BYD S6 Maintenance & Repair Manual

Fuel Supply System and Fuel Evaporation and Purification System

Contents

Section 1: Introduction.............................................................................................................................................1
1.1 Special tools...............................................................................................................................................1
1.2 General Troubleshooting Information.......................................................................................................1
Section 2: Fuel Supply System................................................................................................................................2
2.1 Component Location Index........................................................................................................................2
2.2 Fuel pump circuit troubleshooting.............................................................................................................3
2.3 Releasing fuel pressure..............................................................................................................................3
2.4 Fuel pressure test........................................................................................................................................4
2.5 Draining the fuel tank................................................................................................................................4
2.6 Detection of fuel line..................................................................................................................................5
2.7 Replacing fuel filter...................................................................................................................................6
2.8 Replacing fuel pump..................................................................................................................................7
2.9 Replacing fuel tank....................................................................................................................................7
Section 3: Fuel Evaporation and Purification System.............................................................................................8
3.1 Component Location Index........................................................................................................................8
3.2 Replacing charcoal canister.......................................................................................................................8
Section 4: Acceleration Transmission System.........................................................................................................9
4.1 Adjusting throttle cable..............................................................................................................................9
4.2 Removing/installing throttle cable.............................................................................................................9
 BYD S6 Maintenance & Repair Manual

Section 1: Introduction How to use PGM tester or BYD diagnostic apparatus

If MIL (Malfunction Indicator Lamp) has been lit
1.1 Special tools (1) Start the engine and check MIL (A).
Label Tool No. Name Qty.
O2 Sensor
① 07LAA-PT50101 Socket 1
Wrench
Oil Pressure
② 07NAJ-P070100 Gauge 1
Accessories
Fuel Pressure
③ 07ZAJ-S5A0100 1 (2) If MIL is constantly lit, connect the PGM tester
Gauge Device
Fuel Hose or BYD diagnostic apparatus to the data link
④ 07ZAJ-S7C0100 1 connector (DLC) (A) below the instrument panel at
Attachment
Hoses, Engine driver’s side.
⑤ 07ZAJ-S5A0200 1
Oil Pressure
Low Pressure
⑥ 07406-0070001 1
Gauge
Fuel Pressure
⑦ 07406-0040002 1
Gauge

(3) Turn the ignition switch to ON (II).

1.2 General Troubleshooting
Information
Intermittent fault
“Intermittent fault” is that the system may have been
having fault, but the result of present inspection is
normal. If the Malfunction Indicator Lamp (MIL) on
the instrument panel isn’t lit, check whether any
connector relating to troubleshooting circuit is in
poor connection or has loose wire.
Open-circuit and short-circuit
“Open circuit” and “short circuit” are commonly
used electrical terms. Open circuit is that the wire or
connection breaks. Short circuit is that a wire is
grounded or connected to another wire accidentally.
For simple electronic circuit, it often means that
certain part doesn’t work at all. In complex
electronic circuits (such as ECM and PCM), it means
that although certain part works, it can not work as
scheduled.
(4) Check and record the Diagnostic Trouble Code
(DTC), and check the freeze data at the same time.
Please refer to DTC Diagnostic Trouble Index and
take appropriate troubleshooting procedures.
Note:
· Freezing data indicate the engine state when the
first failure is detected, misfire or fuel is adjusted.
· BYD tester or BYD diagnostic apparatus can read
DTC, freezing data, current data and engine control
module (ECM) /powertrain control module (PCM),
etc.
· Please refer to the User’s Manual of BYD tester or
BYD diagnostic apparatus for specific operation.
(5) If DTC is found, go to MIL troubleshooting.
If MIL isn’t lit, but driving performance failure
exists, please refer to the Symptom and
Troubleshooting Index of this chapter.
If this DTC can’t be repeated
Certain troubleshooting process in this chapter
requires resetting ECM/PCM and then trying to
repeat DTC. If the fault is intermittent and can’t
repeat the code, do not continue to run the program.
Otherwise, it will lead to confusion, and may cause
unnecessary replacement of ECM/PCM.
 BYD S6 Maintenance & Repair Manual

Section 2: Fuel Supply System

2.1 Component Location Index

PGM-FI MAIN RELAY 1(MAIN)

PGM-FI MAIN RELAY 2 (FUEL

PUMP)
See pp. 11-195 for troubleshooting.

ENGINE CONTROL MODULE /

POWERTRAIN CONTROL MODULE

PGM-FI MAIN RELAY 1 (FI MAIN)

PGM-FI MAIN RELAY 1 (FI MAIN)
 BYD S6 Maintenance & Repair Manual

2.2 Fuel pump circuit
troubleshooting
If you suspect that the fuel pump has a fault, please
check whether the pump is running: when it is turned
on, there a sound near the fill inlet if the cap is
removed. When the ignition switch is connected for
the first time, the fuel pump should run for two
seconds. If the fuel pump doesn’t sound, perform the
following checks:
(1) Turn the ignition switch to OFF.
(2) Remove the stepboard, and then take out PGM-FI
MAIN RELAY 2 (FUEL PUMP) (A) from the
fuse/relay box under the cap.
disconnect the fuel pipe in the engine compartment
and thus release the fuel pressure in the system.
(1) Make sure that you have known the password of
audio and navigation system, and then record the
frequency of customer’s radio channel presetting
button.
(2) Turn the ignition switch to OFF.
(3) Remove the stepboard, and then take out PGM-FI
MAIN RELAY 2 (FUEL PUMP) (A) from the
fuse/relay box under the instrument panel.

(4) Start the engine and let it idle until it stalls.

(3) Turn the ignition switch to ON (II).
(4) Measure the voltage between PGM-FI MAIN
RELAY 2 (FUEL PUMP) 4P connector terminal
No.3 and the body grounding.
Note: If any DTC is stored, it should be cleared and
ignored.
(5) Turn the ignition switch to OFF.
(6) Remove the fuel tank cover, and release the fuel
pressure in the fuel tank.
(7) Disconnect the negative cable from the battery
(A).
(8) Loosen worm clamp, type A (A).

2.3 Releasing fuel pressure

Releasing fuel pressure
Use BYD tester or BYD diagnostic system (for
model 483 only)
Before disconnecting fuel pipeline or hose, use BYD
tester or BYD diagnostic system to stop the fuel
pump and thus release the fuel pressure in the
system.
(1) Remove the fuel tank cover.
(9) Put a piece of rag or maintenance cloth on the
(2) Start the engine and let it idle.
hose fitting (A).
(3) Select Fuel Pump OFF in the test menu of BYD
(10) Unplug the hose (A) from the joint, and prevent
tester or BYD diagnostic system, and then let the
the remaining fuel outflowing from the fuel
engine idle until it stops.
distributor or hose with the rag or maintenance cloth.
(4) Turn the ignition switch to OFF.
Do not use any tool, to avoid damaging the hose.
Note:
(11) After the nylon pipe is disconnected, check
· This program allows setting DTC or temporary
whether there is any dirt or damage.
DTC. Check the DTC, and clear if necessary.
(12) Reconnect the negative cable to the battery and
Do not use BYD tester or BYD diagnostic apparatus
do the following:
Before disconnecting fuel pipeline or hose,

ECM/PCM idle learning process
Electric window control unit resetting process
Enter the password of radio device and navigation
system, and then enter the preset frequency of radio
channel.
Reset the clock.
2.4 Fuel pressure test
Special tools required:
· Fuel Pressure Gauge 07406-0040002
· Fuel Pressure Gauge Device 07ZAJ-S5A0100
(1) Release fuel pressure.
(2) Disconnect the hose fitting (A), and connect the
Fuel Pressure Gauge Device and Fuel Pressure
Gauge.
(3) Start the engine and let it idle.
· If the engine is started, go to step (5).
· If the engine isn’t started, go to step (4).
(4) Check whether the fuel pump is running: remove
the fuel tank cover and listen in the filler inlet. When
BYD S6 Maintenance & Repair Manual
the ignition switch is connected for the first time, the
fuel pump should run for two seconds.
If the fuel pump is running, go to step (5).
If the fuel pump isn’t running, implement fuel pump
circuit troubleshooting (see pp. 11-195).
(5) Read the fuel pressure gauge, the reading of
which should be 320-370kPa.
· If the fuel pressure is normal, finish the test.
· If the fuel pressure doesn’t comply with the
technical requirement, replace the fuel pressure
regulator and fuel filter, and then re-test the fuel
pressure.
2.5 Draining the fuel tank
Remove the fuel pump assembly.
Use hand pump, hose and container suitable for
gasoline to draw the fuel from the fuel tank.
 BYD S6 Maintenance & Repair Manual

2.6 Detection of fuel line

Check the line and hose of the fuel system for

damage, leakage and aging. Replace the damaged
parts.

Check all the fixing brackets and hose clamps, and

retighten if necessary.
Note: The oil supply pipe, oil return pipe,
evaporation pipe clamp and brake pipe share part of
the clamp, which will be described in the braking
system.

Notice for fuel line

The fuel line connects fuel rail (A) to fuel delivery
hose (B), connects fuel delivery hose (B) to fuel line
(C), and then connects fuel line (C) to fuel tank
device (F). When remove or install fuel filter, fuel
pump or fuel tank, it is necessary to disconnect or
connect the fuel line.
Please note the following:
· Fuel delivery hose (B), fuel line (C), fuel delivery
hose (E) and quick connector (G) are not heat
resistant; do not damage these parts while welding or
other heating operations.
· Fuel delivery hose (B), fuel line (C), fuel delivery
hose (E) and quick connector (G) are not heat
resistant; do not contact these parts with the towel
for wiping battery electrolyte. Replace any part that
contacts the electrolyte or similar liquid.
When connect or disconnect fuel delivery hose (B),
fuel line (C), fuel delivery hose (E) and quick
connector (G), do not excessively bend or twist these
parts. Replace any damaged part.
 BYD S6 Maintenance & Repair Manual

Removing fuel line/quick connector

(1) Release fuel pressure.
(2) Loosen worm clamp, type A (A).
(3) Put a piece of rag or maintenance cloth on the
hose fitting (A). Unplug the hose (A) from the joint,
and prevent the remaining fuel outflowing from the
fuel distributor or hose with the rag or maintenance
cloth.
(4) Hold the male fitting with left hand, hold the
quick connector with right hand, and press the quick
connector button in the direction of arrow with two Installing fuel line/quick connector
fingers. Unplug the male connector from the quick (1) Check whether the contact area (A) of the line
connector along the axial direction of the pipe. (B) has dirt or damage, and clean or replace if
necessary.

(2) The male connector should be installed in

(5) Check whether the contact area (A) of the line
(B) has dirt or damage.
Clean the surface if it is dirty.
If the surface rusts or is damaged, replace the fuel
pump, fuel filter or fuel delivery pipe.
position along the axial direction of the quick
connector.
· If it deviates from the axis too much, the O-ring in
the shell of the quick connector may be crooked or
misplaced.
· The connector should be inserted manually until
mechanically clamped and a “cracking” sound is
heard.
· To check whether the installation is properly, pull
in the opposite direction shown in the figure below.

(6) To prevent damage and impurity intrusion, please

cover the disconnected connector and line end with
plastic bag (A).

2.7 Replacing fuel filter

When the fuel pressure drops below the specified
value, make sure that fuel pump and fuel pressure
 BYD S6 Maintenance & Repair Manual

regulator are normal, and then replace the fuel filter. 2.9 Replacing fuel tank
(1) Release fuel pressure.
Disassembly
(2) Disconnect the quick connector of the fuel line,
(1) Release fuel pressure.
and discharge the excess fuel to appropriate
(2) Remove the manhole cap of the fuel tank
container.
(3) Remove the electrical connector of the fuel pump
(3) Loosen the mounting bolts of fuel filter and
(4) Disconnect the filler hose (A) and filler
bracket assembly.
ventilation hose II (B).
(4) Take out the fuel filter and bracket assembly
from the vehicle.
Installing fuel filter
(1) Remove the protective cover of the new fuel
filter.
(2) Install the fuel filter and bracket assembly to the
vehicle in proper direction with mounting bolts.
(3) Tighten the fixing bolts.
(3) Connect the fuel inlet/outlet pipe on both sides of
the fuel filter.
(4) Tighten the fuel tank cover.
(5) Re-connect the negative cable of the battery.
(6) Turn on the ignition switch for 2 seconds, turn
off the ignition switch for 10 seconds, and then turn
on the ignition switch again to check for fuel
leakage.
2.8 Replacing fuel pump
Replace the fuel pump if necessary. (5) Disconnect the fuel inlet nylon pipe I (A) from
(1) Release fuel pressure. the fuel filter (C), disconnect the oil return nylon
(2) Remove the manhole cap of the fuel tank pipe (B) from the oil return pipe (D), and disconnect
(3) Remove the electrical connector of the fuel pump the fuel evaporation hose III (E) from the oil return
(4) Remove the inlet/outlet nylon pipe of the fuel pipe (F) in sequence.
pump
(5) Remove the elastic ring of the fuel pump with
circlip pliers
(6) Take out the fuel pump from the tank

Positioning
bulge
Fuel inlet
pipe
Harness
socket Oil return pipe

Elastic
ring Electric fuel
pump
(6) Remove hexagonal flange bolt (A) and fuel tank
fixing belt (B) and fuel tank fixing bracket (C).

Install the new fuel pump in the reverse order.

Note: when install the new fuel pump, make sure that
the O-ring of the pump is installed in position.
 BYD S6 Maintenance & Repair Manual

(7) Lower the fuel tank to the ground with a jack,

bracket or other special tool.

Installing
(1) Lift the fuel tank to close to the floor with a jack,
bracket or other special tool, align the mounting
holes in fuel tank fixing bracket and fixing belt to the
mounting holes in the floor, and then tighten the
hexagonal flange bolts. The tightening torque is

(2) Install the parts in the reverse order as removing.

Section 3: Fuel Evaporation and

Purification System

3.1 Component Location Index

3.2 Replacing charcoal canister
(1) Disconnect fuel evaporative emission hose I (A),
fuel evaporative emission hose II (B)
 BYD S6 Maintenance & Repair Manual

Section 4: Acceleration bracket (D).

(4) Remove the throttle cable (A) from the
Transmission System accelerator pedal (B).

4.1 Adjusting throttle cable

(1) Check the free travel of the cable at the throttle
linkage. The free travel (A) should be 10-12mm.
(2) If the free travel doesn’t meet the specification
(10-12mm), loosen the lock nut (B), turn the
adjusting nut (C) until the deflection meets the
specification, and then retighten the lock nut.

Silicone grease

(5) Install the parts in the reverse order as removing.

(3) While adjusting the cable properly, check the
throttle to make sure it is fully open when the
accelerator pedal is stepped onto the floor, and
returns to idle position when the accelerator pedal is
released.
4.2 Removing/installing throttle cable
(1) Remove the engine cover.
(2) Completely release the throttle, and then remove
the throttle cable (A) from the throttle linkage (B).
(6) Keep the no-load (P or neutral) speed of the
engine at 3,000rpm, even the radiator fan starts to
rotate, and then let the engine idle.
(7) Hold the throttle cable, and remove all loose parts
from the top.
(8) Install lock nut to the cable bracket (A), and
adjust the adjusting nut (B) to make the free travel
0mm.
(9) Remove the cable from the throttle bracket (A),
re-install the adjusting nut (B) and tighten the lock
nut (C).
(10) While adjusting the cable properly, check the
throttle to make sure it is fully open when the
accelerator pedal is stepped onto the floor, and
returns to idle position when the accelerator pedal is
released.

Silicone grease
（P/N 08798-9002）

(3) Remove the cable sheath (C) from the cable

 BYD S6 Maintenance & Repair Manual

No gap is allowed

9.8N.m(1.
0kgf.m,7.2
lbf.ft