose I

Electronic intake air

recirculation valve

(3 in total)
(3 in total)

Intercooler air inlet tube Intercooler air inlet tube

bracket

Intercooler assembly Intercooler air inlet

hose II

(2 in total)

Tightening torque is represented in N•m

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Turbocharger system 2-596 Maintenance Manual of 1.5GDI Engine
2.10.6 Electrical schematic diagram
2.10.6.1 Electrical schematic diagram

Turbine blade Pump impeller blade

Catalytic converter Fresh air

assembly

Bypass valve

To combustion
chamber

Combustion chamber
exhaust gas

High pressure air from solenoid

valve High pressure air to
solenoid valve

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Maintenance Manual of 1.5GDI Engine 2-597Turbocharger system
2.10.7 Diagnostic information and procedure
2.10.7.1 Diagnostic instructions
Familiarize yourself with the system functions and operations before starting the system diagnosis. This
helps you correctly determine the fault cause when a fault occurs, and more importantly, helps
determine whether the situation described by the customer is normal.
2.10.7.2 Visual inspection
• Check the aftermarket parts that may affect the operation of the turbocharger system.
• Check the accessible or visible system components for obvious damage or external leakage.
2.10.7.3 Sudden shutdown of turbocharger
Diagnostic procedure
Step 1 Check whether the turbocharger pump impeller blade is stuck by foreign objects.

Y Remove the foreign materials.

Step 2 Check whether the turbocharger pump impeller blade is broken and stuck.

Y Replace the turbocharger

assembly.
N

Step 3 Check whether the turbocharger pump impeller blade rotates smoothly.

N It is caused by damaged bearing

or burnt rotor assembly. In this
case, replace the turbocharger
assembly.
Y

Step 4 Check whether the turbocharger bypass valve is disconnected or damaged.

Y Replace the turbocharger

assembly.
Y

Step 5 Check whether the turbocharger turbine blade is broken or damaged.

Y Replace the turbocharger

assembly.

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Turbocharger system 2-598 Maintenance Manual of 1.5GDI Engine

Next step

Step 6 End.
2.10.7.4 Oil leakage of turbocharger
Diagnostic procedure
Step 1 Check whether the turbocharger oil passage is connected properly.

N Tighten the oil passage fixing

bolts of the turbocharger.
Y

Step 2 Check whether the engine oil is dirty or deteriorated.

Y Change the engine oil.

Step 3 Check whether oil sticks to the inner wall of intercooler air intake pipe.

Y Check the oil return pipe or

replace the turbocharger
assembly.
Next step

Step 4 End.

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Maintenance Manual of 1.5GDI Engine 2-599Turbocharger system

2.10.8 Removal and installation

2.10.8.1 Removing and installing turbocharger
assembly
Removal procedure
Tip:
If the engine is hot, wait until it cools down naturally
before operation.
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.
3 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly.
4 Remove the air pipe assembly. Refer to
2.6.7.3 Removing and installing intake pipe
assembly.
5 Drain the coolant. Refer to 1.8.4.5 Changing
coolant.
6 Remove the catalytic converter assembly.
Refer to 2.5.6.2 Removing and installing catalytic
converter assembly.
7 Remove the turbocharger assembly.
a. Disconnect the ignition coil connectors (arrow A).
b. Undo the fixing clip (arrow B).

c. Unscrew the fixing bolt of expansion tank water

return tube ① as arrowed.
• Tightening torque of bolt: 8±2Nm

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Turbocharger system 2-600 Maintenance Manual of 1.5GDI Engine

d. Loosen the fixing clamp as arrowed, and

disconnect the turbocharger overflow hose ①
from the turbocharger water return pipe assembly
②.

e. Loosen the fixing clamp as arrowed, and

disconnect the turbocharger cooling tube
connecting hose II ① from the turbocharger water
return pipe assembly.

f. Unscrew the hollow hexagon socket bolt as

arrowed, disconnect the turbocharger oil inlet pipe
assembly ① from the turbocharger assembly,
and remove the gasket.
• Tightening torque of bolt: 25±2.5Nm
Tip:
The gasket must be replaced every time the
turbocharger oil inlet pipe assembly is removed.

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Maintenance Manual of 1.5GDI Engine 2-601Turbocharger system

g. Unscrew the fixing bolt as arrowed, disconnect

the turbocharger water inlet pipe assembly ①
from the turbocharger assembly, and remove the
gasket.
• Tightening torque of bolt: 30±2Nm
Tip:
Before unscrewing the fixing bolts of the
turbocharger water inlet pipe assembly, place a
suitable container below to collect the coolant.
The gasket must be replaced every time the water
inlet pipe assembly of the turbocharger is
removed.

h. Disconnect the boost pressure control solenoid

valve connector as arrowed.

i. Loosen the fixing clamps as arrowed and remove

the intercooler air intake hose ①.

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Turbocharger system 2-602 Maintenance Manual of 1.5GDI Engine

j. Unscrew the fixing bolt (arrow A), and disconnect

the turbocharger oil inlet pipe assembly ① from
the cylinder head.
k. Unscrew the fixing bolt (arrow B), disconnect the
turbocharger oil return pipe assembly ② from the
cylinder block, and remove the gasket.
• Tightening torque of bolt (arrow A): 30±2Nm
• Tightening torque of bolt (arrow B): 9±0.9Nm
Tip:
The gasket must be replaced every time the
turbocharger oil return pipe assembly is removed.

l. Unscrew the fixing nut as arrowed, and remove

the turbocharger assembly ①.
• Tightening torque of nut: 25±2Nm
Tip:
Every time the turbocharger assembly is removed,
the stud and nut must be replaced.

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Maintenance Manual of 1.5GDI Engine 2-603Turbocharger system

m. Unscrew the fixing bolt as arrowed, take off the

turbocharger oil return pipe assembly ① , and
remove the gasket.
• Tightening torque of bolt: 9±0.9Nm
Tip: Every time the turbocharger oil return pipe
assembly is removed, the gasket must be
replaced.

n. Unscrew the fixing bolt as arrowed, disconnect

the turbocharger water return pipe assembly ①,
and remove the gasket.
• Tightening torque of bolt: 30±2Nm
Tip:
The gasket must be replaced every time the
turbocharger water return pipe assembly is
removed.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- Gaskets must be replaced with new ones every
time the turbocharger oil inlet pipe assembly,
turbocharger oil return pipe assembly,
turbocharger water inlet pipe assembly and
turbocharger water return pipe assembly are
removed.
- Every time the turbocharger assembly is
removed, the stud and nut must be replaced.
- Check the coolant level, and add coolant if
necessary.
2.10.8.2 Removing and installing boost
pressure control solenoid valve
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.

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Turbocharger system 2-604 Maintenance Manual of 1.5GDI Engine

3 Remove the boost pressure control solenoid

valve.
a. Remove the engine upper guard plate assembly
①.

b. Disconnect the boost pressure control solenoid

valve connector as arrowed.

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Maintenance Manual of 1.5GDI Engine 2-605Turbocharger system

c. Loosen the fixing clamp as arrowed, and

disconnect the boost pressure control solenoid
valve connecting pipeline.

d. Unscrew the fixing screw as arrowed, and take

off the boost pressure control solenoid valve ①.

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.10.8.3 Removing and installing electronic
intake air recirculation valve
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.
3 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly.

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Turbocharger system 2-606 Maintenance Manual of 1.5GDI Engine

4 Remove the electronic intake air recirculation

valve
a. Disconnect the electronic intake air recirculation
valve connector as arrowed.

b. Unscrew the fixing bolt as arrowed, and take off

the electronic intake air recirculation valve ①.
• Tightening torque of bolt: 8±2Nm

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- During installation of the electronic intake air
recirculation valve, the O-ring ① must be
replaced.

2.10.8.4 Removing and installing intercooler

assembly
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.
3 Remove the front bumper assembly. Refer to
10.6.2.1 Removing and installing front bumper
assembly.

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Maintenance Manual of 1.5GDI Engine 2-607Turbocharger system

4 Remove the intercooler assembly.

a. Unscrew the fixing bolt as arrowed, and remove
the MRR assembly with bracket ①.
• Tightening torque of bolt: 8±2Nm

b. Undo the clamp (arrow A), and disconnect the

intercooler air outlet hose ① from the intercooler
assembly ②.
c. Unscrew the fixing bolt (arrow B) of the
intercooler left mounting bracket.
• Tightening torque of bolt (arrow B): 8±2Nm

GAC Motor 2019

Turbocharger system 2-608 Maintenance Manual of 1.5GDI Engine

d. Undo the clamp (arrow A), and disconnect the

intercooler air intake hose II ① from the
intercooler assembly ②.
e. Unscrew the fixing bolt (arrow B) of the
intercooler right mounting bracket.
• Tightening torque of bolt (arrow B): 8±2Nm

f. Take off the intercooler assembly ①.

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.10.8.5 Removing and installing MAP/IAT
sensor (charge air pressure)
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.
3 Remove the intake pipe assembly. Refer to
2.6.7.3 Removing and installing intake pipe
assembly.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-609Turbocharger system

4 Remove the MAP/IAT sensor (charge air

pressure)
a. Disconnect the MAP/IAT sensor (charge air
pressure) connector as arrowed.

b. Unscrew the fixing bolt as arrowed, and take off

the MAP/IAT sensor (charge air pressure) ①.
• Tightening torque of bolt: 5±0.5Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.10.8.6 Removing and installing intercooler air
outlet tube
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.
3 Remove the intake pipe assembly. Refer to
2.6.7.3 Removing and installing intake pipe
assembly.
4 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly.

GAC Motor 2019

Turbocharger system 2-610 Maintenance Manual of 1.5GDI Engine

5 Remove the intercooler air outlet tube

a. Disconnect the MAP/IAT sensor connector
(arrow A).
b. Press the quick connector (arrow B), and
disconnect the fuel vapor pipe assembly I ② from
the intercooler air outlet tube.
c. Unscrew the fixing bolts (arrow C).
d. Loosen the clamp (arrow D), and remove the
intercooler air outlet tube with MAP/IAT sensor ②.
• Tightening torque of bolt (arrow C): 8±2Nm

e. Unscrew the fixing bolt as arrowed, and take off

the MAP/IAT sensor ①.
• Tightening torque of bolt: 5±0.5Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.10.8.7 Removing and installing intercooler air
intake tube
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.
3 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly.
4 Remove the electronic intake air recirculation
valve

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-611Turbocharger system

5 Remove the intercooler air intake tube

a. Undo the fixing clamp as arrowed, and
disconnect the intercooler air intake hose II from
the intercooler air intake tube ①.

b. Pry up the detent (arrow A) and remove the

relief pipe ①.
c. Loosen the fixing clamp (arrow B), and
disconnect the intercooler air intake hose I ②
from the intercooler air intake tube ③.
d. Undo the clip (arrow C), and unscrew the fixing
bolt (arrow D).e. Take off the intercooler air intake
tube ③.
• Tightening torque of bolt (arrow D): 8±2Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.

GAC Motor 2019

Engine assembly 2-612 Maintenance Manual of 1.5GDI Engine

2.11 Engine assembly

2.11.1 Specifications
2.11.1.1 Fastener specifications
Location Specification Tightening torque, N.m
Engine compartment harness [to
Hexagon flange nut M6 6±1
the positive battery terminal]
Engine harness fixed to the
engine compartment harness Hexagon flange bolt M6×16 8±2
PDU
Hexagon flange bolt M6×16 8±2
Expansion tank assembly
Hexagon flange bolt M6×30 8±2
Engine ground wire [body] Ground bolt M8×20 24±3
Radiator water outlet pipe fixing
Hexagon flange bolt M6×25 8±2
bracket
All-metal hexagon flange lock nut
A/C low-pressure pipe assembly 10±2
M6
All-metal hexagon flange lock nut
A/C exhaust pipe assembly I 10±2
M6
Hexagon flange nut M14×1.5 160±15
Torsion rod assembly fixed on
the subframe Hexagon flange bolt
160±15
M14×1.5×100
Torsion rod assembly fixed on Hexagon flange bolt
160±15
the transmission M14×1.5×85
Left mounting assembly fixed on Hexagon flange bolt
150±15
the transmission M12×1.25×65
Right mounting assembly fixed Hexagon flange bolt
150±15
on the engine M12×1.25×55
Hydraulic torque converter and Hydraulic torque converter bolt
58±8
drive plate connection M10×1.25×13
Transmission and engine block Hexagon flange bolt
100±10
connection M12×1.25×60
Transmission and oil pan Hexagon flange bolt
55±5
connection M10×1.25×50
Transmission and engine block
Hexagon flange nut M12×1.25 100±10
connection

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-613Engine assembly

2.11.2 Location of components

2.11.2.1 Location of components

Engine assembly

GAC Motor 2019

Engine assembly 2-614 Maintenance Manual of 1.5GDI Engine
2.11.3 Special tools
2.11.3.1 List of special tools
No. Legend Tool No. Name

1 8910005BAC0000 Engine stand

Engine stand
2 8910003ASV0000
accessories

3 8910006ASV0000 Engine lifting lug

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-615Engine assembly

2.11.4 Removal and installation

2.11.4.1 Installing engine stand
Installation procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal. Refer to
1.8.6.1 Maintaining and inspecting battery.
3 Remove the wiper cover assembly. Refer to
10.3.2.1 Removing and installing wiper cover.
4 Install the engine stand.
a. Install the engine lifting lug ①
(8910006ASV0000) to the threaded hole as
arrowed on the mechanical vacuum pump, and
tighten the bolts.

b. Install the engine lifting lug ①

(8910006ASV0000) to the threaded hole as
arrowed on the cast exhaust manifold, and tighten
the bolts.

GAC Motor 2019

Engine assembly 2-616 Maintenance Manual of 1.5GDI Engine

c. Assemble the engine stand (8910005BAC0000)

and engine stand accessories (8910003ASV0000)
group ① as shown in the figure, and fix it on the
body.

d. Connect the engine stand adjusting rods ①

and ② to the engine lifting lug
(8910006ASV0000).
e. Adjust the engine stand adjusting rods ① and
② to hoist the engine steadily.

Removal procedure
The removal procedure is in reverse of installation
procedure.
2.11.4.2 Removing and installing powertrain
Removal procedure
Tip:
Remove the engine and transmission together. All
harnesses disconnected during removal must be
restored during installation. After disconnection,
each pipe shall be plugged to prevent impurities
from entering.
1 Release the fuel system pressure. Refer to
2.3.9.1 Releasing fuel system pressure.
2 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
3 Recover the A/C refrigerant. Refer to 8.4.7.1
Recovering/adding refrigerant.
4 Drain the coolant. Refer to 1.8.4.5 Changing
coolant.
5 Remove the left and right front wheel
assemblies. Refer to 5.4.8.12 Removing and
installing front left driving axle assembly.
6 Remove the left and right front driving axle
assembly. Refer to 5.4.8.13 Removing and
installing front right driving axle assembly.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-617Engine assembly

7 Remove the catalytic converter assembly II.

Refer to 2.5.6.3 Removing and installing catalytic
converter assembly II.
8 Remove the front pedestrian lower leg
protection support assembly. Refer to 10.6.2.4
Removing and installing front pedestrian lower leg
protection support assembly.
9 Remove the air pipe assembly. Refer to
2.6.7.4 Removing and installing air pipe assembly.
10 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly.
11 Remove the battery. Refer to 2.15.8.3 Removing
and installing battery.
12 Remove the battery tray. Refer to 2.15.8.5
Removing and installing battery tray.
13 Remove the cooling fan assembly. Refer to
2.9.8.6 Removing and installing cooling fan
assembly.
14 Remove the powertrain
a. Press the clip as arrowed, and remove the
engine compartment PDU cover ①.

b. Unscrew the fixing nut (arrow A), and disengage

the fixing clip (arrow B) of harness ①.
• Tightening torque of nut (arrow A): 6±1Nm

GAC Motor 2019

Engine assembly 2-618 Maintenance Manual of 1.5GDI Engine

c. Disconnect the engine harness connectors

(arrows A, B and C).
d. Unscrew the fixing bolt (arrow D).
e. Disconnect the fixing clip (arrow E), and
disconnect the engine harness ① from the body.
• Tightening torque of bolt (arrow D): 8±2Nm

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-619Engine assembly

f. Disconnect the connector (arrow A), and undo

the fixing clip (arrow B).

g. Disconnect the vent pipe ① (arrow A) from the

vacuum brake hose assembly ②.
h. Disconnect the vacuum brake hose assembly
② (arrow B) from the vacuum booster.

i. Loosen the clamp as arrowed, and disconnect

the heater water outlet pipe ① and heater water
inlet pipe ②.

GAC Motor 2019

Engine assembly 2-620 Maintenance Manual of 1.5GDI Engine

j. Undo the fixing clamp as arrowed, and

disconnect the intercooler air intake hose II ①
from the intercooler air intake tube.

k. Undo the fixing clamp as arrowed, and

disconnect the radiator water inlet hose ① from
the radiator.

l. Loosen the fixing clamps (arrows A, B and C),

and disconnect each pipe.
m. Unscrew the fixing bolt (arrow D), and remove
the expansion tank with accessories ①.
• Tightening torque of bolt (arrow D): 8±2Nm

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-621Engine assembly

n. Press the quick connector (arrow A), and

disconnect the engine oil inlet pipe ① from the
fuel evaporation and supply pipe assembly Ⅱ.
o. Press the quick connector (arrow B), and
disconnect the canister outlet hose Ⅲ ② from the
fuel evaporation and supply pipe assembly Ⅱ.
p. Unscrew the fixing bolt (arrow C), and remove
the engine oil inlet pipe ① with canister outlet
hose Ⅲ ②.
• Tightening torque of bolt (arrow C): 8±2Nm

q. Unscrew the fixing bolt of engine ground wire ①

as arrowed.
• Tightening torque of bolt: 24±3Nm

r. Loosen the fixing clamp (arrow A), and

disconnect the radiator water outlet hose ① from
the radiator.
s. Undo the clip (arrow B), unscrew the fixing bolt
(arrow C), and take off the radiator water outlet
hose fixing bracket ②.
• Tightening torque of bolt (arrow C): 8±2Nm

GAC Motor 2019

Engine assembly 2-622 Maintenance Manual of 1.5GDI Engine

t. Loosen the fixing clamp as arrowed, and remove

the intercooler air outlet hose I ①.

u. Unscrew the fixing nut as arrowed, and

disconnect the A/C exhaust pipe assembly I ①
and the A/C low-pressure pipe assembly ②.
• Tightening torque of nut: 10±2Nm

v. Unscrew the fixing bolts (arrows A and B), and

remove the torsion rod assembly ①.
• Tightening torque of bolt (arrow A): 160±15Nm
• Tightening torque of bolt (arrow B): 160±15Nm

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-623Engine assembly

w. Place a movable flat workbench under the

powertrain, and lower the vehicle until the
workbench supports the powertrain firmly.
x. Unscrew the fixing bolts (arrows A and B) of left
mounting assembly. Remove the left mounting
assembly ①.
Tightening torque of bolt (arrow A): 150±15Nm
Tightening torque of bolt (arrow B): 110±10Nm
• Tip:
The disassembly here is based on the 6MT model
as an example. For the disassembly steps of the
6AT model, refer to the Maintenance Manual of
Automatic Transmission - Disassembling and
assembling automatic transmission assembly.
y. Unscrew the fixing bolts (arrows A and B).
z. Remove the right mounting assembly ①.
Tightening torque of bolt (arrow A): 150±15Nm
Tightening torque of bolt (arrow B): 110±10Nm
• Tip:
When removing the powertrain as a whole,
carefully check whether the connections such as
harnesses and pipelines between the engine,
transmission and the body are disconnected while
slowly raising the lift.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- Fill all components with oil as specified.
2.11.4.3 Separating engine assembly and
transmission assembly
Removal procedure
1 Remove the powertrain. Refer to 2.11.4.2
Removing and installing powertrain.
2 Remove the intercooler air intake tube. Refer
to 2.10.8.7 Removing and installing intercooler air
intake tube.
3 Remove the starter. Refer to 2.15.8.2 Removing
and installing starter.
4 Remove the shift-by-wire actuator assembly

GAC Motor 2019

Engine assembly 2-624 Maintenance Manual of 1.5GDI Engine

5 Separate the engine and the transmission

a. Loosen the clamp as arrowed, and disconnect
the oil cooler water pipe ①.

b. Rotate the fixing bolt (arrow B) of crankshaft

damper pulley ① in the direction of arrow A, and
unscrew the bolts (arrow C) (6 in total) connecting
the hydraulic torque converter assembly and the
drive plate.
• Tightening torque of bolt (arrow C): 58±8Nm

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-625Engine assembly

c. Disconnect the TCM connector as arrowed.

d. Unscrew the bolts (arrows A and B) connecting

the engine assembly and the transmission
assembly.
e. Unscrew the fixing nut (arrow C), and separate
the transmission assembly ① and the engine
assembly.
• Tightening torque of bolt (arrow A): 100±10Nm
• Tightening torque of bolt (arrow B): 55±5Nm
• Tightening torque of nut (arrow C): 100±10Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.

GAC Motor 2019

Engine mounting 2-626 Maintenance Manual of 1.5GDI Engine

2.12 Engine mounting

2.12.1 Specifications
2.12.1.1 Fastener specifications
AT Location Specification Tightening torque, N.m
Torsion rod assembly and
Hexagon flange bolt M14×1.5×85 160±15
transmission connection
Torsion rod assembly and
Hexagon flange nut M14×1.5 -----
subframe connection
Torsion rod assembly and
Hexagon flange bolt M14×1.5×100 160±15
subframe connection
Left mounting assembly mounted
Hexagon flange bolt M12×1.25×35 110±10
on body
Left mounting assembly mounted
Hexagon flange bolt M12×1.25×60 110±10
on body longitudinal beam
Left mounting assembly mounted
Hexagon flange bolt M12×1.25×60 65±5
on transmission
Right mounting assembly and
Hexagon flange bolt M12×1.25×92 110±10
body longitudinal beam
Right mounting assembly and
Hexagon flange bolt M12×1.25×35 110±10
body connection
Right mounting assembly
Hexagon flange bolt M12×1.25×55 150±15
mounted on powertrain bracket

MT Location Specification Tightening torque, N.m

Torsion rod assembly and
Hexagon flange bolt M14×1.5×80 160±15
transmission connection
Torsion rod assembly and
Hexagon flange nut M14×1.5 -----
transmission connection
Torsion rod assembly and
Hexagon flange nut M14×1.5 -----
subframe connection
Torsion rod assembly and
Hexagon flange bolt M14×1.5×100 160±15
subframe connection
Left mounting assembly mounted
Hexagon flange bolt M12×1.25×35 110±10
on body
Left mounting assembly mounted
Hexagon flange bolt M12×1.25×60 110±10
on body longitudinal beam
Left mounting assembly mounted
Hexagon flange bolt M12×1.25×55 65±5
on transmission upper bracket
Right mounting assembly and
Hexagon flange bolt M12×1.25×60 110±10
body longitudinal beam
Right mounting assembly and
Hexagon flange bolt M12×1.25×35 110±10
body connection
Right mounting assembly
Hexagon flange bolt M12×1.25×55 150±15
mounted on powertrain bracket

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-627Engine mounting

2.12.2 Location of components

2.12.2.1 Location of components

Right mount
assembly

Left mount
assembly

Torsion rod
assembly

GAC Motor 2019

Engine mounting 2-628 Maintenance Manual of 1.5GDI Engine
2.12.3 Exploded view
2.12.3.1 Exploded view

(2 in total)

(3 in total) (3 in total)

Torsion rod
assembly
(2 in total)

Right mount
Left mount assembly
assembly

(2 in total)

(2 in total)
(4 in total)
(3 in total)
Torsion rod
assembly

Left mount Right mount

assembly assembly

Tightening torque is represented in N•m

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-629Engine mounting

2.12.4 Removal and installation

2.12.4.1 Removing and installing left mounting
assembly
Removal procedure
1 Power off all electrical consumers, and turn
off the ignition switch or ENGINE START/STOP
button.
2 Remove the air cleaner assembly. Refer to
11.8.4.2 Replacing air cleaner.
3 Remove the battery
4 Remove the battery tray
5 Install the engine stand.
6 Remove the left mounting assembly
a. Unscrew the fixing bolts (arrows A and B) of left
mounting assembly.
b. Take off the left mounting assembly ①.
Tightening torque of bolt (arrow A): 150±15Nm
Tightening torque of bolt (arrow B): 110±10Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.

GAC Motor 2019

Engine mounting 2-630 Maintenance Manual of 1.5GDI Engine

2.12.4.2 Removing and installing right

mounting assembly
Removal procedure
1 Power off all electrical consumers, and turn
off the ignition switch or ENGINE START/STOP
button.
2 Disconnect the negative battery terminal.
3 Recover the refrigerant. Refer to 8.4.7.1
Recovering/adding refrigerant.
4 Remove the A/C high- and low-pressure pipe
assembly I
5 Install the engine stand.
6 Remove the right mounting assembly
a. Unscrew the bolt as arrowed, and move the
expansion tank assembly ① aside.
Tightening torque of bolt: 8±2Nm

b. Unscrew the fixing bolt of the high- and low-

pressure pipe assembly Ⅰ ① as arrowed.
Tightening torque of bolt: 8±2Nm

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-631Engine mounting

c. Unscrew the fixing bolts (arrows A and B) of

right mounting assembly, and take off the right
mounting assembly ①.
Tightening torque of bolt (arrow A): 150±15Nm
Tightening torque of bolt (arrow B): 110±10Nm

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
Replace the O-ring with a new one, and apply the
A/C compressor lubricating oil to the new O-ring.
Vacuumize the HVAC system after installation.
Refer to 8.4.7.3 Vacuumizing HVAC system.
Add the refrigerant. Refer to 8.4.7.1
Recovering/adding refrigerant.

GAC Motor 2019

Engine mounting 2-632 Maintenance Manual of 1.5GDI Engine

2.12.4.3 Removing and installing torsion rod

assembly
Removal procedure (AT model)
1 Lift the vehicle.
2 Remove the torsion rod assembly.
a. Unscrew the fixing bolts (arrows A and B) of
torsion rod assembly.
b. Unscrew the bolt (arrow C) of the transmission
lower bracket, and take off the transmission lower
bracket ② and the torsion rod assembly ①.
Tightening torque of bolt (arrow A): 160±15Nm
Tightening torque of bolt (arrow B): 160±15Nm
Tightening torque of bolt (arrow C): (65±5) Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.
1 Lift the vehicle (MT model)
2 Remove the torsion rod assembly.
a. Unscrew the fixing bolts (arrows A and B) of
torsion rod assembly, and take off the torsion rod
assembly ①.
Tightening torque of bolt (arrow A): 160±15Nm
Tightening torque of bolt (arrow B): 160±15Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-633Mechanical system

2.13 Mechanical system

2.13.1 Specifications
2.13.1.1 Fastener specifications
Location Specification Tightening torque, N.m
Accessory tensioner Accessory tensioner 50±5
Crankcase vent pipe pressure Hexagon socket head cap bolt
sensor bracket assembly (China and conical elastic washer 9±0.9
VI) assembly M6×18
Oil-gas separator assembly Hexagon flange bolt M6X25 9±0.9
Engine harness grounding point Hexagon flange bolt M6×12 8±2
Expansion tank water return tube Hexagon flange bolt M6×12 8±2
Ignition coil Shoulder stud M6×16×M6×30 9±0.9
Hexagon socket head cap bolt
Phase sensor and conical elastic washer 9±0.9
assembly M6×18
Dipstick tube Hexagon flange bolt M6×12 9±0.9
Oil control valve Hexagon flange bolt M5×12 6±0.5
Mechanical vacuum pump Bolt M6×28 9±1
High-pressure fuel pump Hexagon flange bolt M6×20 9±0.9
High-pressure fuel pipe High-pressure fuel pipe 22.5±2.5
Engine harness [harness guard
Hexagon flange bolt M6×16 8±2
plate 1]
Cylinder head heat shield Hexagon flange bolt M6×12 9±0.9
Hexagon flange bolt M6×50 9±0.9
Cylinder head cover assembly
Hexagon flange bolt M6×53 25±2.5
Cylinder head Cylinder head bolt M9×1.25×137 25+180°
Hexagon flange bolt
50±5
Mounting bracket fixed to engine M10x1.25x75
Hexagon flange bolt M6×75 30±3
Crankshaft damper pulley Damper pulley bolt 120+130°
Hexagon flange bolt M8×16 25±2.5
Water inlet pipe
Hexagon flange bolt M6×12 25±2.5
Shoulder stud M6×16×M6×20 9±0.9
Hexagon flange bolt M6×20 9±0.9
Timing chain cover
Hexagon flange bolt M6×35 9±0.9
Hexagon flange bolt M6×22 20±2.5
Timing tensioner Hexagon flange bolt M6×25 9±0.9
Moving rail Moving rail dowel pin 20±2.5
Fixed rail Hexagon flange bolt M6×12 9±0.9
Cylinder head cover cam phaser
Hexagon head plug M16×1.5 20±2.5
hole
Camshaft bearing cap Hexagon flange bolt M6×30 9±0.9
Hexagon flange bolt
Phase regulator 25+90°
M10×1.25×65

GAC Motor 2019

Mechanical system 2-634 Maintenance Manual of 1.5GDI Engine

Location Specification Tightening torque, N.m

Drive plate Drive plate bolt 30+70°
Hexagon socket head cap screw
Drive plate dust cover I 9±0.9
M6×12
Oil pan baffle Hexagon flange bolt M6×20 9±0.9
Oil cooling nozzle assembly Bolt M10×1.5 25±2.5
Connecting rod Connecting rod bolt 17+90°
Main bearing cap bolt
Main bearing cap 50+90°
M10×1.5×83.5
Hexagon lobular socket pan
Crankshaft rear oil seal assembly 9±0.9
head screw M6×14
2.13.1.2 Specifications of mechanical system
Engine Numerical value
Displacement (mL) 1495
Engine serial number 4A15J1
Number of cylinders/valves for each cylinder 4/4
Rated power/speed (kW/(r/min)) 124/5000
Maximum torque/speed (N·m/(r/min)) 265/1700~4000
Maximum net power/speed (kW/(r/min)) 117/5000
Maximum net torque/speed (N·m/(r/min)) 250/1700~4000
Engine idle speed (r/min) 700±50
Ignition order 1-3-4-2
Bore Φ (mm) 75
Stroke (mm) 84.6
Compression ratio 9.8:1
Fuel #92 or above unleaded gasoline
Emission level China VI
Self-diagnosis Y
Electronic throttle Y
Three-way catalytic converter Y
Air-fuel ratio control and adjustment Y
Camshaft drive mode Chain
2.13.1.3 Selection method of piston, main bearing shell and connecting rod bearing shell
Selection of main bearing shell
- Perform selection according to the selection table and based on the diameter class of crankshaft main
journal and the diameter of cylinder block main bearing hole

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-635Mechanical system

Matching of Diameter and grouping of crankshaft main journal

main bearing
shell
Class

Blue/blue Blue/red Red/red

Diameter and grouping of cylinder block crankshaft hole

Yellow/blue Blue/blue Blue/red

Yellow/yel Yellow/blue Blue/blue

low

Classificatio
n of
crankshaft Diameter of cylinder block main bearing hole Φmm (50.000~50.013)
hole

Class
00 01 02 03 04 05 06 07 08 09 10 11 12 13
number

Class 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0 50.0
(diameter) - 00 - 01 - 02 - 03 - 04 - 05 - 06 - 07 - 08 - 09 - 10 - 11 - 12 - 13

Class and color of main bearing shell

Class of main bearing shell

No. Bearing shell thickness

Color Class
(mm)
1 1.985-1.991 Red 1 or A
2 1.990-1.996 Blue 2 or B
3 1.995-2.001 Yellow 3 or C
Class of main journal

GAC Motor 2019

Mechanical system 2-636 Maintenance Manual of 1.5GDI Engine

Class of main journal

No. Diameter Φmm Class
1 45.982-45.986 A
2 45.987-45.992 B
3 45.993-45.997 C
Selection of connecting rod bearing shell
- Perform selection according to the selection table and based on the diameter class of crankshaft
connecting rod journal and the diameter of connecting rod big end hole

Matching of Diameter and grouping of crankshaft main journal

main bearing
shell
Class

Blue/blue Blue/red Red/red

Diameter and grouping of cylinder block crankshaft hole

Yellow/blue Blue/blue Blue/red

Yellow/yel Yellow/blue Blue/blue

low

Thickness, class and color of connecting rod bearing shell

Class of connecting rod bearing shell
No. Bearing shell thickness
Color Class
(mm)
1 1.485-1.491 Red 1 or A
2 1.490-1.496 Blue 2 or B
3 1.495-1.501 Yellow 3 or C

Class of crankshaft connecting rod journal

No.
Diameter Φmm Class
1 44.982-44.986 Class A or 1

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Maintenance Manual of 1.5GDI Engine 2-637Mechanical system

2 44.987-44.992 Class B or 2
3 44.993-44.997 Class C or 3
Piston selection
Cylinder block Piston
No. Bore diameter Piston Db
Class of bore Piston class
Φmm diameter Φmm
1 75.000-75.010 Class A or 1 74.965-74.975 Class A or 1
2 75.010-75.020 Class B or 2 74.975-74.985 Class B or 2
3 75.020-75.030 Class C or 3 74.985-74.995 Class C or 3

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Mechanical system 2-638 Maintenance Manual of 1.5GDI Engine

2.13.2 Description and operation

2.13.2.1 Overview
Camshaft
The double overhead camshaft (DOHC) is used, including two camshafts. One camshaft controls the
intake valve, and the other one controls the exhaust valve. The camshaft is located in the journal of the
cylinder head on the top of the engine, and fixed by the camshaft bearing cap. The hole on the camshaft
journal of the cylinder head is used as oil passage. Engine oil flows to the camshaft under the action of
pressure, and lubricates each camshaft journal. The engine oil returns to the oil pan through the oil
return hole on the cylinder head. The camshaft lobe is machined, and, at the right amount and time,
accurately opens and closes the intake and exhaust valves. The camshaft lobe is lubricated by the
high-pressure engine oil sprayed by the high-pressure oil pump nozzle installed on the cylinder head.
Crankshaft
The crankshaft is of integral structure, and its blank is made by forging the entire steel strip. The integral
crankshaft features reliable operation, light weight, high rigidity and strength, and a few machined
surfaces. Generally, it is matched with the sliding bearing. The crankshaft is designed with the timing
gear and pulley at the front end, achieving simple structure and easy maintenance. It is designed with
the flange at the rear end. The drive plate is connected to the crankshaft with bolts and dowel pins. The
dowel pin is aimed to ensure correct position relation between the drive plate and the crankshaft during
installation of the drive plate. This connection relation features simple structure and reliable operation.
Piston assembly
The piston assembly includes the piston, piston pin, piston ring and other parts that reciprocate in the
cylinder block. These parts suffer the most severe operating conditions in a piston engine. The operation
reliability and durability of the engine largely depend on the working condition of the piston assembly.
The service life of the piston assembly determines the repair interval of the engine.
Connecting rod assembly
The connecting rod assembly of the internal combustion engine consists of the connecting rod body,
connecting rod cover, connecting rod bearing shell and connecting rod bolt. The connecting rod
assembly changes the reciprocating motion of the piston into the rotation of the crankshaft, and
transmits the force of the piston assembly to the crankshaft.

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Maintenance Manual of 1.5GDI Engine 2-639Mechanical system
2.13.3 System working principles
2.13.3.1 Operating principle of engine
Operating principle of engine
Intake stroke
The piston moves from the TDC to the BDC under the drive of the crankshaft. In this case, the exhaust
valve is closed and the intake valve is opened. During the movement of the piston, the cylinder volume
increases gradually, forming a certain degree of vacuum in the cylinder. At this time, the intake valve
opens to draw air into the cylinder, and meanwhile the ECM controls the fuel rail injector assembly to
inject gasoline into the cylinder to generate a combustible mixture in the cylinder.
Compression stroke
After the intake stroke, the crankshaft continues to drive the piston to move from the BDC to the TDC. At
the moment, both the intake valve and exhaust valve are closed. As the piston moves, the cylinder
volume decreases gradually. Because gas is compressible, when it is compressed, its temperature rises
rapidly.
Power stroke
At the end of the compression stroke, the ECM controls the primary coil circuit of the ignition coil to
disconnect, and produces high induced voltage in the secondary coil. The high voltage is quickly
transmitted to the spark plug installed on the top of the cylinder head through the ignition wire, and finally
the high voltage breaks through the spark plug gap and generates electric sparks to ignite the
combustible mixture in the cylinder. Flame spreads rapidly to the whole combustion chamber, and
generates a large amount of thermal energy at the same time. The volume of burning gas expands
rapidly. The pressure and temperature also rise at the same time, and the expansion force acts on the
top of the piston, moving the piston from the TDC to the BDC, and converting the reciprocating motion of
the piston into the rotation through the connecting rod. In this case, the intake and exhaust valves are
still closed.
Exhaust stroke
When the exhaust stroke begins, the exhaust valve is opened and the intake valve remains closed. The
crankshaft drives the piston to TDC from BDC through the connecting rod. At the moment, the expanded
burning gas is discharged from the cylinder through the exhaust valve under residual pressure and the
actions of the piston. When the piston reaches the TDC, the exhaust stroke ends and the exhaust valve
closes.
However, in the actual process, the intake valve opens before the TDC and closes after the BDC. This
design aims to achieve more sufficient air intake and reduce work consumed in the intake process. In the
exhaust emission process, the exhaust value opens earlier than BDC and closes later than TDC. This
aims to decrease the amount of mixture in the cylinder and reduce work consumed in the intake process.
At the same time, as the intake valve and exhaust valve overlap by a certain angle, namely that the
intake valve and exhaust valve open simultaneously within a certain crankshaft angle, a certain inertia is
formed to drive combustible gas into the combustion chamber due to discharge of burned gas from the
exhaust valve. Therefore, it is beneficial to achieving more sufficient air intake to some extent. However,
the greater valve overlap angle does not mean the better. Different working conditions require different
valve overlap angles. Thus, this engine uses VVT for intake valve, which aims to meet the requirements
for the intake valve opening angle of the engine under different working conditions. This function is
achieved through VVT system.
Operating principle of VVT system
VVT is the abbreviations of variable valve timing. Anything with mass has inertia. Air drawn into the
engine cylinder also has inertia, and it retains the tendency to enter the cylinder after the intake process.
In this case, if the valve closing time is delayed, the cylinder can take in more air and improve the
volumetric efficiency. As a result, the longer the valve closing time delayed, the higher the performance
at high speeds; on the contrary, the earlier the valve closed, the more stable the operation and the
greater the torque at low speeds.

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Mechanical system 2-640 Maintenance Manual of 1.5GDI Engine
2.13.4 Location of components
2.13.4.1 Location of components

Timing chain
cover

Accessory tensioner

V-ribbed belt

Crankshaft damper
pulley

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Maintenance Manual of 1.5GDI Engine 2-641Mechanical system

Cylinder head cover

assembly

Drive plate

Drive plate dust cover I

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Mechanical system 2-642 Maintenance Manual of 1.5GDI Engine
2.13.5 Exploded view
2.13.5.1 Exploded view

Crankshaft rear oil

seal assembly

Drive plate dust (8 in total)

cover I

Drive plate gasket

Drive plate

(6 in total)

Tightening torque is represented in N•m

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Exhaust phase
regulator

Rail between cams Intake phase regulator

(2 in total)

Timing chain

Moving rail dowel pin

Moving rail

Timing tensioner

Fixed rail

Crankshaft sprocket

(2 in total)

(2 in total)

Tightening torque is represented in N•m

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Mechanical system 2-644 Maintenance Manual of 1.5GDI Engine

(6 in total)

Oil-gas separator
assembly
(2 in total)

Gasket
(2 in total)

Cylinder head cover

Crankcase vent pipe

Exhaust camshaft Intake camshaft

assembly assembly

Camshaft bearing
cap

Hollow pin (14 in

total)

Camshaft front
bearing cap

(16 in total)
Tightening torque is represented in N•m

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Rocker arm
assembly

Valve collet

Valve spring upper

seat

Hydraulic tappet
assembly
Valve spring

Valve oil seal

Cylinder head

Intake valve
Exhaust valve

Disposable part:

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Mechanical system 2-646 Maintenance Manual of 1.5GDI Engine

Cylinder block

Crankshaft thrust
plate

Main bearing upper

shell

Crankshaft
assembly

Crankshaft speed
ring gear

Main bearing cap

Main bearing lower
shell

(10 in total)

Tightening torque is represented in N•m

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Piston pin snap ring

(2 in total)

Piston pin

Piston

First compression
ring
Connecting
rod
Oil cooling nozzle
assembly
Second
compression ring

Connecting rod bearing

shell (upper)

Connecting rod bearing Oil control ring

shell (lower) assembly

Connecting rod
bearing cap

Connecting rod bolt

17+90°
(2 in total)

Disposable part:
Tightening torque is represented in N•m

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Mechanical system 2-648 Maintenance Manual of 1.5GDI Engine
2.13.6 Electrical schematic diagram
2.13.6.1 Electrical schematic diagram

Engine load feedback Oil control valve (2 pcs)

Brake switch Oil pump solenoid valve

Upstream oxygen sensor Throttle valve

Electronic intake air

Downstream oxygen sensor
recirculation valve

Water temperature sensor Fuel injector (4 pcs)

Electronic accelerator pedal Ignition coil (4 pcs)

assembly

Speed sensor Starter relay (2 pcs)

MAP / IAT sensor Main relay

ECM

A/C compressor relay

Vacuum sensor

MAP/IAT sensor (charge air Cooling fan relay

pressure)

Knock sensor Canister control valve

Phase sensor (exhaust) Fuel pump relay

Phase sensor (intake) Electronic throttle body

Cruise control switch

(hardwired input ECU)

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High-pressure fuel rail High-pressure fuel pump

pressure sensor
ECM

EBS
CAN bus

Alternator

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Mechanical system 2-650 Maintenance Manual of 1.5GDI Engine
2.13.7 Diagnostic information and procedure
2.13.7.1 Diagnostic instructions
Familiarize yourself with the system functions and operations before starting the system diagnosis. This
helps correctly determine the diagnostic procedure when a fault occurs, and more importantly, helps
determine whether the situation described by the customer is normal.
2.13.7.2 Visual inspection
• Check the aftermarket parts that may affect the performance of the mechanical system.
• Check the accessible or visible system components for obvious damage or conditions which may
cause faults.
• Verify if the level and viscosity of engine oil are normal.
• Record specific factors such as engine speed and ambient temperature.
• Compare with a known good engine to verify if the current engine conditions are normal.
2.13.7.3 Noise from engine with load
Diagnostic procedure
Step 1 Check whether the V-ribbed belt emits frequent, shrill and continuous “squeaks”.

a. The V-ribbed belt is stretched after long-term

use.
b. The V-ribbed belt incurs aging and cracking.
Y Replace the V-ribbed belt and
then verify if the fault is
eliminated.
N

Step 2 Check whether rhythmic, clear and uniform “clicks” near the cylinder head cover are obvious
at idle speed and reduced at higher speed.

Y The measured oil pressure is

consistent with the standard
value, indicating the hydraulic
tappet failure. In this case, replace
the hydraulic tappet.
N

Step 3 Check whether the main bearing shell clearance exceeds the specified value.

Y Replace the main bearing shell

and then verify if the fault is
eliminated.
N

Step 4 Check whether the connecting rod bearing shell clearance exceeds the specified value.

Y Replace the connecting rod

bearing shell and then verify if the
fault is eliminated.
Next step

Step 5 End.

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2.13.7.4 Engine vibration when engine is idling or hot

Diagnostic procedure
Step 1 Check whether the V-ribbed belt is too loose, worn or faulty.

Y Replace the V-ribbed belt and

then verify if the fault is
eliminated.
N

Step 2 Check whether the engine oil viscosity is abnormal.

Y Re-add engine oil suitable for the

current climate, and verify if the
fault is eliminated.
N

Step 3 Check whether the alternator and A/C compressor work improperly with abnormal sound.

Y Replace faulty parts, and verify if

the fault is eliminated.
N

Step 4 Check whether the valve assemblies such as valve tappets and valve springs are faulty.

Y Replace faulty parts, and verify if

the fault is eliminated.
N

Step 5 Check whether the clearance of the piston pin exceeds the standard value.

Y Replace faulty parts, and verify if

the fault is eliminated.
N

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Mechanical system 2-652 Maintenance Manual of 1.5GDI Engine

Step 6 Check whether the connecting rod is bent.

Y Replace faulty parts, and verify if

the fault is eliminated.
N

Step 7 Check whether the clearance between the piston and the cylinder liner exceeds the standard
value.

Y Replace faulty parts, and verify if

the fault is eliminated.
N

Step 8 Check whether the offset of the piston pin exceeds the standard value.

Y Replace the faulty component,

and verify if the fault is eliminated.
Next step

Step 9 End.
2.13.7.5 Engine misfire with abnormal noise
Diagnostic procedure
Step 1 Check whether there is a DTC in the ECM with the diagnostic scan tool.

Y Repair the faulty part according to

the DTC.
N

Step 2 Check the data related to "knock" in the engine data flow with the diagnostic scan tool. Are
there abnormal data when compared with those of a normal vehicle?

Y Check whether the fuel and the

timing system are normal, repair
the faulty location, and verify if the
fault is eliminated.
N

Step 3 Check whether the valve spring is too soft or broken.

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Y Replace faulty parts, and verify if

the fault is eliminated.
N

Step 4 Check whether the valve is stuck or bent.

Y Replace faulty parts, and verify if

the fault is eliminated.
N

Step 5 Check whether the valve tappet is scratched, stuck, worn, etc.

Y Replace faulty parts, and verify if

the fault is eliminated.
N

Step 6 Check whether the camshaft cam is excessively worn or obviously defective.

Y Replace the camshaft.

Step 7 Check whether the valve guide is cracked, excessively worn, etc.

Y Replace faulty parts, and verify if

the fault is eliminated.
N

Step 8 Check whether the valve spring seat and valve spring gasket are assembled incorrectly.

Y Replace the faulty component,

and verify if the fault is eliminated.
Next step

Step 9 End.

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Mechanical system 2-654 Maintenance Manual of 1.5GDI Engine

2.13.8 Special tools

2.13.8.1 List of special tools
No. Legend Tool No. Name

Flywheel disassembling
1 8910060BAC0000
tool

Crankshaft rear oil seal

2 8910001ASV0000
installing tool

3 8910004ASV0000 Camshaft fixing plug

Valve spring compressor

4 8910135BAC0000
tool

Valve oil seal removal

5 8910140BAC0000
pliers

6 8910065BAC0000 Flywheel locking tool

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No. Legend Tool No. Name

Crankshaft front oil seal

7 8910007ASV0000
installing tool

Piston ring disassembling

8 8910045BAC0000
tool

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Mechanical system 2-656 Maintenance Manual of 1.5GDI Engine

2.13.9 Removal and installation

2.13.9.1 Removing and installing V-ribbed belt
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Remove the front right wheel assembly. Refer
to 5.2.7.1 Removing and installing wheel
assembly.
3 Remove the front right wheel mudguard
assembly. Refer to 11.4.1.4 Removing and
installing front wheel mudguard.
4 Remove the V-ribbed belt
a. Use a tool to pull the accessory tensioner ① as
arrowed until the V-ribbed belt can be removed.
b. Take off the V-ribbed belt ②.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- Remove oil stains from the V-ribbed belt before
installation.
- Visually check the V-ribbed belt for excessive
wear or cord pulled out.
- Replace V-ribbed belts with incomplete rack.
- After installing the V-ribbed belt, make sure that it
is correctly installed in the ribbed groove of
crankshaft damper pulley.
- After installation, turn the crankshaft damper pulley
clockwise to check whether the V-ribbed belt is driven
smoothly.
2.13.9.2 Removing and installing accessory
tensioner
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Remove the front right wheel assembly. Refer
to 5.2.7.1 Removing and installing wheel
assembly.
3 Remove the front right wheel mudguard
assembly. Refer to 11.4.1.4 Removing and
installing front wheel mudguard.
4 Remove the V-ribbed belt

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5 Remove the accessory tensioner

a. Unscrew the accessory tensioner ① fixing bolt
as arrowed.
• Tightening torque of bolt: 50±5Nm

b. Take off the accessory tensioner ① as

arrowed.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- Before installing the accessory tensioner, make sure that
the accessory tensioner bolt is fitted in the water pump
bracket hole.
- Rotate the accessory tensioner to align its dowel
pin with the pin hole on the water pump bracket.
- Tighten the fixing bolt of the accessory tensioner
to the specified torque.
• Tightening torque of bolt: 50±5Nm
2.13.9.3 Removing and installing cylinder head
cover assembly
Removal procedure
1 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
2 Remove the powertrain. Refer to 2.11.4.2
Removing and installing powertrain.
3 Separate the engine assembly and
transmission assembly. Refer to 2.11.4.3
Separating engine assembly and transmission
assembly.
4 Remove the catalytic converter assembly.
Refer to 2.5.6.2 Removing and installing catalytic
converter assembly.
5 Remove the turbocharger assembly. Refer to
2.10.8.1 Removing and installing turbocharger
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Mechanical system 2-658 Maintenance Manual of 1.5GDI Engine
assembly.
6 Remove the drive plate. Refer to 2.13.9.11
Removing and installing drive plate.
7 Remove the crankshaft rear oil seal. Refer to
2.13.9.12 Removing and installing crankshaft rear
oil seal.

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8 Remove the oil pan. Refer to 2.14.8.1 Removing

and installing oil pan.
9 Remove the timing chain cover. Refer to 2.13.9.5
Removing and installing timing chain cover.
10 Remove the timing chain. Refer to 2.13.9.6
Removing and installing timing chain.
11 Remove the phase regulator. Refer to 2.13.9.10
Removing and installing phase regulator.
12 Remove the cylinder head cover assembly
a. Loosen the fixing clamp as arrowed, and take off
the crankcase vent pipe ①.

b. Unscrew the fixing bolts (arrows A and B).

c. Loosen the clamp (arrow C), disconnect the
connector (arrow D), and take off the oil-gas
separator with crankcase vent pipe ①.
• Tightening torque of bolt (arrow A): 9±0.9Nm
• Tightening torque of bolt (arrow B): 9±0.9Nm

d. Disconnect the engine harness connectors

(arrow A).
e. Undo the fixing clip (arrow B).
f. Unscrew the fixing bolt (arrow C) and screw
(arrow D), and remove the engine harness ①.
• Tightening torque of bolt (arrow C): 8±2Nm

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Mechanical system 2-660 Maintenance Manual of 1.5GDI Engine

g. Undo the fixing clip (arrow A) of each pipe.

h. Press the quick connector (arrow B), and
disconnect the engine fuel inlet hose ①.
i. Unscrew the fixing bolt (arrow C), press the quick
connector (arrow D), and detach the fuel vapor
pipe assembly ②.
j. Remove the fuel vapor pipe assembly I ③.
k. Loosen the clamp (arrow E), press the quick
connector (arrow F), and remove the vacuum
brake pipe assembly ④.
• Tightening torque of bolt (arrow C): 8±2Nm

l. Unscrew the fixing bolt (arrow A), loosen the

clamp (arrow B), and take off the expansion tank
water return tube ①.
• Tightening torque of bolt: 8±2Nm

m. Unscrew the shoulder stud (arrow A), and take

off the ignition coil ①.
n. Unscrew the fixing bolt (arrow B), and take off
the phase sensor ②.
o. Unscrew the fixing bolt (arrow C), and take off
the oil control valve ③.
p. Unscrew the fixing bolt (arrow D), and take off
the oil dipstick tube ④.
• Tightening torque of shoulder stud (arrow A):
9±0.9Nm
• Tightening torque of bolt (arrow B): 9±0.9Nm
• Tightening torque of bolt (arrow C): 6±0.5Nm
• Tightening torque of bolt (arrow D): 9±0.9Nm

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q. Unscrew the fixing bolt as arrowed, and remove

the mechanical vacuum pump ①.
• Tightening torque of bolt: 9±1Nm
Tip:
After the mechanical vacuum pump is removed,
the rubber ring of the vacuum pump must be
replaced.

r. Unscrew the nut (arrow A) and fixing bolt (arrow

B) of high-pressure fuel pipe, and take off the
high-pressure fuel pipe ①.
s. Unscrew the fixing bolts (arrow C) and take off
the high-pressure fuel pump ②.
• Tightening torque of nut (arrow A): 22.5±2.5Nm
• Tightening torque of bolt (arrow B): 8±2Nm
• Tightening torque of bolt (arrow C): 9±0.9Nm
Tip:
Before removing the high-pressure fuel pipe
connector, place a clean shop towel under the
connector to prevent the residual gasoline from
dripping on other accessories.
After the high-pressure fuel pipe is removed, the
fuel rail port shall be sealed to prevent debris from
entering the fuel rail.
The high-pressure fuel pipe can only be used
once, and must be replaced with a new one after
removal.

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Mechanical system 2-662 Maintenance Manual of 1.5GDI Engine

t. Unscrew the fixing bolt as arrowed, and take off

the cylinder head heat shield ①.
• Tightening torque of bolt: 9±0.9Nm

u. Unscrew the fixing bolts (arrows A and B), and

remove the cylinder head cover assembly ①.
• Tightening torque of bolt (arrow A): 9±0.9Nm
• Tightening torque of bolt (arrow B): 25±2.5Nm

Installation procedure

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
- As shown in the figure, apply the sealant evenly
to the sealing surface of the cylinder head cover as
arrowed, instead of the bolt holes.
- The ignition coil sealing strip ① must be
replaced.
• Sealant: ThreeBond 1217H
• Diameter: 3mm

2.13.9.4 Removing and installing cylinder head

assembly
Removal procedure
1 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
2 Remove the powertrain. Refer to 2.11.4.2
Removing and installing powertrain.
3 Separate the engine assembly and
transmission assembly. Refer to 2.11.4.3
Separating engine assembly and transmission
assembly.
4 Remove the catalytic converter assembly.
Refer to 2.5.6.2 Removing and installing catalytic
converter assembly.
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5 Remove the turbocharger assembly. Refer to

2.10.8.1 Removing and installing turbocharger
assembly.
6 Remove the cast exhaust manifold. Refer to
2.5.6.1 Removing and installing cast exhaust
manifold.
7 Remove the intake manifold. Refer to 2.6.7.5
Removing and installing intake manifold.
8 Remove the fuel rail injector assembly. Refer
to 2.3.9.6 Removing and installing fuel rail injector
assembly.
9 Remove the drive plate. Refer to 2.13.9.11
Removing and installing drive plate.
10 Remove the crankshaft rear oil seal
assembly. Refer to 2.13.9.12 Removing and
installing crankshaft rear oil seal assembly.
11 Remove the oil pan. Refer to 2.14.8.1 Removing
and installing oil pan.
12 Remove the timing chain cover. Refer to 2.13.9.5
Removing and installing timing chain cover.
13 Remove the timing chain. Refer to 2.13.9.6
Removing and installing timing chain.
14 Remove the phase regulator. Refer to 2.13.9.10
Removing and installing phase regulator.
15 Remove the cylinder head cover assembly. Refer to
2.13.9.3 Removing and installing cylinder head
cover assembly.
16 Remove the cylinder head assembly
a. Unscrew the water inlet pipe fixing bolt as
arrowed.
• Tightening torque of bolt: 25±2.5Nm

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Mechanical system 2-664 Maintenance Manual of 1.5GDI Engine

b. Unscrew the fixing bolts in the order of ① to ⑩

, and remove the cylinder head assembly.
• Tightening torque of bolt: 25Nm+180°

c. Remove the cylinder head gasket ①.

Installation procedure

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Maintenance Manual of 1.5GDI Engine 2-665Mechanical system

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
- Ensure that the cylinder head gasket is free of
scratches, creases, impurities, etc.
- Align the cylinder head gasket with the two dowel
pins for installation, and ensure the side with
lettering faces upward.

- There shall be no oil or coolant in the cylinder

block bolt hole; otherwise, when the cylinder head
bolt is installed, the cylinder block will crack due to
excessive pressure.
- Align the cylinder head with the dowel pin, and
then place it on the cylinder block.
- Tighten the cylinder head bolts (plastic) not more
than 3 times; otherwise, replace them with new
ones.
- As shown in the figure, tighten the bolts in the
order of ① to ⑩ in three steps:
1. Install the cylinder head bolts and tighten them
by hand.
2. Pre-tighten the cylinder head bolts by using
common tools.
3. Tighten the cylinder head bolts to the specified
torque.
• Tightening torque of bolt: 25Nm+180°
2.13.9.5 Removing and installing timing chain
cover
Removal procedure
1 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
2 Remove the powertrain. Refer to 2.11.4.2
Removing and installing powertrain.
3 Separate the engine assembly and
transmission assembly. Refer to 2.11.4.3
Separating engine assembly and transmission
assembly.
4 Remove the drive plate. Refer to 2.13.9.11
Removing and installing drive plate.
5 Remove the crankshaft rear oil seal
assembly. Refer to 2.13.9.12 Removing and
installing crankshaft rear oil seal assembly.
6 Remove the V-ribbed belt. Refer to 2.13.9.1
Removing and installing V-ribbed belt.
7 Remove the oil pan. Refer to 2.14.8.1 Removing
and installing oil pan.

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Mechanical system 2-666 Maintenance Manual of 1.5GDI Engine

8 Remove the timing chain cover

a. Disconnect the oil solenoid valve connector
(arrow A) and the speed sensor connector (arrow
B).
b. Undo the engine harness fixing clips (arrow C).

c. Unscrew the engine harness ① fixing bolt

(arrow A), and water inlet pipe ② fixing bolt
(arrow B).
• Tightening torque of bolt (arrow A): 8±2Nm
• Tightening torque of bolt (arrow B): 25±2.5Nm

d. Unscrew the fixing bolts (arrows A and B), and

take off the mounting bracket ①.
• Tightening torque of bolt (arrow A): 50±5Nm
• Tightening torque of bolt (arrow B): 30±3Nm

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e. Use the flywheel disassembling tool ①

(8910060BAC0000) to lock the drive plate.

f. Unscrew the fixing bolt (arrow A), and take off

the crankshaft damper pulley ①.
g. Unscrew the fixing bolt (arrow B), and take off
the accessory tensioner ②.
• Tightening torque of bolt (arrow A): 120Nm+130°
• Tightening torque of bolt (arrow B): 50±5Nm
h. Remove the oil pan. Refer to 2.14.8.1 Removing and
installing oil pan.

i. Unscrew the shoulder stud (arrow A).

j. Unscrew the fixing bolts (arrows B, C and D).
k. Carefully pry off the timing chain cover ①.
• Tightening torque of shoulder stud (arrow A):
9±0.9Nm
• Tightening torque of bolt (arrow B): 9±0.9Nm
• Tightening torque of bolt (arrow C): 9±0.9Nm
• Tightening torque of bolt (arrow D): 20±2.5Nm

Installation procedure

GAC Motor 2019

Mechanical system 2-668 Maintenance Manual of 1.5GDI Engine

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
- Apply sealant to the timing chain cover according
to the paths as arrowed in the figure.
• Sealant: ThreeBond 1217H
• Diameter: 3mm

- Install the timing chain cover, and tighten the

timing chain cover fixing bolts in the order of ① to
⑲.
• Tightening torque of bolts ①~⑪: 20±2.5Nm
• Tightening torque of bolts ⑫~⑲: 9±0.9Nm

2.13.9.6 Removing and installing timing chain

Removal procedure
1 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
2 Remove the powertrain. Refer to 2.11.4.2
Removing and installing powertrain.
3 Separate the engine assembly and
transmission assembly. Refer to 2.11.4.3
Separating engine assembly and transmission
assembly.
4 Remove the drive plate. Refer to 2.13.9.11
Removing and installing drive plate.
5 Remove the crankshaft rear oil seal assembly. Refer
to 2.13.9.12 Removing and installing crankshaft rear oil
seal assembly.
6 Remove the V-ribbed belt. Refer to 2.13.9.1
Removing and installing V-ribbed belt.
7 Remove the oil pan. Refer to 2.14.8.1 Removing
and installing oil pan.
8 Remove the timing chain cover. Refer to 2.13.9.5
Removing and installing timing chain cover.

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Maintenance Manual of 1.5GDI Engine 2-669Mechanical system

9 Remove the timing chain

a. Remove the crankshaft speed ring gear ①.

b. Compress the timing tensioner tappet in place

and insert the detent ①.

c. Unscrew the fixing bolt as arrowed, and take off

the timing tensioner ①.
• Tightening torque of bolt: 9±0.9Nm

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Mechanical system 2-670 Maintenance Manual of 1.5GDI Engine

d. Unscrew the moving rail dowel pin (arrow A),

and take off the movable rail ①.
e. Unscrew the fixing bolt (arrow B), and take off
the fixed rail ②.
• Tightening torque of moving rail dowel pin (arrow
A): 20±2.5Nm
• Tightening torque of bolt (arrow B): 9±0.9Nm

f. Take off the timing chain ①.

Installation procedure

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Maintenance Manual of 1.5GDI Engine 2-671Mechanical system

Install the timing chain.

- Rotate the phase regulator to align its mark
(arrow A) with the inverted triangle mark (arrow B)
on the cylinder head cover.

- Unscrew the fixing plug (arrow A), and install the

camshaft fixing plug (shorter one)
(8910004ASV0000) to fix the exhaust camshaft.
- Unscrew the fixing plug (arrow B), and install the
camshaft fixing plug (longer one)
(8910004ASV0000) to fix the intake camshaft.
• Tightening torque of plug (arrow A): 20±2.5Nm
•Tightening torque of plug (arrow B): 20±2.5Nm

- Install the timing chain ①, and align the gray

mark (arrow A) of the chain with the dent mark
(arrow B) on the exhaust phase regulator.
- Align the gray mark (arrow C) of the chain with
the dent mark (arrow D) on the intake phase
regulator.
- Align the gray mark (arrow E) of the chain with
the dent mark (arrow F) on the crankshaft
sprocket.

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Mechanical system 2-672 Maintenance Manual of 1.5GDI Engine

- Install the moving rail ①, and tighten the moving

rail dowel pin (arrow A).
- Install the fixed rail ②, and tighten the fixing bolt
(arrow B).
• Tightening torque of moving rail dowel pin (arrow
A): 20±2.5Nm
• Tightening torque of bolt (arrow B): 9±0.9Nm

- Install the timing tensioner ①, tighten the fixing

bolts as arrowed, and pull out the detent.
• Tightening torque of bolt: 9±0.9Nm

The installation procedure is in reverse of removal

procedure.
2.13.9.7 Removing and installing timing
tensioner
Removal procedure
1 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
2 Remove the powertrain. Refer to 2.11.4.2
Removing and installing powertrain.
3 Separate the engine assembly and
transmission assembly. Refer to 2.11.4.3
Separating engine assembly and transmission
assembly.
4 Remove the drive plate. Refer to 2.13.9.11
Removing and installing drive plate.
5 Remove the crankshaft rear oil seal
assembly. Refer to 2.13.9.12 Removing and
installing crankshaft rear oil seal assembly.
6 Remove the V-ribbed belt. Refer to 2.13.9.1
Removing and installing V-ribbed belt.
7 Remove the oil pan. Refer to 2.14.8.1 Removing
and installing oil pan.
8 Remove the timing chain cover. Refer to 2.13.9.5
Removing and installing timing chain cover.

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Maintenance Manual of 1.5GDI Engine 2-673Mechanical system

9 Remove the timing tensioner

a. Unscrew the fixing plug (arrow A), and install the
camshaft fixing plug (shorter one)
(8910004ASV0000) to fix the exhaust camshaft.
b. Unscrew the fixing plug (arrow B), and install the
camshaft fixing plug (longer one)
(8910004ASV0000) to fix the intake camshaft.
• Tightening torque of plug (arrow A): 20±2.5Nm
•Tightening torque of plug (arrow B): 20±2.5Nm

c. Compress the timing tensioner tappet in place

and insert the detent ①.

d. Unscrew the fixing bolt as arrowed, and take off

the timing tensioner ①.
• Tightening torque of bolt: 9±0.9Nm

Installation procedure

GAC Motor 2019

Mechanical system 2-674 Maintenance Manual of 1.5GDI Engine

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
- Install the timing tensioner ①, tighten the fixing
bolts as arrowed, and pull out the detent.
• Tightening torque of bolt: 9±0.9Nm

- Remove the camshaft fixing plug (shorter one)

(8910004ASV0000), and tighten the fixing plug
(arrow A).
- Remove the camshaft fixing plug (longer one)
(8910004ASV0000), and unscrew the fixing plug
(arrow B).
• Tightening torque of plug (arrow A): 20±2.5Nm
•Tightening torque of plug (arrow B): 20±2.5Nm

2.13.9.8 Removing and installing camshaft

Removal procedure
1 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
2 Remove the powertrain. Refer to 2.11.4.2
Removing and installing powertrain.
3 Separate the engine assembly and
transmission assembly. Refer to 2.11.4.3
Separating engine assembly and transmission
assembly.
4 Remove the catalytic converter assembly.
Refer to 2.5.6.2 Removing and installing catalytic
converter assembly.
5 Remove the turbocharger assembly. Refer to
2.10.8.1 Removing and installing turbocharger
assembly.
6 Remove the drive plate. Refer to 2.13.9.11
Removing and installing drive plate.
7 Remove the crankshaft rear oil seal
assembly. Refer to 2.13.9.12 Removing and
installing crankshaft rear oil seal assembly.
8 Remove the oil pan. Refer to 2.14.8.1 Removing
and installing oil pan.
9 Remove the timing chain cover. Refer to 2.13.9.5
Removing and installing timing chain cover.
10 Remove the timing chain. Refer to 2.13.9.6
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Maintenance Manual of 1.5GDI Engine 2-675Mechanical system
Removing and installing timing chain.
11 Remove the phase regulator. Refer to 2.13.9.10
Removing and installing phase regulator.
12 Remove the cylinder head cover assembly. Refer to
2.13.9.3 Removing and installing cylinder head
cover assembly.

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Mechanical system 2-676 Maintenance Manual of 1.5GDI Engine

13 Remove the camshaft

a. Unscrew the fixing bolt as arrowed, and take off
the camshaft front bearing cover ①.
• Tightening torque of bolt: 9±0.9Nm

b. Unscrew the fixing bolts of intake camshaft

bearing cap in the order of ① to ⑥.
c. Remove the intake camshaft bearing cap and
intake camshaft ⑦.
• Tightening torque of bolt: 9±0.9Nm
Note:
- Mark the removed intake camshaft bearing caps
to avoid confusion.

d. Unscrew the fixing bolts of exhaust camshaft

bearing caps in the order of ① to ⑥.
e. Take off the exhaust camshaft bearing caps and
exhaust camshaft ⑦.
• Tightening torque of bolt: 9±0.9Nm
Note:
- Mark the removed exhaust camshaft bearing
caps to avoid confusion.

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.13.9.9 Removing and installing valve oil seal
Removal procedure
1 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
2 Remove the powertrain. Refer to 2.11.4.2
Removing and installing powertrain.
3 Separate the engine assembly and
transmission assembly. Refer to 2.11.4.3
Separating engine assembly and transmission
assembly.

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Maintenance Manual of 1.5GDI Engine 2-677Mechanical system

4 Remove the catalytic converter assembly.

Refer to 2.5.6.2 Removing and installing catalytic
converter assembly.
5 Remove the turbocharger assembly. Refer to
2.10.8.1 Removing and installing turbocharger
assembly.
6 Remove the cast exhaust manifold. Refer to
2.5.6.1 Removing and installing cast exhaust
manifold.
7 Remove the intake manifold. Refer to 2.6.7.5
Removing and installing intake manifold.
8 Remove the fuel rail injector assembly. Refer
to 2.3.9.6 Removing and installing fuel rail injector
assembly.
9 Remove the drive plate. Refer to 2.13.9.11
Removing and installing drive plate.
10 Remove the crankshaft rear oil seal
assembly. Refer to 2.13.9.12 Removing and
installing crankshaft rear oil seal assembly.
11 Remove the oil pan. Refer to 2.14.8.1 Removing
and installing oil pan.
12 Remove the timing chain cover. Refer to 2.13.9.5
Removing and installing timing chain cover.
13 Remove the timing chain. Refer to 2.13.9.6
Removing and installing timing chain.
14 Remove the phase regulator. Refer to 2.13.9.10
Removing and installing phase regulator.
15 Remove the cylinder head cover assembly. Refer to
2.13.9.3 Removing and installing cylinder head
cover assembly.
16 Remove the cylinder head assembly. Refer to
2.13.9.4 Removing and installing cylinder head
assembly.
17 Remove the valve oil seal
a. Remove the rocker arm assembly with hydraulic
tappet assembly ①.
Tip:
After removing the rocker arm assembly with
hydraulic tappet assembly, be sure to make marks
properly or place parts in order.

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Mechanical system 2-678 Maintenance Manual of 1.5GDI Engine

b. Use the valve spring compressor tool ①

(8910135BAC0000) to compress the valve spring.

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Maintenance Manual of 1.5GDI Engine 2-679Mechanical system

c. Use tweezers or a suction rod to remove the

valve collet ①.
d. Remove the valve spring compression tool ②
(8910135BAC0000), and remove the valve spring
upper seat and valve spring.

e. Use the valve oil seal removal pliers ①

(8910140BAC0000) to clamp the valve oil seal,
and pull it out along the axial direction of valve
stem.

Installation procedure

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Mechanical system 2-680 Maintenance Manual of 1.5GDI Engine

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
- Lubricate the valve guide with oil during
installation.
- Use the tool ① to press the valve oil seal into
the valve guide along the mounting direction of the
valve.

- After installation, check the distance (a) between

the oil seal and the cylinder head.
• Mounting height of valve oil seal (intake):
20.15mm
• Mounting height of valve oil seal (exhaust):
18.4mm

2.13.9.10 Removing and installing phase

regulator
Removal procedure
1 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
2 Remove the powertrain. Refer to 2.11.4.2
Removing and installing powertrain.
3 Separate the engine assembly and
transmission assembly. Refer to 2.11.4.3
Separating engine assembly and transmission
assembly.
4 Remove the drive plate. Refer to 2.13.9.11
Removing and installing drive plate.
5 Remove the crankshaft rear oil seal
assembly. Refer to 2.13.9.12 Removing and
installing crankshaft rear oil seal assembly.
6 Remove the V-ribbed belt. Refer to 2.13.9.1
Removing and installing V-ribbed belt.
7 Remove the oil pan. Refer to 2.14.8.1 Removing
and installing oil pan.
8 Remove the timing chain cover. Refer to 2.13.9.5
Removing and installing timing chain cover.
9 Remove the timing chain. Refer to 2.13.9.6
Removing and installing timing chain.

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Maintenance Manual of 1.5GDI Engine 2-681Mechanical system

10 Remove the phase regulator

a. Loosen the fixing clamp as arrowed, and take off
the crankcase vent pipe ①.

b. Unscrew the fixing plug (arrow A), and install the

camshaft fixing plug (shorter one)
(8910004ASV0000) to fix the exhaust camshaft.
c. Unscrew the fixing plug (arrow B), and install the
camshaft fixing plug (longer one)
(8910004ASV0000) to fix the intake camshaft.
• Tightening torque of plug (arrow A): 20±2.5Nm
•Tightening torque of plug (arrow B): 20±2.5Nm

d. Unscrew the exhaust phase regulator fixing bolt

(arrow A), and take off the exhaust phase regulator
①.
e. Unscrew the intake phase regulator fixing bolt
(arrow B), and take off the intake phase regulator
②.
• Tightening torque of bolt (arrow A): 25Nm+90°
• Tightening torque of bolt (arrow B): 25Nm+90°

Installation procedure

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Mechanical system 2-682 Maintenance Manual of 1.5GDI Engine

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
- As shown in the figure, the intake phase regulator
is marked with characters IN in the front.
- When installing the intake/exhaust phase
regulator, take care to match its locating slot with
the camshaft dowel pin.

2.13.9.11 Removing and installing drive plate

Removal procedure
1 Install the engine stand. Refer to 2.11.4.1
Installing engine engine.
2 Remove the transmission assembly. Refer to
the Maintenance Manual - transmission assembly.
3 Remove the drive plate
a. Use the flywheel disassembling tool ①
(8910060BAC0000) to lock the drive plate.

b. Unscrew the fixing bolt as arrowed, and take off

the drive plate gasket ②.
c. Remove the flywheel disassembling tool ①
(8910060BAC0000).
• Tightening torque of bolt: 30Nm+70°

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Maintenance Manual of 1.5GDI Engine 2-683Mechanical system

d. Take off the drive plate ①.

e. Unscrew the fixing bolt as arrowed, and take off

the drive plate dust cover I ①.
• Tightening torque of bolt: 9±0.9Nm

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- Install the drive plate and drive plate gasket, and
pre-tighten the fixing bolts ①~⑥.
- Use the flywheel disassembling tool
(8910060BAC0000) to lock the drive plate.
- Tighten the fixing bolts in the diagonal order from
① to ⑥.
• Tightening torque of bolt: 30Nm+70°

2.13.9.12 Removing and installing crankshaft

rear oil seal assembly
Removal procedure
1 Install the engine stand. Refer to 2.11.4.1
Installing engine engine.
2 Remove the transmission. Refer to the
Maintenance Manual - transmission.
3 Remove the drive plate. Refer to 2.13.9.11
Removing and installing drive plate.

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Mechanical system 2-684 Maintenance Manual of 1.5GDI Engine

4 Remove the crankshaft rear oil seal assembly

a. Unscrew the fixing screw as arrowed, and
remove the crankshaft rear oil seal assembly ①.
• Tightening torque of screw: 9±0.9Nm

b. Remove the crankshaft rear oil seal ①.

Installation procedure

GAC Motor 2019

Maintenance Manual of 1.5GDI Engine 2-685Mechanical system

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
- Before installing the oil seal, be sure to clean the
surface of the cylinder block.
- Install the crankshaft rear oil seal ① to its seat in
place.

- Before installing the crankshaft rear oil seal

assembly, evenly apply plane sealant to its seal
groove (area as arrowed).
• Sealant: ThreeBond 1217H

GAC Motor 2019

Mechanical system 2-686 Maintenance Manual of 1.5GDI Engine

- As shown in the figure, use the crankshaft rear oil

seal installing tool ① (8910001ASV0000) to
carefully install the crankshaft rear oil seal
assembly ② into the rear end of the crankshaft.

- Tighten the fixing screws of the crankshaft rear oil

seal assembly in the diagonal order of ① to ⑧.
• Tightening torque of screw: 9±0.9Nm

2.13.9.13 Removing and installing crankshaft

front oil seal
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.
3 Remove the front right wheel assembly. Refer
to 5.2.7.1 Removing and installing wheel
assembly.
4 Remove the front right wheel mudguard
assembly. Refer to 11.4.1.4 Removing and
installing front wheel mudguard.
5 Remove the starter. Refer to 2.15.8.2 Removing
and installing starter.
6 Remove the V-ribbed belt. Refer to 2.13.9.1
Removing and installing V-ribbed belt.
7 Remove the crankshaft front oil seal.
a. Install the flywheel locking tool ①
(8910065BAC0000) to lock the flywheel.

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Maintenance Manual of 1.5GDI Engine 2-687Mechanical system

b. Unscrew the fixing bolt as arrowed, and take off

the crankshaft damper pulley ①.
• Tightening torque of bolt: 120Nm+130°

c. Remove the crankshaft front oil seal ①.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- Because the oil seal is a disposable part, a new
oil seal must be used during installation.
- First install the crankshaft front oil seal on the
timing chain cover.
- Install the crankshaft front oil seal installing tool
① (8910007ASV0000), and tighten the bolt as
arrowed to install the crankshaft front oil seal in
place.

2.13.9.14 Removing and installing oil cooling

nozzle assembly
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
3 Install the engine stand. Refer to 2.11.4.1
Installing engine engine.
4 Remove the transmission assembly. Refer to
the Maintenance Manual - transmission
5 Remove the drive plate. Refer to 2.13.9.11
Removing and installing drive plate.
GAC Motor 2019
Mechanical system 2-688 Maintenance Manual of 1.5GDI Engine

6 Remove the crankshaft rear oil seal

assembly. Refer to 2.13.9.12 Removing and
installing crankshaft rear oil seal assembly.
7 Remove the V-ribbed belt. Refer to 2.13.9.1
Removing and installing V-ribbed belt.
8 Remove the A/C compressor assembly.
Refer to 8.4.7.13 Removing and installing A/C
compressor.
9 Remove the oil cooler. Refer to 2.14.8.3
Removing and installing oil cooler.
10 Remove the oil pan. Refer to 2.14.8.1 Removing
and installing oil pan.
11 Remove the oil cooling nozzle assembly
a. Unscrew the fixing bolt as arrowed, and take off
the oil pan baffle ①.
• Tightening torque of bolt: 9±0.9Nm

b. Rotate the crankshaft pulley to a suitable

position, unscrew the fixing bolt as arrowed, and
take off the oil cooling nozzle assembly ①.
• Tightening torque of bolt: 25±2.5Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.13.9.15 Removing and installing crankshaft
speed ring gear
Removal procedure
1 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
2 Remove the powertrain. Refer to 2.11.4.2
Removing and installing powertrain.
3 Separate the engine assembly and
transmission assembly. Refer to 2.11.4.3
Separating engine assembly and transmission
assembly.
4 Remove the drive plate. Refer to 2.13.9.11

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Maintenance Manual of 1.5GDI Engine 2-689Mechanical system
Removing and installing drive plate.
5 Remove the crankshaft rear oil seal
assembly. Refer to 2.13.9.12 Removing and
installing crankshaft rear oil seal assembly.
6 Remove the V-ribbed belt. Refer to 2.13.9.1
Removing and installing V-ribbed belt.
7 Remove the oil pan. Refer to 2.14.8.1 Removing
and installing oil pan.

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Mechanical system 2-690 Maintenance Manual of 1.5GDI Engine

8 Remove the timing chain cover. Refer to 2.13.9.5

Removing and installing timing chain cover.
9 Remove the crankshaft speed ring gear
a. Remove the crankshaft speed ring gear ①.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- For installation of the crankshaft speed ring gear,
the marked side as arrowed should face outward.

2.13.9.16 Removing and installing connecting

rod
Removal procedure
1 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
2 Remove the powertrain. Refer to 2.11.4.2
Removing and installing powertrain.
3 Separate the engine assembly and
transmission assembly. Refer to 2.11.4.3
Separating engine assembly and transmission
assembly.
4 Remove the catalytic converter assembly.
Refer to 2.5.6.2 Removing and installing catalytic
converter assembly.
5 Remove the turbocharger assembly. Refer to
2.10.8.1 Removing and installing turbocharger
assembly.
6 Remove the cast exhaust manifold. Refer to
2.5.6.1 Removing and installing cast exhaust
manifold.
7 Remove the intake manifold. Refer to 2.6.7.5
Removing and installing intake manifold.
8 Remove the fuel rail injector assembly. Refer
to 2.3.9.6 Removing and installing fuel rail injector
assembly.
9 Remove the drive plate. Refer to 2.13.9.11
Removing and installing drive plate.
10 Remove the crankshaft rear oil seal

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Maintenance Manual of 1.5GDI Engine 2-691Mechanical system
assembly. Refer to 2.13.9.12 Removing and
installing crankshaft rear oil seal assembly.
11 Remove the oil pan. Refer to 2.14.8.1 Removing
and installing oil pan.
12 Remove the timing chain cover. Refer to 2.13.9.5
Removing and installing timing chain cover.
13 Remove the timing chain. Refer to 2.13.9.6
Removing and installing timing chain.

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Mechanical system 2-692 Maintenance Manual of 1.5GDI Engine

14 Remove the cylinder head cover assembly. Refer to

2.13.9.3 Removing and installing cylinder head
cover assembly.
15 Remove the cylinder head assembly. Refer to
2.13.9.4 Removing and installing cylinder head
assembly.
16 Remove the connecting rod
a. Unscrew the fixing bolt as arrowed, and take off
the oil pan baffle ①.
• Tightening torque of bolt: 9±0.9Nm

b. Unscrew the fixing bolt as arrowed, and remove

the connecting rod bearing cap ①.
• Tightening torque of bolt: 17Nm+90°

c. Use the handle of a hammer ① or a soft tool to

push off the piston assembly ②.
Tip:
When removing the piston & connecting rod, be
sure to make a mark on each piston & connecting
rod to avoid confusing respective cylinders.

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Maintenance Manual of 1.5GDI Engine 2-693Mechanical system

d. Use a slotted screwdriver ① or other suitable

tools to pry off the piston pin snap ring ②.
Tip:
Each time the piston pin snap ring is removed, it
must be replaced with a new one.

e. Remove the piston pin ①, and take off the

connecting rod ②.

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.13.9.17 Removing and installing piston ring
Removal procedure
1 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
2 Remove the powertrain. Refer to 2.11.4.2
Removing and installing powertrain.
3 Separate the engine assembly and the
transmission assembly. Refer to 2.11.4.3
Separating engine assembly and transmission
assembly.
4 Remove the catalytic converter assembly.
Refer to 2.5.6.2 Removing and installing catalytic
converter assembly.
5 Remove the turbocharger assembly. Refer to
2.10.8.1 Removing and installing turbocharger
assembly.
6 Remove the cast exhaust manifold. Refer to
2.5.6.1 Removing and installing cast exhaust
manifold.
7 Remove the intake manifold. Refer to 2.6.7.5
Removing and installing intake manifold.
8 Remove the fuel rail injector assembly. Refer
to 2.3.9.6 Removing and installing fuel rail injector
assembly.

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Mechanical system 2-694 Maintenance Manual of 1.5GDI Engine
9 Remove the drive plate. Refer to 2.13.9.11
Removing and installing drive plate.
10 Remove the crankshaft rear oil seal
assembly. Refer to 2.13.9.12 Removing and
installing crankshaft rear oil seal assembly.
11 Remove the oil pan. Refer to 2.14.8.1 Removing
and installing oil pan.
12 Remove the timing chain cover. Refer to 2.13.9.5
Removing and installing timing chain cover.
13 Remove the timing chain. Refer to 2.13.9.6
Removing and installing timing chain.

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Maintenance Manual of 1.5GDI Engine 2-695Mechanical system

14 Remove the cylinder head cover assembly. Refer to

2.13.9.3 Removing and installing cylinder head
cover assembly.
15 Remove the cylinder head assembly. Refer to
2.13.9.4 Removing and installing cylinder head
assembly.
16 Remove the piston ring
a. Unscrew the fixing bolt as arrowed, and take off
the oil pan baffle ①.
• Tightening torque of bolt: 9±0.9Nm

b. Unscrew the fixing bolt as arrowed, and remove

the connecting rod bearing cap ①.
• Tightening torque of bolt: 17Nm+90°

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Mechanical system 2-696 Maintenance Manual of 1.5GDI Engine

c. Use the handle of a hammer ① or a soft tool to

push off the piston assembly ②.
Tip:
When removing the piston & connecting rod, be
sure to make a mark on each piston & connecting
rod to avoid confusing respective cylinders.

d. Use the piston ring disassembling tool

(8910045BAC0000) to remove the piston ring ①.
Tip:
The piston ring disassembling tool cannot be used
to remove oil control rings.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- First install the oil control ring (blade and bushing
ring), then install the second compression ring, and
finally install the first compression ring.
- When installing the blade and bushing ring, insert
the blade on both sides of the bushing ring, with
the openings staggered by about 180°.
- When installing the second compression ring
which is thinner than the first compression ring,
direct the “N” mark (arrow A) on the piston ring
towards the top of the piston.
- When installing the first compression ring which
is thicker than the second compression ring, direct
the “N” mark (arrow B) on the piston ring towards
the top of the piston.
- After installing the piston rings, check that their
notches do not face the piston pin side and the
piston working surface. The openings of adjacent
rings shall be staggered evenly by 180°, rather
than overlap.
- Check whether the piston rings can rotate freely
after installation.
2.13.9.18 Tightening sequence of main bearing
cap bolts
Tightening procedure
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Maintenance Manual of 1.5GDI Engine 2-697Mechanical system

Tightening sequence of main bearing cap bolts

- Tighten the main bearing cap bolts ①~⑩ in the
order shown in the figure.
• Tightening torque of bolt: 50Nm+90°

2.13.9.19 Assembly relationship of main

bearing caps
Assembly relationship
Assembly relationship of main bearing caps
- The arrow on the top of main bearing cap points
towards the timing chain side.
- The tops of the first, second, third, fourth and fifth
bearing caps are marked with numbers 1, 2, 3, 4
and 5 respectively.

2.13.9.20 Assembly relationship of main

bearing shells
Assembly procedure

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Mechanical system 2-698 Maintenance Manual of 1.5GDI Engine

Assembly relationship of main bearing shells

- The arrowed direction is the timing chain side.

- The arrowed position is the color mark of main

bearing shell thickness.
- The thickness class of main bearing shells are
indicated by three colors, i.e. yellow, blue and red.
Bearing shell
Class Color
thickness/mm
1 or A 1.985-1.991 Red
2 or B 1.990-1.996 Blue
3 or C 1.995-2.001 Yellow

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Maintenance Manual of 1.5GDI Engine 2-699Mechanical system

2.13.9.21 Assembly relationship of piston and

connecting rod
Tip:
When removing the piston & connecting rod, be
sure to make a mark on each piston & connecting
rod to avoid confusing respective cylinders.
Assembly relationship of piston and connecting rod
- As shown in Fig. 1, the convex mark as arrowed
of connecting rod bearing cap faces the timing
chain side.
- As shown in Fig. 2, the connecting rod dowel pin
(arrow A) is aligned with the connecting rod
bearing cap positioning hole (arrow B) for
installation.
- As shown in Fig. 3: the connecting rod is
engraved with a mark as arrowed, and the arrow
points toward the drive plate side.

- There is an arrow mark (arrow A) on the top of

the piston, and the arrow points toward the timing
chain side.
- Piston top is marked (arrow B): "B" or "2" means
class B or 2; "A" or "1" means class A or 1; "C" or
"3" means class C or 3.

2.13.9.22 Assembly position of piston ring

Assembly position of piston ring
- First install the oil control ring (blade and bushing
ring), then install the second compression ring, and
finally install the first compression ring.
- When installing the blade and bushing ring, insert
the blade on both sides of the bushing ring, with
the openings staggered by about 180°.
- When installing the second compression ring
which is thinner than the first compression ring,
direct the “N” mark (arrow A) on the piston ring
towards the top of the piston.
- When installing the first compression ring which
is thicker than the second compression ring, direct
the “N” mark (arrow B) on the piston ring towards
the top of the piston.
- After installing the piston rings, check that their
notches do not face the piston pin side and the
piston working surface. The openings of adjacent
rings shall be staggered evenly by 180°, rather
than overlap.
- Check whether the piston rings can rotate freely
after installation.
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Mechanical system 2-700 Maintenance Manual of 1.5GDI Engine

2.13.9.23 Description of cylinder block and

crankshaft barcodes
Description of cylinder block and crankshaft
barcodes
- A: bore identification code, bore diameter class,
model identification, production serial number.
- B: identification code and class of crankshaft hole
- C: diameter class of main journals and connecting
rod journals.

- The cylinder block barcode should be pasted in

the arrowed position.

- The diameter class of crankshaft main journals

and connecting rod journals should be printed in
the arrowed positions at the rear end of the
crankshaft.

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Maintenance Manual of 1.5GDI Engine 2-701Mechanical system

- The diameter class of connecting rod big end

hole should be printed in the arrowed position on
the joint surface between the connecting rod and
the connecting rod bearing cap.
- 2 means “class 2 (48.004~48.008)”.

Description of bore diameter class and serial

number barcode
Example
- A: model (the clear code does not need to be
recorded in the bar code)
- B: production serial number, total of 9
alphanumeric characters
- C: model identification, total of 2 alphanumeric
characters
- D: bore diameter class
1st character: cylinder 1 bore class (class 2)
2nd character: cylinder 2 bore class (class 2)
3st character: cylinder 3 bore class (class 2)
4st character: cylinder 4 bore class (class 2)
- E: bore identification code
Description of crankshaft hole class barcode
Example
- A: crankshaft hole class
1st and 2nd characters: 1st crankshaft hole
diameter: 50.007mm, class: 07
3rd and 4th characters: 2nd crankshaft hole
diameter: 50.007mm, class: 07
5th and 6th characters: 3rd crankshaft hole
diameter: 50.007mm, class: 07
7th and 8th characters: 4th crankshaft hole
diameter: 50.007mm, class: 07
9th and 10th characters: 5th crankshaft hole
diameter: 50.008mm, class: 08
- B: crankshaft hole identification code

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Mechanical system 2-702 Maintenance Manual of 1.5GDI Engine

Description of diameter class barcode of

connecting rod journals and crankshaft main
journals
- A: diameter class of connecting rod journals
1st character: diameter class of #1 cylinder
crankshaft connecting rod journal (class 2)
2nd character: diameter class of #2 cylinder
crankshaft connecting rod journal (class 2)
3rd character: diameter class of #3 cylinder
crankshaft connecting rod journal (class 2)
4th character: diameter class of #4 cylinder
crankshaft connecting rod journal (class 2)
- B: diameter class of main journals
1st character: diameter class of 1st crankshaft
main journal (class B or 2)
2nd character: diameter class of 2nd crankshaft
main journal (class B or 2)
1st character: diameter class of 3rd crankshaft
main journal (class B or 1)
4th character: diameter class of 4th crankshaft
main journal (class B or 2)
5th character: diameter class of 5th crankshaft
main journal (class B or 2)
Note:
- The diameter class of crankshaft main journal
must be used together with the selection table of
main bearing shell.

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Maintenance Manual of 1.5GDI Engine 2-703Lubrication system

2.14 Lubrication system

2.14.1 Specifications
2.14.1.1 Fastener specifications
Location Specification Tightening torque, N.m
Oil pan Hexagon flange bolt M6×30 25±2.5
Oil pump sprocket Hexagon flange bolt M8×16 25±2.5
Oil pump Hexagon flange bolt M6×40 25±2.5
Oil filter Oil filter 15+180°
Oil cooler connector Oil cooler connector 50±5
Water inlet pipe Hexagon flange bolt M8×16 25±2.5
Oil pressure switch Oil pressure switch 30±2.5
Oil pump solenoid valve Hexagon flange bolt M6x10 9±0.9
Dipstick tube Hexagon flange bolt M6×12 9±0.9

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Lubrication system 2-704 Maintenance Manual of 1.5GDI Engine

2.14.2 Description and operation

2.14.2.1 Overview
Overview
In order to ensure the normal operation of the engine, the surface of related moving parts must be
lubricated; that is, a thin, uniform layer of lubricating oil (oil) film must be applied between the friction
surfaces to reduce the frictional resistance, power consumption and parts wear and to extend the service
life of the engine. A system that conveys lubricating oil to the surface of moving parts for lubrication is
called the engine lubrication system, referred to as the lubrication system.
The lubrication system is used to lubricate the surface of moving parts to reduce the frictional resistance
and wear and to ensure the normal operation of the engine. In addition, it also cleans the friction surface
to take away chips and other foreign objects; the oil circulating in the lubrication system also takes away
the heat generated by friction for cooling; an oil film formed between moving parts (e.g., piston and
cylinder) can improve the tightness to prevent air or oil leakage; an oil film formed on the surface of parts
can prevent corrosion and rust to protect the surface of parts; lubricating oil can also be used as
hydraulic oil, for example, achieving a hydraulic effect in hydraulic tappets; an oil film formed on the
surface of moving parts can absorb shock and reduce vibration for damping.
Oil is the medium of the lubrication system, and its quality directly affects the operation of the lubrication
system. The selected oil must meet the operation requirements. Thick oil is difficult to circulate in the
pipeline and oil passage, increasing the resistance to motion of components or friction surfaces, and
even fails to form an oil film, causing direct friction of parts; thin oil has excessively high fluidity, and the
oil film formed will be damaged quickly at high temperature. Oil mixed with water will form a milky liquid
mixture which will not only fail to lubricate the parts, but also rust the parts, causing direct seizure of
components or friction surfaces. Therefore, the oil level and quality must be checked regularly.
The 1.5TGDI engine adopts an electronically controlled variable displacement oil pump. Compared with
the traditional fixed displacement oil pump, the fuel consumption can be saved by approximately 2.5% in
the NEDC.

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Maintenance Manual of 1.5GDI Engine 2-705Lubrication system
2.14.3 System working principles
2.14.3.1 System working principles
Control principle of oil pressure switch
The oil pressure switch is installed on the cylinder block to detect the oil pressure in the main oil
passage. When the engine is shut down or the oil pressure is lower than the specified value, the
contacts in the oil pressure switch are closed and the oil pressure warning lamp comes on. When the
engine is started or the oil pressure is higher than the specified value, the oil pressure pushes the
diaphragm in the oil pressure switch to open the contacts in the oil pressure switch, and the oil pressure
warning lamp goes out.
Oil pan
The oil pan is installed at the bottom of the crankcase. The oil pump draws engine oil from the oil pan.
After passing the oil filter, the engine oil enters two oil passages, receptively lubricating the cylinder
block and cylinder head. In the first oil passage, the engine oil is supplied to the connecting rod through
the oil passage of the crankshaft, and then to the piston and cylinder; finally, it returns to the oil pan. In
the second oil passage, the engine oil is supplied to the camshaft through the oil passage, and lubricates
the valve assembly through the internal oil passage of the camshaft; finally, it returns to the oil pan.
Oil pump
The oil pump draws engine oil from the oil pan, and then, through pressure action, delivers the engine oil
to all parts of the engine. The oil pump draws engine oil from the oil pan and then delivers it to various
parts of the engine. A filter screen installed at the oil pump inlet port filters the impurities in the engine oil,
and then the oil enters the oil pump to make the oil pump work normally.
The 1.5TGDI engine adopts an electronically controlled variable displacement oil pump. Compared with
the traditional fixed displacement oil pump, the fuel consumption can be saved by approximately 2.5% in
the NEDC. The variable displacement oil pump changes its eccentricity with the rotor through the sliding
or swing of the outer adjusting ring, thereby changing the displacement of the vane pump. When the
engine oil pressure fed back reaches the set value of the variable, the spring is compressed and the
outer adjusting ring slides or swings, so that the eccentricity between the inner ring and the outer ring of
the blade is reduced, and the oil pressure chamber formed between the blade and the inner and outer
ring changes less accordingly during the operation of the oil pump, so that the oil pump flow is reduced;
when the engine oil pressure fed back decreases, the spring gradually returns to reset the adjusting ring.

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Lubrication system 2-706 Maintenance Manual of 1.5GDI Engine
2.14.4 Location of components
2.14.4.1 Location of components

Oil pump solenoid valve

Oil pan

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Maintenance Manual of 1.5GDI Engine 2-707Lubrication system

Oil pressure switch

Oil cooler

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Lubrication system 2-708 Maintenance Manual of 1.5GDI Engine
2.14.5 Exploded view
2.14.5.1 Exploded view

Oil pan baffle

(8 in total)

Oil pump assembly

Oil pump chain

Dipstick tube
(4 in total)

Oil pump sprocket

Dipstick tube gasket

Oil pump solenoid

valve

Oil cooler

Oil pan

Gasket Oil cooler connector

Drain plug

Oil filter
(14 in total)

Disposable part:
Tightening torque is in N•m

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Maintenance Manual of 1.5GDI Engine 2-709Lubrication system
2.14.6 Diagnostic information and procedure
2.14.6.1 Diagnostic instructions
Familiarize yourself with the system functions and operations before starting the system diagnosis. This
helps you correctly determine the fault cause when a fault occurs, and more importantly, helps
determine whether the situation described by the customer is normal.
2.14.6.2 Visual inspection
• Check the aftermarket parts that may affect the operation of the lubrication system.
• Check the accessible or visible system components for obvious blockage or leakage. If any,
confirm whether it is engine oil leakage.
• Check whether the oil filter is dirty or blocked, and replace it if necessary.
2.14.6.3 Low oil pressure
Diagnostic procedure
Step 1 Check whether the engine oil used meets the standard?

N Change the engine oil with that

meeting the standard.
Y

Step 2 Check whether the engine oil level is normal.

N Add the engine oil to the normal

level.
Y

Step 3 Check whether the oil filter is dirty.

Y Replace the oil filter.

Step 4 Check whether the oil pressure switch works normal.

N Replace the oil pressure switch.

Step 5 Check whether the oil pump solenoid valve is stuck.

Y Replace the oil pump solenoid

valve.

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Lubrication system 2-710 Maintenance Manual of 1.5GDI Engine

Step 6 Check whether the oil pump filter screen is dirty or broken.

Y Clean the oil pump filter screen.

Step 7 Check whether the crankshaft bearing clearance is too large.

Y Replace the main bearing shells,

and if necessary, replace the
crankshaft.
Next step

Step 8 End.
2.14.6.4 Abnormal engine oil consumption
Diagnostic procedure
Step 1 Check whether the engine oil leaks.

Y Check and repair the leaking

parts.
N

Step 2 Check whether the engine oil viscosity is abnormal and whether inferior engine oil is used.

Y Replace the oil filter and change

the engine oil.
N

Step 3 Check whether the engine oil is changed regularly.

N Change the engine oil regularly.

Step 4 Check whether the components of the positive crankcase ventilation system are damaged.

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Maintenance Manual of 1.5GDI Engine 2-711Lubrication system

Y Replace the damaged

components.
N

Step 5 Check whether the valve guide/valve stem is worn, and whether the valve stem oil seal is
worn, missing or improperly installed.

Y Repair the faulty location.

Step 6 Check whether the piston and piston ring are improperly installed in the cylinder.

Y Repair the faulty location.

Step 7 Check whether the piston ring is correctly sealed, and whether the piston ring is broken or
worn.

Y Repair the faulty location.

Next step

Step 8 End.

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Lubrication system 2-712 Maintenance Manual of 1.5GDI Engine

2.14.7 Special tools

2.14.7.1 List of special tools
No. Legend Tool No. Name

1 8910225BAD0000 Oil filter puller

Oil pressure switch

2 8910240BAD0000 installer and remover
socket

Oil pump and injector

3 8910001ADE0000
disassembling tool

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Maintenance Manual of 1.5GDI Engine 2-713Lubrication system

2.14.8 Removal and installation

2.14.8.1 Removing and installing oil pan
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
3 Install the engine stand. Refer to 2.11.4.1
Installing engine engine.
4 Remove the transmission assembly. Refer to
the Maintenance Manual - transmission
5 Remove the drive plate. Refer to 2.13.9.11
Removing and installing drive plate.
6 Remove the crankshaft rear oil seal
assembly. Refer to 2.13.9.12 Removing and
installing crankshaft rear oil seal assembly.
7 Remove the V-ribbed belt. Refer to 2.13.9.1
Removing and installing V-ribbed belt.
8 Remove the A/C compressor assembly.
Refer to 8.4.7.13 Removing and installing A/C
compressor.
9 Remove the oil cooler. Refer to 2.14.8.3
Removing and installing oil cooler.
10 Remove the oil pan
a. Unscrew the fixing bolt as arrowed. b. Remove
the oil pan assembly ①.
• Tightening torque of bolt: 25±2.5Nm

Installation procedure

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Lubrication system 2-714 Maintenance Manual of 1.5GDI Engine

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
- The oil pump assembly must be inspected and
cleaned before installation of the oil pan.
- The mating face of the oil pan and cylinder block
shall be cleaned.
- For installation of the oil filter, the seal ring needs
to be coated with oil.
- As shown in the figure, apply the sealant evenly
to the sealing surface of oil pan as arrowed,
instead of bolt holes. Install the oil pan assembly in
3 min after applying the sealant.
• Diameter: 2.5~3.0mm
• Sealant: Loctite 5900
- As shown in the figure, install the oil pan, and
tighten the 14 fixing bolts in the order shown in the
figure.
• Tightening torque of bolt: 25±2.5Nm

2.14.8.2 Removing and installing oil pump

assembly
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
3 Install the engine stand. Refer to 2.11.4.1
Installing engine engine.
4 Remove the transmission assembly. Refer to
the Maintenance Manual - transmission
5 Remove the drive plate. Refer to 2.13.9.11
Removing and installing drive plate.
6 Remove the crankshaft rear oil seal
assembly. Refer to 2.13.9.12 Removing and
installing crankshaft rear oil seal assembly.
7 Remove the V-ribbed belt. Refer to 2.13.9.1
Removing and installing V-ribbed belt.
8 Remove the A/C compressor assembly.
Refer to 8.4.7.13 Removing and installing A/C
compressor.
9 Remove the oil cooler. Refer to 2.14.8.3
Removing and installing oil cooler.
10 Remove the oil pan. Refer to 2.14.8.1 Removing
and installing oil pan.
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Maintenance Manual of 1.5GDI Engine 2-715Lubrication system

11 Remove the oil pump assembly.

a. As shown in the figure, use the tool ①
(8910001ADE0000/4) to fix the oil pump sprocket
②.
b. Unscrew the fixing bolt as arrowed, and remove
the tool ① (8910001ADE0000/4) and the oil
pump sprocket ②.
• Tightening torque of bolt: 25±2.5Nm

c. Unscrew the fixing bolts as arrowed, and take off

the oil pump assembly ①.
• Tightening torque of bolt: 25±2.5Nm

Installation procedure

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Lubrication system 2-716 Maintenance Manual of 1.5GDI Engine

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
- Before installation of the oil pump, the surface of
the oil pump must be cleaned.
- The mounting surface of the cylinder block and
the oil pump shall be cleaned.
- As shown in the figure, for installation of the oil
pump, the feedback oil passage seal ring ① must
be replaced.

- For installation of the oil pump sprocket ②, the

end with the part number should face outward.
- For installation of the oil pump sprocket ②, make
sure that the oil pump chain has been fitted on the
crankshaft end oil pump sprocket and the oil pump
sprocket ② , and pre-tighten the fixing bolt as
arrowed.
- Use the tool ① (8910001ADE0000/4) to fix the
oil pump sprocket ②, and tighten the fixing bolt as
arrowed to the specified torque.
• Tightening torque of bolt: 25±2.5Nm

2.14.8.3 Removing and installing oil cooler

Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Drain engine oil. Refer to 1.8.4.1 Changing
engine oil, and replacing oil filter.
3 Drain the coolant. Refer to 1.8.4.5 Changing
coolant.
4 Remove the oil cooler
a. Loosen the fixing clamp as arrowed, and
disconnect the oil cooler hose I ① and the oil
cooler hose II ② from the oil cooler.

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Maintenance Manual of 1.5GDI Engine 2-717Lubrication system

b. Remove the oil filter ② with the oil filter puller

(8910225BAD0000) ①.
• Tightening torque of oil filter: 15Nm+180°

c. Unscrew the oil cooler connector as arrowed,

and take off the oil cooler ①.
• Tightening torque of oil cooler connector:
50±5Nm

Installation procedure

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Lubrication system 2-718 Maintenance Manual of 1.5GDI Engine

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
- Replace the oil cooler gasket ①.

- The positioning points (arrow A) of the oil cooler

are on both sides of the positioning point (arrow B).

2.14.8.4 Removing and installing oil pressure

switch
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.
3 Remove the air cleaner assembly. Refer to
2.6.7.1 Removing and installing air cleaner
assembly.
4 Remove the starter. Refer to 2.15.8.2 Removing
and installing starter.
5 Remove the oil pressure switch
a. Remove the engine upper guard plate assembly
①.

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Maintenance Manual of 1.5GDI Engine 2-719Lubrication system

b. Unscrew the upper fixing bolts of water inlet pipe

① as arrowed.
• Tightening torque of bolt: 25±2.5Nm

c. Unscrew the lower fixing bolts of water inlet pipe

① (arrow A).
d. Disconnect the oil pressure switch connector
(arrow B).
• Tightening torque of bolt (arrow A): 25±2.5Nm

e. Remove the oil pressure switch with the oil

pressure switch installer and remover socket ①
(8910240BAC0000).
• Tightening torque of oil pressure switch:
30±2.5Nm

Installation procedure

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Lubrication system 2-720 Maintenance Manual of 1.5GDI Engine

The installation procedure is in reverse of removal

procedure. Moreover, pay attention to the
following:
- When installing the oil pressure switch, apply the
sealant to the area (a) of the thread.
• Standard width: 3±1mm

2.14.8.5 Removing and installing oil pump

solenoid valve
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal.
Refer to 1.8.6.1 Maintaining and inspecting
battery.
3 Remove the oil pump solenoid valve
a. Lift the vehicle.
b. Unscrew the fixing screw (arrow A), bolt (arrow
B), and remove the lower guard plate ① of the
engine compartment.
• Tightening torque of bolt (arrow B): 6±2Nm

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Maintenance Manual of 1.5GDI Engine 2-721Lubrication system

c. Disconnect the oil pump solenoid valve

connector as arrowed.

d. Unscrew the fixing bolt as arrowed, and take off

the oil pump solenoid valve ①.
• Tightening torque of bolt: 9±0.9Nm
Note:
Plug the mounting hole after the oil pump solenoid
valve is removed to prevent debris from falling into
it. The oil pump solenoid valve is a precision part
and must be properly placed after removal to
prevent scratches, impacts and contamination.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- During installation, replace the O-ring ①, and
apply a little oil to the surface of new O-ring ①.
- Check whether the new O-ring ① is in good
condition.
- Pay attention to whether the thickness of the new
O-ring ① is consistent with that of the old O-ring
①.

2.14.8.6 Removing and installing dipstick tube

Removal procedure

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Lubrication system 2-722 Maintenance Manual of 1.5GDI Engine

1 Turn off all electrical consumers and set the

ENGINE START/STOP button to “OFF” position.
2 Remove the dipstick tube
a. Remove the engine upper guard plate assembly
①.

b. Pull out the dipstick ①.

c. Unscrew the fixing bolt as arrowed, and take off
the dipstick tube ②.
• Tightening torque of bolt: 9±0.9Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.14.8.7 Inspecting oil level
Inspection procedure

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Maintenance Manual of 1.5GDI Engine 2-723Lubrication system

1 Inspection conditions
- Park the vehicle on a level ground.
- The oil pan is not deformed.
- When the engine is stopped, wait 10 min to allow
the oil to flow back to the oil pan.
2 Inspection steps
a. Pull out the dipstick ①, dry it with a shop towel,
then reinsert it, push it all the way down, and wait a
moment.
b. Pull out the oil dipstick ① again and read the oil
level.

3 Marks on the oil dipstick

H - MAX mark
L - MIN mark
If the oil level is between the H and L marks, it is
normal
If the oil level is above the H mark, the oil shall be
drained until the oil level is between the H and L
marks.
If the oil level is below the L mark, the oil shall be
added until the oil level is between the H and L
marks.

Filling requirements of engine oil

Oil grade/viscosity Total filling amount
SN and above/SAE5W30 4.5L

GAC Motor 2019

Start and charging system 2-724 Maintenance Manual of 1.5GDI Engine

2.15 Start and charging systems

2.15.1 Specifications
2.15.1.1 Fastener specifications
Location Specification Tightening torque, N.m
Hexagon flange nut M8 15±2
Hexagon head bolt
45±5
M10×1.25×80
Alternator Hexagon flange nut M10×1.25 45±5
Hexagon head bolt
70±7
M12×1.25×110
Hexagon flange nut M12×1.25 70±7
Hexagon flange nut M8 10±1
Starter Hexagon flange bolt
30±3
M10×1.25×45
Hexagon flange nut M6 10±2
EBS
Hexagon nut M6 6±1
Battery platen Hexagon flange nut M6 3±0.5
Engine harness [positive battery
Attached device 6±1
terminal]
Battery tray Hexagon flange bolt M8×16 22±2
DC-DC converter Hexagon flange nut M6 8±1

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Maintenance Manual of 1.5GDI Engine 2-725Start and charging system

2.15.2 Description and operation

2.15.2.1 Overview
Overview of charging system
The alternator is the main power supply of the vehicle. It is used to power all electrical consumers
(except the starter) during normal operation of the engine, and to charge the battery at the same time.
The alternator is mainly composed of five parts: rotor, stator, voltage regulator, housing and end cover.
The rotor and stator generate an alternating current based on the electromagnetic cutting principle, and
then the current is rectified and stabilized by the voltage regulator to become stable DC 14V.
When the engine speed is constant, the magnitude of direct current output by the alternator is controlled
by the magnetic field control circuit in the powertrain control module. The circuit is connected in series
between the excitation coil terminal of secondary rotor and the ground.
Overview of start system
The engine needs external support to complete the starting process from a stationary status to a running
status. The engine is started with the engagement of the starter pinion and the drive plate gear, so as to
drive the drive plate to rotate.
The control unit of the vehicle's starter consists of the solenoid switch, starter relay, ENGINE
START/STOP button, etc. The solenoid switch is installed together with the starter.
The start system has two independent circuits: one provides high ampere current for the starter
operation, and the other is a low-current control circuit that controls the operation of the starter relay. The
start system is mainly composed of the following components:
- Starter relay
- Starter assembly
- ENGINE START/STOP button
When the engine is started or running, the start system and the charging system work together.
Therefore, during diagnosis of the start system, the influence by the charging system cannot be ignored.
When diagnosing either of the two systems, be sure to remember their relation.

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Start and charging system 2-726 Maintenance Manual of 1.5GDI Engine
2.15.3 System working principles
2.15.3.1 System working principles
Operating principle of alternator charging
When the ENGINE START/STOP button is in "ON" position, the alternator is powered and the current
flows into the excitation coil to achieve initial excitation. When the stator coil starts to generate electricity
after engine starts, the excitation coil is energized by the output current of the stator coil. The alternator
supplies power to the electrical system of the vehicle and charges the battery. The IC regulator checks
the input voltage, and thus controls the output voltage. If the excitation current rises, the output power of
the alternator increases; if the excitation current goes down, the output power decreases. When the
battery voltage is about 14.4V regulating voltage, the excitation current is cut off. When the battery
voltage drops below the regulating voltage, the voltage regulator adjusts the output voltage by controlling
the excitation current to keep it at a constant level.

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Maintenance Manual of 1.5GDI Engine 2-727Start and charging system
2.15.4 Location of components
2.15.4.1 Location of components

Alternator

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Starter

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EBS

Battery

Battery tray

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DC-DC converter

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Maintenance Manual of 1.5GDI Engine 2-731Start and charging system
2.15.5 Exploded view
2.15.5.1 Exploded view

Starter

(2 in total)

Alternator

Tightening torque is represented in N•m

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Start and charging system 2-732 Maintenance Manual of 1.5GDI Engine
2.15.6 Electrical schematic diagram
2.15.6.1 Electrical schematic diagram
Engine

EBS

Alternator Battery

Engine
compartme
nt PDU

PFB

Starter Starter relay 1

Starter relay 2

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Maintenance Manual of 1.5GDI Engine 2-733Start and charging system
2.15.7 Diagnostic information and procedure
2.15.7.1 Diagnostic instructions
Familiarize yourself with the system functions and operations before starting the system diagnosis. This
helps you correctly determine the fault cause when a fault occurs, and more importantly, helps
determine whether the situation described by the customer is normal.
2.15.7.2 Visual inspection
• Check whether there is any aftermarket part that may affect the operation of the start or charging
system.
• Check the accessible or visible system components for obvious damage or conditions which may
cause faults.
• Check whether the battery is installed correctly.
• Test the status of the battery. The battery voltage shall not be less than 11V.
• Check whether the relevant wires are damaged and whether the starter, alternator, battery and all
relevant ground points are connected reliably.
• If the batteries, wires and switches are normal and the engine functions normally, remove and test
the starter and the alternator.
• When the charging system works normally, the charging indicator lamp will come on if the ENGINE
START/STOP button is set to “ON” position, and go out after the engine is started.
• Check whether the alternator is installed loosely or improperly, whether the pre-tightening force of
the drive belt is normal, and whether there is a possibility of slip.
2.15.7.3 Alternator output fault
Diagnostic procedure
Step 1 Check whether the V-ribbed belt is aging or loose.

Y Replace the V-ribbed belt.

Step 2 Check whether the control circuit of the alternator is normal.

N Check and repair the control

circuit of the alternator.
Y

Step 3 Check whether the internal regulator or coil of the alternator is ablated.

Y Replace the alternator.

Next step

Step 4 End.
2.15.7.4 Abnormal operation of starter
Diagnostic procedure

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Start and charging system 2-734 Maintenance Manual of 1.5GDI Engine

Step 1 Check whether the battery level is normal.

N Charge or replace the battery.

Step 2 Check whether the starter relay is normal.

N Replace the starter relay.

Step 3 Check whether the control circuit of the starter is normal.

N Check and repair the control

circuit of the starter.
Y

Step 4 Check whether the starter coil is abnormal, the coil is ablated or the carbon brush is in poor
contact.

Y Replace the alternator.

Next step

Step 5 End.

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Maintenance Manual of 1.5GDI Engine 2-735Start and charging system

2.15.8 Removal and installation

2.15.8.1 Removing and installing alternator
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal. Refer to
1.8.6.1 Maintaining and inspecting battery.
3 Remove the V-ribbed belt. Refer to 2.13.9.1
Removing and installing V-ribbed belt.
4 Remove the intercooler air outlet tube. Refer to
2.10.8.6 Removing and installing intercooler air
outlet tube
5 Remove the intake manifold. Refer to 2.6.7.5
Removing and installing intake manifold.
6 Support the right side of the engine firmly with
a jack.
7 Remove the right mounting assembly. Refer
to 2.12.4.2 Removing and installing right mounting
assembly.
8 Remove the alternator
a. Disconnect the alternator connector (arrow A).
b. Remove the insulating sleeve.
c. Unscrew the fixing nut (arrow B), and disconnect
the charging wire ① from the alternator.
• Tightening torque of nut (arrow B): 15±2Nm

d. Adjust the jack to raise the powertrain to a

certain level (enough space for removing the
alternator fixing bolt (arrow B)).
e. Unscrew the fixing bolts (arrows A and B), and
remove the nuts. f. Carefully take off the alternator
①.
• Tightening torque of bolt (arrow A): 45±5Nm
• Tightening torque of bolt (arrow B): 70±7Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.15.8.2 Removing and installing starter
Removal procedure
1 Turn off all electrical consumers and set the
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Start and charging system 2-736 Maintenance Manual of 1.5GDI Engine
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery
terminal. Refer to 1.8.6.1 Maintaining and
inspecting battery.

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3 Remove the air cleaner assembly. Refer to

2.6.7.1 Removing and installing air cleaner
assembly.
4 Remove the starter
a. Press the quick connector (arrow A), and
disconnect the fuel vapor pipe assembly I ① from
the intercooler air outlet tube.
b. Disengage the fixing clip (arrow B).

c. Disconnect the starter connector (arrow A).

d. Remove the insulating sleeve (arrow B).

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Start and charging system 2-738 Maintenance Manual of 1.5GDI Engine

e. Unscrew the fixing nut as arrowed, and

disconnect the starter harness ①.
• Tightening torque of nut: 10±1Nm

f. Unscrew the fixing bolt as arrowed, and take off

the starter ①.
• Tightening torque of bolt: 30±3Nm

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- As shown in the figure, check whether the gasket
① is installed in place.

2.15.8.3 Removing and installing battery

Removal procedure

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Maintenance Manual of 1.5GDI Engine 2-739Start and charging system

1 Turn off all electrical consumers and set the

ENGINE START/STOP button to “OFF” position.
2 Remove the battery
a. Lift up the battery heat shield ① as arrowed.

b. Disconnect the EBS connector (arrow A).

c. Loosen the EBS nut (arrow B), and disconnect
the EBS with battery negative harness ①.
• Tightening torque of nut (arrow B): 6±1Nm

d. Unscrew the fixing nut as arrowed, and remove

the battery platen with screw ①.
• Tightening torque of nut: 3±0.5Nm

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e. Remove the protective cap ① of positive

battery terminal as arrowed.

f. Unscrew the fixing nut as arrowed, and

disconnect the positive battery terminal ①.
• Tightening torque of nut: 6±1Nm

g. Take off the battery heat shield ① and battery

②.

Installation procedure
The installation procedure is in reverse of removal
procedure. Moreover, pay attention to the
following:
- The battery must be installed and connected
firmly. Otherwise, the following damage will occur:
if the battery falls off, there will be a danger of
explosion. If the battery terminals are connected
loosely, sparks will be generated when the
terminals are contacted, likely to burn up the
onboard electrical consumers. The battery case
will be worn by metal fasteners, causing electrolyte
leakage.
2.15.8.4 Removing and installing EBS
Removal procedure
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Maintenance Manual of 1.5GDI Engine 2-741Start and charging system

1 Turn off all electrical consumers and set the

ENGINE START/STOP button to “OFF” position.
2 Remove the EBS
a. Unscrew the fixing nut as arrowed, and
disconnect the negative battery harness ①.
• Tightening torque of nut: 10±2Nm

c. Disconnect the EBS connector (arrow A).

d. Unscrew the fixing nut (arrow B), and take off
the EBS ①.
• Tightening torque of nut (arrow B): 6±1Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.
2.15.8.5 Removing and installing battery tray
Removal procedure

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Start and charging system 2-742 Maintenance Manual of 1.5GDI Engine

1 Turn off all electrical consumers and set the

ENGINE START/STOP button to “OFF” position.
2 Remove the battery. Refer to 1.8.6.1
Maintaining and inspecting battery.
3 Remove the battery tray
a. Unscrew the fixing bolt as arrowed, and take off
the battery tray ①.
• Tightening torque of bolt: 22±2Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.

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Maintenance Manual of 1.5GDI Engine 2-743Start and charging system

2.15.8.6 Removing and installing DC-DC

converter assembly
Removal procedure
1 Turn off all electrical consumers and set the
ENGINE START/STOP button to “OFF” position.
2 Disconnect the negative battery terminal. Refer to
1.8.6.1 Maintaining and inspecting battery.
3 Remove the console body assembly. Refer to
11.1.4.7 Removing and installing console body
assembly.
4 Remove the instrument panel body
assembly. Refer to 11.1.3.1 Removing and
installing instrument panel body assembly.
5 Remove the DC-DC converter assembly
a. Disconnect the DC-DC converter assembly
connector as arrowed.

b. Unscrew the fixing nut as arrowed, and take off

the DC-DC converter assembly ①.
• Tightening torque of nut: 8±1Nm

Installation procedure
The installation procedure is in reverse of removal
procedure.

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