2016 NL-3 Service Manual - V0.8 - 20160419-EN-20160930

2016 Geely NL-3 Service Manual
This Repair Manual provides the information about specification, diagnosis and repair of NL-3
model (2016 version).
2016 Geely Automobile Co., Ltd.

All Rights Reserved
Information as of the date of January 2016
Without written permission from Geely Automobile Co., Ltd., any form or means (including, but not limited to, electronic
duplicating, photocopying, scanning and recording) of copying, storing or distribution of any part or the whole manual is not
allowed. The above statement is applicable to all texts, figures and tables.
Foreword
This is the repair guidance manual for NL-3. Please refer to the index to retrieve the section you need.
Applicable vehicle model NL-3
Please note that the following publication is also for the related components and systems of this model maintenance.
Manual Name Publication Number
Manual name Publication number
Repair Manual for Geely NL-3
All the information in this manual is based on the latest products available at the time of publishing. The specifications and the
repair procedures may change without prior notice.
It is recommended that you contact Geely Automobile Co., Ltd. to obtain the information about the brands & products, part
numbers or special tools referred in this manual.
If there are any omissions or mistakes, please contact Geely Automobile Co., Ltd. to amend.
(c) 2016 Geely Automobile Co., Ltd.
All rights are reserved. Without written permission from Geely Automobile Co., Ltd., this manual may not be replicated in
whole or part.
Warning
This manual does not include all the repair information required. It is for experienced and qualified personnel. If a
non-professional or non-qualified technician uses the manual or does not have the appropriate equipment and tools for
maintenance, it may cause serious personal injury or damage to the vehicle.
To prevent dangerous operation or damage to the vehicles, please make sure of following the instructions below.
− Carefully read through this manual. It is especially important to fully understand all ―Warnings‖ and ―Notes‖ in Section
―General‖ relating to fault diagnostic interface.
− Repair methods described in this manual are helpful for the repair work. When following the repair procedures in this
manual, make sure to use the recommended tools. If using tools other than recommended or not following the repair
procedures, prior to commencing repair, ensure the safety of technical personnel and prevent personal injury or damage
to customer vehicles.
− When replacing parts, please use parts approved by Geely Automobile Co., Ltd. with the same part numbers. Do not use
inferior parts.
− In order to reduce the risk of personal injury in the course of repair, or reduce the likelihood that the vehicle becomes
damaged or unsafe owing to incorrect repair, please strictly comply with all ―Warnings‖ and ―Notes‖ relating to fault
diagnostic interface in this Manual. Just as important, please be noted that the ―Warnings‖ and ―Notes‖ relating to fault
diagnostic interface in this Manual are not exaggerative. Non-compliance may lead to dangerous consequences.
− Before carrying out any repair on or near any component or circuit of airbag system, please refer to the Position Diagram
of Components of Airbag System in Section ―Safety Protection Devices‖ relating to fault diagnostic interface in this
Manual and the Position Diagram of Harnesses relating to fault diagnostic interface in circuit album, and understand the
position of airbag system on vehicle. Strictly follow all of the contents in the "Warnings and Notices". Violating them will
result in airbag deployment, personal injury or unnecessary maintenance to airbag system.
General Contents
Overview IN-1
Preparatory Work PP-1
Specifications of Repair SS-1
JLD-4G20/24 Engine Control System ES-1
JLE-4G18TDB Engine Control System ES-1
JLD-4G20/24 Cooling System CO-2
JLE-4G18TDB Cooling System CO-2
JLD-4G20/24 Intake System AI-2
JLE-4G18TDB Intake System AI-2
JLD-4G20/24 Exhaust System EX-2
JLE-4G18TDB Exhaust System EX-2
JLD-4G20/24 Fuel System FU-2
JLE-4G18TDB Fuel System FU-2
JLD-4G20/24 Mechanical System EM-2
JLE-4G18TDB Mechanical System EM-2
JLD-4G20/24 Lubrication System LU-3
JLE-4G18TDB Lubrication System LU-3
JLD-4G20/24 Auxiliary Emission Control Device EC-3
JLE-4G18TDB Auxiliary Emission Control Device EC-3
JLD-4G20/24 Ignition System IG-3
JLE-4G18TDB Ignition System IG-3
JLD-4G20/24 Start System ST-3
JLE-4G18TDB Start System ST-3
JLD-4G20/24 Charging System CH-3
JLE-4G18TDB Charging System CH-3
DSI575F6 Transmission AT-3
6MTT250 Transmission MT-3
Clutch System CL-3
Brake System BR-3

Brake Control BC-4
Suspension System; SP-4
Constant-velocity Drive Shaft DS-4
Power Takeoff System TP-4
TPMS System TP-4
Steering System EP-4
Tire and Wheel TW-4
A/C System AC-4
Audio Entertainment System AV-5
Cruise Control System CC-5
Active Safety System AS-5
Emergency Power Supply BP-5
Intelligent Entry & Start System TD-5
Rearview Mirror MI-5
Combination Instrument ME-5
Lighting System LI-5
Horn System HO-5
Door Lock DL-5
Defrosting System DF-5
Wiper and Washer WW-5
Windshield & Window Glass WS-6
Sunroof System RF-6
Parking Assist System RR-6
Safety Control System SC-6
Seat Belt SB-6
Electrical Control System of Vehicle Body BE-6
On-board Network CA-6
Front-end of Vehicle Body BF-6
Door CD-6
Instrument Panel IP-6
Seats SE-6
Interior Trim IR-6
Rear-end of Vehicle Body BB-6
Appearance of Vehicle ET-6

Overview-Contents IN-1
IN
IN General
How to Use This Manual ........................................................................................................................... IN-2

General Information ............................................................................................................................. IN-2
Identification Information ......................................................................................................................... IN-4
Vehicle Identification ............................................................................................................................ IN-4
Instructions on Repair ............................................................................................................................ IN-15
Precautions ........................................................................................................................................ IN-15
Lifting and Supporting Position of Vehicle ......................................................................................... IN-31
How to Eliminate the Fault in EMS Control System ............................................................................ IN-34
General Information ........................................................................................................................... IN-34
Circuit Check Procedure .................................................................................................................... IN-34
How to Identify the Fault .................................................................................................................... IN-40
NL-3 01/2016
IN-2 Overview-How to use this manual
IN How to Use This Manual

General Information
1 Brief introduction
a. The repair operation mainly falls into the following 3 processes:
1) Diagnosis.
2) Removal/installation, replacement, disassembly/reassembly, check and adjustment.
3) Final check.
b. In this Manual, the following procedures are omitted. However, these procedures shall be implemented
1) Use jack or lifting machine to carry out the operation.
2) Clean up all dismantled parts.
3) Before and after any operation, be sure to carry out visual check.
2. Preparatory works
a. In the course of repair, maybe it is necessary to use special service tools (SST) and special service materials (SSM). If
necessary, be sure to use SST and SSM, and strictly follow the correct repair procedure. In this Manual, the Section
―Preparatory Works‖ provides the list of SST and SSM.
3. Repair procedure
a. If necessary, the component diagram is given under the relevant title.
b. In the component diagrams, the parts which may not be reused, the locations where the lubricating grease shall apply, the
pre-coated parts and the specification of torque are stated.
c. In the repair procedure, the specification of torque, the locations where the lubricating grease shall apply and the parts
which may not be reused will also be emphasized.
Notices
Under some circumstances, the above information can only be expressed by means of illustrations. In such case, the torque,
engine oil and other information will be explained in illustrations.
d. The main body of this Manual only introduces the important contents. The contents of operation and other details will be
explained by means of illustrations given near text. In the text, the standard values and notices will be given.
e. Sometimes the illustrations for similar vehicle models will be used. In such case, some details may vary from actual vehicle.
f. The operating procedure is introduced step by step.
4. Repair specifications
a. In this Manual, the specifications are stated in bold font. In addition, you are also advised to refer to the Section ―Repair
Specifications‖ in this Manual for specifications.
5. Definitions
Notices Indicates that you or other persons may incur personal injury.
Warning Severe personal injury

6. The units used in this Manual meet the standards of internal system of units (SI UNIT), and both the metric units and
imperial units are given. For example:
Torque：10N·m （Metric）7.3lb-ft （English）
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Overview-How to use this manual IN-3
7. Explanation on abbreviations used in this manual IN

Abbreviations Meaning Description
GW Gateway 网关
HVAC Heating Ventilation and Air Conditioning 空调控制器
IHU Infotainment Head Unit 信息娱乐主机单元
PEPS Passive Entry Passive Start 无钥匙进入一键式启动单元
ESCL Electronic Steering Column Lock 电子转向柱锁控制单元
TPMS Tire Pressure Monitor System 胎压监测系统
BCM Body Control Module 车身控制模块
APWL Automatism Power Window Lifter 自动玻璃升降器
RLS Rain Light Sensor 雨量光线传感器
ROOF Roof 天窗
ESP Electronic Stabilization Program 电子稳定控制单元
TCM Top Column Module 转向柱组合开关
FRS Front Radar System 前雷达系统
FCS Front Camera System 前摄像头系统
ESP Electronic Power Steering 电子助力转向系统
4WD 4 Wheel Drive 四轮驱动系统
EMS Engine Management System 发动机管理系统
TCU Transmission Control Unit 变速器控制器
ACU Airbag Control Unit 安全气囊控制单元
ICU Integrated Cluster Unit 仪表
RCM Rear Camera Module 后摄像头模块
T-BOX E-call Telematics BOX 紧急呼叫通信匣
AVM All View Moudle 360 度环车影像
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IN-4 Overview-Identification Information
IN Identification Information Position of identification number sign
Vehicle Identification
Vehicle identification number
A vehicle identification number (VIN) plate is located at the

left upper corner of the instrument panel, which can be
viewed through the front windshield.
Vehicle Identification Number (VIN) Description
Vehicle identification number (VIN) plate is a statutory Composition of a vehicle identification number:
marker. World's manufacturer identification code (WMI), vehicle
1. Engine code description section (VDS) and vehicle parts instructions
2. Transmission code (VIS) three parts (17 bit), as shown below:
3. Vehicle identification number VIN
Location of Vehicle Identification Number (VIN)
(Part one) (Part two) (Part three)
Serial number
Geographic Assembly plant
region
Year
Country
Check station
Manufacturer
Vehicle characteristics
Take the vehicle identification number

L6T7964S6DN075548 as an example, the meaning of each
The vehicle identification number (VIN) is printed on the figure is shown as follows:
mounting crossbeam of right front seat. 1. The vehicle identification number is printed on vehicle
body and certification sign.
The fourth digit code provisions
No. Vehicle class Code
1 Chassis(Non-complete Vehicle) 0
2 Trunk 1
3 Special purpose vehicle 5
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Overview-Identification information IN-5
No. Vehicle class Code IN

4 Bus 6
5 Wheel base<2.5m 7
6 Passenger vehicle Wheel base>2.5-2.7m 8
7 Wheel base>2.7m 9
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IN The fifth digit code provisions

Passenger vehicle / bus Van / special purpose vehicle
Vehicle length, Vehicle length,
Code Code Gross mass ,kg Code Gross mass ,kg Code
m m
≤ 3.5 0 >4.0-4.2 5 ≤ 1,000 K >3,000-3,500 R
>3.5- 3.6 1 >4.2-4.4 6 >1,000-1,500 L >3,500-4,000 S
>3.6-3.7 2 >4.4-4.6 7 >1,500-2,000 M >4,000-4,500 T
>3.7-3.8 3 >4.6-4.8 8 >2,000-2,500 N >4,500-5,000 U
>3.8-4.0 4 >4.8 9 >2,500-3,000 P >5,000 V
The sixth digit code provisions
No. Engine location Fuel Engine displacement, L Code
1 ≤1 0
Front mounted Gasoline
2 >1-1.3 1
3 >1.3-1.5 2
4 >1.5-1.7 3
5 Gasoline >1.7-1.9 4
6 >1.9-2.1 5
Front mounted
7 >2.1 6
8 ≤ 1.3 A
9 Diesel >1.3-2.5 B
10 >2.5 C
11 ≤1 L
12 Gasoline >1.1-1.3 M
13 >1.3 N
Rear mounted
14 ≤ 1.3 T
15 Diesel >1.3-2.5 U
16 >2.5 V
Engine
No. Power source Code
displacement, L
1 ≤ 1.3 E
Oil-electric hybrid
2 >1.3-3.0 F
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No. Power source Engine displacement, L Code IN

3 Gasoline/ liquefied ≤ 1.3 G
4 petroleum gas (LPG) >1.3-3.0 H
Dual fuel
5 Gasoline/ compressed ≤ 1.3 J
6 natural gas (CNG) >1.3-3.0 K
The seventh digit code provisions
Load-bearing Number of compartments/Number
No. Drop head Convertible Code
type of doors
1 2 compartments /2 doors －－ 1
Integral body
3 2 and a half compartments/4 doors －－ 3
construction
5 2 compartments /2 doors 1 － A
6 2 compartments /5 doors 1 － B
7 2 and a half compartments/4 doors 1 － C
8 3 compartments /4 doors 1 － D
Integral body
9 2 compartments /2 doors － 1 R
construction
10 2 compartments /5 doors － 1 S
11 2 and a half compartments/4 doors － 1 T
12 3 compartments /4 doors － 1 U
15 2 and a half compartments /4 doors －－ 8
17 2 compartments /2 doors 1 － F
18 Separate frame 2 compartments /5 doors 1 － G
19 construction 2 and a half compartments /4 doors 1 － H
20 3 compartments /4 doors 1 － J
21 2 compartments /2 doors － 1 L
22 2 compartments /5 doors － 1 M
23 2 and a half compartments /4 doors － 1 N
24 3 compartments /4 doors － 1 P
Note: "1" indicates YES: "—" indicates NO.
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IN Code table for cab and compartment type

No. Cab type Compartment type Code
1 Tail-lift 1
Flat head
2 Compartment 3
3 Tail-lift 5
Long head
4 Compartment 7
The eighth digit code provisions
No. Drive type Transmission type Code
1 Front wheel drive Manual transmission S
2 Front wheel drive Automatic Transmission Z
3 Rear wheel drive Manual transmission A
4 Rear wheel drive Automatic Transmission B
The ninth digit code provisions
It is the value calculated by the manufacturer through certain formula according to other 16-digit values. It may be any
number from 0 to 9 or letter "X" and used to verify the authenticity of a VIN code, to ensure the unique and effectiveness of a
VIN code.
The tenth digit code provisions
It is used to distinguish the year. The code is used according to Table 11 (Repeat in a 30-year cycle).
Year Code Year Code Year Code Year Code
2001 1 2011 B 2021 M 2031 1
2002 2 2012 C 2022 N 2032 2
2003 3 2013 D 2023 P 2033 3
2004 4 2014 E 2024 R 2034 4
2005 5 2015 F 2025 S 2035 5
2006 6 2016 G 2026 T 2036 6
2007 7 2017 H 2027 V 2037 7
2008 8 2018 J 2028 W 2038 8
2009 9 2019 K 2029 X 2039 9
2010 A 2020 L 2030 Y 2040 A
The eleventh digit code provisions
It is used to distinguish different assembly plants.
No. Description Code
1 Zhejiang Haoqing Automotive Manufacturing Co., Ltd H
The first branch of Zhejiang Haoqing Automotive
2 L
Manufacturing Co., Ltd(Bridge Branch)
3 Geely Automobile Co., Ltd N
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4 Maple automobile co., Ltd S IN

5 CiXi Branch C
6 HaoQing Company Xiangtan Branch X
7 Gansu Lanzhou Branch G
Specifications for 12th-17th code
It is used as vehicle production numbers. According to the sequence of vehicles manufactured in the same year, it starts
from 000001 on-ward. The 12th digit of VIN can also be used as the month code.
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IN Refer to the following table

No. Month Code No. Month Code
1 January 1 7 July 7
2 February 2 8 August 8
3 March 3 9 September 9
4 April 4 10 October 0
5 May 5 11 November A
6 June 6 12 December B
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Compliance label—vehicle certificate Tire placard IN
1. Name of manufacturer Tire placard is always located on the lower part of the
2. Vehicle Identification Number (VIN) driver door. For tire information, please refer to tire
3. Brand placard. Wheel and tire sizes (including spare tire),
4. Complete vehicle model inflation pressures (including spare tire) and load capacity
5. Engine model are specified on a tire placard.
6. Number of passengers Engine identification number and location
7. Maximum engine net power Engine identification number
8. Engine displacement
9. Maximum permissible gross mass of vehicle
10. Production date
− JL: Enterprise code

− E: Year (D stands for 2013)
− 6: month
The quality certificate sign is located on bottom of − J: Jinan Base
passenger-side middle column. − C: 4G24C
− 03105: Serial number
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IN The position of the engine identification number Engraving position of identification number of manual
（JLD-4G20/24) transmission
The position of the engine identification number Position of identification number of automatic
(JLE-4G18TDB) transmission
Identification number of automatic transmission
Position of identification number of manual transmission Identification number sign of automatic transmission
Identification number sign of manual transmission (DSI575F6)
 JL: Enterprise code The identification number of transmission is printed on

 6MT: 6-gear manual transmission differential-side transmission casing.
 T: torque
 250: Maximum torque
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Position of identification number of automatic IN

transmission
Position of identification number sign of automatic

transmission
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IN JLE-4G18TDB Position of rear stage sign for three-way Sign of three-way catalytic converter
catalytic converter front
Number in
environmental Assembly
protection catalogue manufacturer
Sign of manufacturer Part No.
Packing Product model

manufacturer
Coating Supplier code
manufacturer
Carrier manufacturer Batch number
Sign of air flow

direction
Position of rear stage sign for three-way catalytic

converter on JLE-4G18TDB/JLD-4G20 vehicle
Explanation on signs of catalytic converter

As for three-way catalytic converter, under the circumstance that the vehicle is normally used and maintained, the service
life of three-way catalytic converter in compliance with the Nation IV Emission Standard is no less than 10W km (the service
life of three-way catalytic converter in compliance with the Nation V Emission Standard is no less than 16W km).
On the surface of three-way catalytic converter, there is the sign of information about manufacture and model, of which the
appearance and contents are indicated in the figure above.
Where:
SC: □□□ means the assembly manufacturer. For example: FAURECIA - Faurecia; HT – Chongqing Haite; WFLD - Wuxi
Weifu Lida; KESEN – Ningbo Kesen.
FZ: □□□ means the packing manufacturer. For example: FAURECIA - Faurecia; HT – Chongqing Haite; WFLD - Wuxi Weifu
Lida; KESEN - Ningbo Kesen.
TC: □□□ means the coating manufacturer. For example: JM - Johnson Matthey; WFLD - Wuxi Weifu Lida; KESEN - Ningbo
Kesen; BASF - BASF.
ZT: □□□ means the carrier manufacturer. For example, CORNING- Corning; NGK - NGK.
NL-3 01/2016
Overview- Instructions on Repair IN-15
Instructions on Repair IN
Precautions
1. Basic Repair Hints
a. Operation hints
Be sure to wear the clean working clothes.
1 Dressing
Please wear the cap and safety shoes.
Before the operation, please prepare the cover for radiator
2 Protection of Vehicle grille, the protective cover for fender, the protective cover
for seat and the protective pad for floor.
NL-3 01/2016
IN-16 Overview- Instructions on Repair
IN When two or more persons are working together, be sure to carry out
safety check for each other.
When working under the circumstance that the engine is running, please
make sure that the ventilation equipment is installed in repair workshop, so
as to discharge the exhaust.
3 Safety in Operation When repairing any high-temperature, high-pressure, rotating, moving or
vibrating part, be sure to wear the appropriate safety equipment, and be
careful not to hurt yourself or others.
When lifting up the vehicle, be sure to get the vehicle supported by safe
bracket at the specified position.
When lifting up the vehicle, please use the appropriate safety equipment.
Preparation of Tools and Before the operation, please prepare the tool bench, SST, instruments,
4
Measuring Instruments engine oil and replacement parts.
After fully understanding the correct repair procedure, carry out the
diagnosis for fault.
Before dismantling a part, check the overall conditions of assembly, so as
to confirm whether there is any deformation or damage.
As for any relatively complicated procedure, please make records
Removal/Installation and
5 properly. For example, record the total numbers of electrical connectors,
Disassembly/Assembly
bolts or hoses dismantled. In addition, please leave the fitting marks, so as
to ensure that all components will be mounted onto their original positions.
If necessary, temporary marks may be left on hose and its joints.
If necessary, clean up the dismantled parts, carry out thorough check, and
then assemble such parts.
Please place the dismantled parts in a separate box, so as to prevent
them from getting confused with new parts or contaminating the new parts.
As for the parts which may not be reused (such as gasket, O-ring and
6 Removed Parts self-locking nut), please replace them with new parts in accordance with
the instructions given in this Manual.
If required by customer, please keep the dismantled part for reference by
customer in future.
b. Lifting-up and supporting of vehicle
1) Be careful when lifting up and supporting the vehicle. Make sure that the vehicle is lifted up and supported at the correct
position.
c. Pre-coated parts
1) Pre-coated parts shall mean the parts which have been coated with sealant in factory, such as bolts and nuts.
2) If any pre-coated part is re-tighten up, loosened or otherwise moved, please coat the part with the specified sealant again.
3) When reusing any pre-coated part, be sure to clear away the old sealant, and dry up the part with compressed air. Coat the
corresponding new sealant onto the part.
4) The curing of some kinds of sealant will be relatively slow. Maybe you have to wait a while until the sealant is cured.
d. Gasket
NL-3 01/2016
1) If necessary, apply the sealant onto gaskets so as to prevent leakage. IN

e. Bolt, nut and screw
1) Strictly comply with all technical specifications relating to tightening torque. Be sure to use torque spanner.
f. Fuse
1) When checking a fuse, please check whether the metal filament on fuse is broken.
Normal fuse Blown fuse
2) When replacing a fuse, please make sure that the rated current of new fuse is correct. It is prohibited to use any fuse of
which the rated current is too high or too low.
g. Clip
1) The dismantlement and installation methods for jackcatch commonly used in vehicle body parts are detailed as follows.
Notices
If a clip is damaged in the course of operation, be sure to replace it with a new one.
NL-3 01/2016
IN Shape (example) Use the clip dismantler or pliers
Use the clip dismantler or pliers
Use the wide scraper to dismantle the clip, so as to prevent

the panel from getting damaged
Push in the pin shaft, pry open the pin casing, and dismantle
Shape (example)
the clip
NL-3 01/2016
IN
Screw off the pin shaft, pry open the pin casing, and
dismantle the clip
Pry out the pin shaft, pry open the pin casing, and dismantle
the clip
h. Jackcatch
NL-3 01/2016
IN 1) The dismantlement and installation methods for jackcatch commonly used in vehicle body parts are detailed as follows.
Notices
If a clamp is damaged in the course of operation, be sure to replace the cover on which the clamp is damaged with a
new one.
Use a screwdriver to disconnect the jackcatch, and then
Shape (example)
dismantle the cover
Use a screwdriver to disconnect the jackcatch, and then

dismantle the cover
NL-3 01/2016
Shape (example)
Use a screwdriver to disconnect the jackcatch, and then IN
dismantle the cover
i. Hinge, guide Pin, clamp and pin

1) The dismantlement and installation methods for hinges, guide pins, clamps and pins commonly used in vehicle body parts
are detailed as follows.
Notices
If a clamp is damaged in the course of operation, be sure to replace the cover on which the clamp is damaged with a
new one.
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IN Shape (example) Pull the pin so as to disconnect it
Pull the pin so as to disconnect it
Use pliers to dismantle the clamp
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Shape (example) Pull the pin so as to disconnect it IN
j. Removal and installation of vacuum hose

1) For the purpose of disconnecting a vacuum hose, please
pull and twist the end of hose. Don’t pull the middle portion of
hose; otherwise the hose may get damaged.
Wrong Right
2) When disconnecting a vacuum hose, please use a label to

state the position where it shall be re-connected.
2. As for Vehicle Equipped with Airbag and Seat beltSeat belt Pretensioner
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IN This vehicle is equipped with the supplementary restraint system (SRS).

Notices
If the repair is not carried out in the correct sequence, the SRS may get deployed unexpectedly in the course of repair
and thus cause serious personal injury. In addition, if any mistake occurs in the course of repair of SRS, maybe the
SRS will not work normally.
a. General Precautions
1) Since it is difficult to identify the fault of SRS, the diagnostic fault code (DTC) will become the most important information
source in the course of elimination of fault. When eliminating a fault of SRS, be sure to check the SRS for DTC before
disconnecting the battery
2) The operation may commence only after the ignition switch is turned to the position OFF and the negative cable of battery
has been disconnected for at least 90 seconds. The SRS is equipped with standby power supply. If the operation is carried out
when the ignition switch is at the position OFF and the negative cable of battery has not been disconnected for 90 seconds,
the SRS may get deployed. When the cable is disconnected from negative pole of battery, the data stored in clock and audio
system will be cleared. Before the operation, please record the setting of every memory system. After the operation is
completed, set the clock and audio system to their original state.
Notices
Be sure not to use the standby power supply (battery or other power supply); otherwise the data stored in memory
system will be cleared. The standby power supply may unexpectedly power on the SRS and then the SRS may get
deployed.
3) If any minor collision occurs and the SRS is not deployed, then before using the vehicle again, please check the trim cover
of steering wheel, the front passenger airbag assembly, the driver airbag assembly, the front seat side airbag assembly, the
curtain-type airbag assembly and the front seat belt assembly.
4) Be sure not to use any SRS part from other vehicle. When replacing any part, be sure to use a new part.
5) If the airbag sensor may be touched in the course of repair, please dismantle the airbag sensor assembly before repair.
6) Be sure not to disassemble or repair any airbag sensor assembly or any airbag assembly.
7) Under any of following two circumstances, please replace the airbag sensor assembly and airbag assembly: 1) They drop
and get damaged, or 2) Their casing, bracket or connector is cracked, dented or otherwise damaged.
8) It is prohibited to directly expose the airbag sensor assembly or airbag assembly to hot air or flame.
9) When eliminating the fault of any circuit, please use the high-impedance (minimum value =10kΩ) voltage gauge/ohm
gauge.
10) The information label is pasted on every SRS component. Please comply with the instructions given on lag.
11) After the handling of SRS is completed, please check the SRS warning lamp.
b. Decorative Cover of Steering Wheel
1) When placing a dismantled or new trim cover of steering wheel, be sure to let its surface facing upwards. When the trim
cover of steering wheel is placed with its surface facing downwards, if the airbag is deployed, serious accident may occur. In
addition, don’t place any article on the top of trim cover of steering wheel.
2) Be sure not to measure the resistance of ignition cartridge of airbag. Otherwise, the airbag may get deployed and then
cause serious injury.
3) It is prohibited to apply any kind of lubricating grease or detergent onto trim cover of steering wheel.
4) Store the trim cover of steering wheel in a place where the ambient temperature is lower than 93°C (200℉), the humidity is
not high and there is no electrical noise interference.
5) When carrying out electrical welding operation on any portion of the vehicle, please always disconnect the connector of
central airbag sensor assembly. The connector contains spring. This can reduce the likelihood that the current flows into
conductor of ignition cartridge and then the airbag is deployed
6) Before scraping the vehicle or scraping the trim cover of steering wheel, please use the special tool to deploy the airbag.
Deploy the airbag in a safe place far away from electrical noise interference
c. Front Passenger Airbag Assembly.
1) When placing the dismantled or new front passenger airbag assembly, be sure to let the surface of its trim cover facing
upwards. If the airbag assembly is placed with the deploying direction of airbag facing downwards, once the airbag is deployed,
serious accident may occur.
3) It is prohibited to apply any kind of lubricating grease or detergent onto front passenger airbag assembly.
4) Store the airbag assembly in a place where the ambient temperature is lower than 93°C (200℉), the humidity is not high
and there is no electrical noise interference.
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6) Before scraping the vehicle or scraping the airbag assembly, please always use SST to deploy the airbag in SRS. Deploy IN
the airbag in a safe place far away from electrical noise interference.
d. Front Seat Side Airbag Assembly
1) When placing the dismantled or new front seat side airbag assembly, be sure to let the deployment direction of airbag facing
upwards.
3) It is prohibited to apply any kind of lubricating grease or detergent onto front seat side airbag assembly.
6) Before scraping the vehicle or scrap the airbag assembly, please use the special tool to deploy the airbag. Deploy the
airbag in a safe place far away from electrical noise interference.
Notices
This plastic bag may not be reused.
8) It is prohibited to apply any kind of lubricating grease or detergent onto curtain-type airbag assembly.
11) Before scraping the vehicle or scraping the airbag assembly, please use the SST to deploy the airbag. Deploy the airbag in
a safe place far away from electrical noise interference.
e. Front Seat Outer Safety Belt Assembly (seat belt pretensioner)
1) Be sure not to measure the resistance of front seat belt assembly. This will activate the pretensioner of front s seat belt
assembly, and then serious personal injury may occur.
2) Be sure not to disassemble the front seat belt assembly.
3) Be sure not to install the front seat belt assembly on any other vehicle.
4) Please store the front seat belt assembly in a place where the ambient temperature is lower than 80°C (176℉), the humidity
is not high and there is no electrical noise interference.
6) Before scraping the vehicle or scraping the front seat belt assembly, please activate the front seat belt assembly. Please
activate the front seat belt assembly in a safe place far away from electrical noise interference.
7) The front seat belt assembly will get heated after being activated. Therefore, please wait until it has fully cooled down, and
then scrap it. Be sure not to use water to cool down the front seat belt assembly.
8) It is prohibited to apply lubricating grease, detergent, engine oil or water into front seat belt assembly.
f. Central Airbag Sensor Assembly
1) If the SRS has been deployed in the course of collision, be sure not to reuse the bus of central airbag sensor involved.
2) When connecting or disconnecting any connector of central airbag sensor assembly, please place the sensor on floor. If the
connector is connected or disconnected when the central airbag sensor assembly is not placed on floor, the SRS may be
activated.
3) Even the simple operation such as loosening the fixing bolt of central airbag sensor assembly may be carried out only after
the ignition switch has been turned to the position OFF and the negative (-) Cable of battery
has been disconnected for at least 90 seconds.
g. Harness and Connector
1) All connectors in the system are in the standard yellow color. If the SRS harness is disconnected or the connector is broken,
please carry out repair or replacement.
3. Electronic Control
a. Removal and Installation of Battery Terminal
Notices
After the cable to the negative pole of battery is re-connected, the initialization operation shall be carried out for
some systems.
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IN 1) Before carrying out any electrical operation, please disconnect the cable from negative terminal of battery, so as to prevent
the components or wiring from being damaged by unexpected short circuit.
Negative Cable
Negative terminal
2) When disconnecting the cable, please turn the ignition switch to the position OFF and fully screw off the nut on cable. When
carrying out these operations, don’t twist or pry out the cable. Then disconnect the cable.
3) When the cable is disconnected from negative (-) terminal of battery, the setting of clock, the setting of radio, the data stored
in audio system, the DTC and other data will be cleared. Please record the necessary data before dismantling the cable.
b. Handling of Electronic Parts
1) Unless absolutely necessary, don’t open the EMS cover or casing. If the integrated circuit terminal is touched, the integrated
circuit may fail owing to static electricity.
2) When disconnecting any electronic connector, it is prohibited to pull the harness. Please pull the connector.
3) Be sure not to drop any electronic component such as sensor or relay. If they drop onto hard surface, please replace them.
4) When using the steam to clean up the engine, please prevent water from entering into electronic component, air filter and
emission-related component.
5) It is prohibited to use any impact spanner to dismantle or install temperature switch or temperature sensor.
6) When measuring the resistance between terminals in harness connector, please carefully insert the tester probe, so as to
prevent the terminals from getting bent.
4. Removal and Installation of Fuel Control Parts
a. Removal and Installation of Parts of Fuel System
1) Please carry out the operation in a well-ventilated place where there is no welding machine, grinding machine, drilling
machine, electrical motor, furnace or other any ignition source.
2) Be sure not to carry out the operation in or near any sap, because the fuel vapor may be accumulated there.
b. Removal and Installation of Parts of Fuel System
1) Before the operation, please prepare a fire extinguisher.
2) In order to prevent static electricity, the grounding wire shall be installed on vehicle and fuel tank, and it is prohibited to
spray water in surrounding areas. When carrying out operation in this area, please be especially careful, because the
operation face may become very slippery. It is prohibited to use water to clear away the splashed gasoline; otherwise the
gasoline may spread and may cause fire.
3) Don’t use any motor, working lamp and other equipment which can generate spark or heat.
4) Don’t use any iron hammer, because it may generate spark.
5) Please use a fireproof container to separately contain the fuel-stained cloth.
5. Removal and Installation of Intake Parts of Engine
a. The metal particles entering into parts of intake system may damage the engine.
b. When dismantling and installing any part of intake system, please seal up the opening on such part and the opening on
engine. Use adhesive tape or other appropriate materials.
c. When installing any part of intake system, please check and make sure that no metal particle has entered into the engine or
the part installed.
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IN
6. Handling of Hose Clamp

a. Before dismantling any hose, check the position of clamp, so as to ensure that it will be re-installed on the same position.
b. Please replace the deformed or dented clamp with a new one.
c. When reusing a hose, please fix the clamp at the position on hose where there is the impression left by such clamp.
d. As for the spring-type clamp, please push the projecting lug at the direction of arrow as indicated in the illustration, so as to
slightly widen the lug after the installation is completed.
7. Repair of 4WD Vehicle

a. Measuring Point on Test Bench for Speedometer
Notices
Don’t use the tester which is applicable to two wheels only and is equipped with the loaded setting function.
Please carry out the check in front wheels.
Don’t suddenly start up, accelerate or decelerate the vehicle.
The maximum speed shall be lower than 60 km/h (37 mph) (If the movable roller is used, the vehicle speed shall be
lower than 50 km/h (31 mph)).
The running time shall be less than 1 minute.
1) Place the front wheels on roller.
2) Use the movable roller or rigid bracket to fix the rear wheels.
3) Use a chain to fix the vehicle.
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IN 4) Start the engine, gradually increase the speed with the gear shift lever at position D, and measure the vehicle speed (for
vehicle with automatic transmission); start the engine, shift the gear shift lever from gear 1 to gear 5, and then measure vehicle
speed (for vehicle with manual transmission).
5) After the measurement is completed, gradually slow down the vehicle by applying brake, and finally stop the vehicle.
b. Measuring Point on Test Bench for Brake
Notices
Don’t use any tester which has the load measuring function.
The high-speed braking can’t be carried out.
1) Place the wheels to be tested (front wheels or rear wheels) on roller.
2) Place the gear shift lever at neutral position.
3) Drive the roller of tester, and carry out measurement.
c. On-board Measuring Point for Balance

1) Use the 2-post-type lifting machine to lift up all the 4 wheels.
2) By setting the 2 fixtures on bottom of suspension arm of front wheel and rear wheel to be tested, fix the vehicle.
3) Use a rigid bracket to support the vehicle, and make sure that the vehicle does not tilt at any direction.
4) Release the parking brake.
5) Turn every wheel with hand, and check and confirm that there is no jamming force.
6) Set the wheel balancer.
7) Complete the measurement by using the drive from engine and roller of wheel balancer.
Notices
Start the engine, gradually increase the speed with the gear shift lever at position D, and measure the vehicle speed
(for vehicle with automatic transmission); start the engine, shift the gear shift lever from 1st gear to 6th gear, and
then measure vehicle speed (for vehicle with manual transmission).
Don’t accelerate or decelerate the vehicle suddenly.
Please carry out deceleration by applying the brake gradually.
Be sure not to move the vehicle.
Please complete the measurement as quickly as possible.
8. Towing of 4WD Vehicle
a. Use any of the following methods to tow the vehicle
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b. If there is any fault in chassis or drive system of vehicle, please use the method 1 (flat-bed lorry). IN
1) Flat-bed lorry.
2) Wheel lifted type truck (to tow the vehicle from front
end).
3) Wheel lifted type truck (to tow the vehicle from rear
end).
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IN c. The following towing methods are dangerous and may damage vehicle. Therefore, don’t use them.
1) Please don’t tow the vehicle with only 2 wheels on ground.
2) Please don’t use chain-type towing method to tow the front

end or rear end of vehicle.
9. For Vehicle Equipped with Catalytic Converter

Notices
If a lot of uncombusted gasoline or gasoline vapor enters into catalytic converter, the catalytic converter may get
overheated and then fire may occur. In order to prevent the occurrence of such situation, please comply with the
following notices:
a. Use unleaded gasoline only.
b. Don’t make the engine run at idle speed for more than 20 minutes.
c. Avoid the unnecessary spark tests.
d. Don’t prolong the measuring time of compression pressure of engine. The measurement of compression pressure of engine
shall be completed as quickly as possible.
e. When the fuel tank is almost empty, don’t run the engine. This may lead to flame missing in engine and apply additional load
on catalytic converter.
10. Check and Adjustment of Included Angle of Universal Joint in Removal/Installation of Drive Shaft (4WD)
a. In the operation which involves the dismantlement and installation of drive shaft, be sure to check the included angle of
universal joint. If necessary, please carry out adjustment.
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Lifting and Supporting Position of Vehicle IN

Warning!
Warning: To avoid any vehicle damage, serious personal injury even death when major components are dismantled
from the vehicle and the vehicle is supported by a hoist, support with jack the components standing at the opposite
end from which the components are being dismantled of the vehicle.
Warning!
To avoid personal injury, always use jack stands when you are working on or under any vehicle that is supported
only by a jack.
Notices
When you are jacking or lifting a vehicle at the frame side rails or other prescribed lift points, be certain that the jack
pads do not contact the catalytic converter, the brake pipes or the fuel pipe. If such contact occurs, vehicle damage
or unsatisfactory vehicle performance may result. Before you begin any lifting procedure, be sure the vehicle is on a
clean, hard and level surface. Be sure all the lifting equipment meets weight standards and is in good working
condition. Be sure all the vehicle loads are equally distributed and secure. If you are only supporting the vehicle at
the frame side rails, make sure the lifting equipment does not put too much stress on or damage the frame side rails.
Vehicle lifting point
Lift up the vehicle, contact lifter of frame

Rear-end chock of frame-contact type lifting machine
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IN
Notices
The rear-end chock may not touch the portion between doorsill plate and longitudinal beam of vehicle frame or the
floor.
Place the chock of rear-end lifting machine at the following position:
Under the junction between the rear frame rails and the side frame rails.
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IN
Notices
The front-end chock may not touch the portion between doorsill plate and longitudinal beam of vehicle frame or the
floor.
Place the chock of front-end lifting machine at the following position:
Under the junction between the front frame rails and the side frame rails.
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IN-34 Overview- How to Eliminate the Fault in EMS Control System
IN How to Eliminate the Fault in EMS Control

System
General Information
On the vehicle, a lot of EMS control systems are used.
Generally speaking, the EMS control system is very
complicated, and the elimination of its fault can be carried
out only with high-level technical knowledge. However,
most of the check procedures for faults only involve the
one-by-one check on circuits of EMS control system. Only
with the full understanding on the system and the mastering
of basic electrical knowledge, can the effective fault
elimination, accurate diagnosis and necessary repair be
carried out.
Use of Intelligent Tester
- Before using the intelligent tester, please carefully read
the operation manual.
- If after the tester cable has been connected to the
diagnostic interface, the ignition switch has been turned to
the position ON (IG) and the tester has been switched on,
the tester can’t communicate with EMS control system, then
there is fault in vehicle side or tester side.
(a) If after the tester is connected to other vehicle, the
communication is normal, please check the diagnostic data
link (bus (+) Circuit) or EMS power circuit of vehicle.
(b) If after the tester is connected to other vehicle, the
communication is still abnormal, then it is very likely that the
tester fails. Please implement the self-check procedure as
stated in operation manual of tester.
Circuit Check Procedure
Basic Inspection
(a) When measuring the resistance of electronic component
1. Unless otherwise specified, the measurement of
resistance shall be carried out at the ambient temperature
of 20°C (68℉). If the measurement is carried out when the
temperature is very high (for example, the vehicle has been
just used), the measured value of resistance may be
inaccurate The measurement shall be carried out after the
engine has fully cooled down.
(b) Handling of connector
1. When disconnecting a connector, firstly firmly press the
mating portions of two halves of connector so as to get
them unlocked, and then press down the locking claw and
disconnect the connector.
2. When disconnecting a connector, it is prohibited to
forcibly pull the harness. Directly hold the connector and
then disconnect it.
3. Before connecting a connector, please check and make
Wrong
sure whether any terminal is deformed, damaged, loosened
or lost.
Wrong
4. When connecting a connector, please press it forcibly
until the connector give a sound ―click‖ and gets locked.
Notices
Right Since it is impossible to check the waterproof
connector from rear side, please carry out check by
connecting the sub-harness.
Don’t move the inserted tester probe; otherwise the
terminal may get damaged.
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Overview- How to Eliminate the Fault in EMS Control System IN-35
(c) Check the connector IN

1. When connecting the connector, please carry out the
following check: squeeze the connector, so as to confirm
Core line whether it is fully connected and locked up.
Tightness of
beaded edge 2. Check after disconnect a connector: gently pull the harness
from the rear end of connector, so as to carry out the check.
Check whether the terminals are loosened or lost, whether the
connected portion is loosened and whether the conductor is
broken. Visually check for corrosion, metal filings or foreign
Terminal deformed
matter and water, and check whether the terminal is bent, rust,
overheated, stained or deformed.
Gently pull
3. Check the contact pressure of terminal: prepare a spare

male terminal. Insert it into a female terminal, and check
whether the tense force in the course of insertion and after
connection is sufficient.
Notices
When testing a gold-plated female terminal, be sure to use
a gold-plated male terminal.
(d) Repair method for connector terminal

1. If there is foreign matter on terminal, use compressed air or
cloth to clean up the contact point. It is prohibited to use sand
paper to grind the contact point; otherwise the plating will fall
Right Wrong
off.
2. If the contact pressure is abnormal, replace the female
terminal. If the male terminal is gold-plated (gold), please use
the gold-plated female terminal; If the male terminal is
silver-plated (silver), please use the silver-plated female
terminal.
3. If the terminal is damaged, deformed or corroded, please
replace it. If the terminal can’t be locked in external casing,
please replace such casing.
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IN (e) Handling of harness

1. If you want to dismantle the harness, please firstly check the
wiring, so as to facilitate the re-installation.
2. Be sure not to excessively twist, pull or loosen the harness.
Wrong Wrong
3. Be sure not to let the harness touch any hot, rotating,
moving, vibrating or sharp part. Avoid the contact between it
and any edge of plate, tip of screw and other sharp article.
4. When installing a part, be sure not to squeeze any harness.
5. It is prohibited to scratch or damage the sheath of harness. If
the sheath is scratched or cracked, please replace the harness
or use the polyvinyl chloride based insulating tape to carry out
Wrong
repair.
Check whether there is broken circuit

(a) As for broken circuit in harness in Figure 1, measure the
resistance and voltage as follows:
Figure 1
Broken
circuit
Sensor
(b) Check the resistance.

Figure 2
1. Disconnect the connectors A and C, and measure the
resistance between connector terminals.
Standard resistance (Figure 2)
Tester connection Specified state
Terminal 1 of connector A -Terminal 1 of
10 kΩ or higher
connector C
＜ 1Ω
connector C
Sensor
Notices
While gently shaking the harness at the vertical and
horizontal directions, measure the resistance. If the
measurement result is identical with the above value, then
there is broken circuit between terminal 1 of connector A
and terminal 1 of connector C.
2. Disconnect the connector B and measure the resistance
between connector terminals. Standard resistance (Figure 3)
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Notices IN
If the result is identical with the above specified value,
then there is broken circuit between terminal 1 of
connector B2 and terminal 1 of connector C.
Figure 3
Sensor Less than 1Ω
connector B1
Terminal 2 of connector B2 -Terminal 2 of 10 kΩ or
connector C higher
Terminal 1 of connector B - 1- grounding
5V
point on vehicle body
Terminal 1 of connector C – grounding
Less than 1 V
point on vehicle body
Notices
If the result is identical with the above specified value,
then there is broken circuit between terminal 1 of
connector B and terminal 1 of connector C.
Figure 4
Sensor
Check the short circuit

(a) If the harness is short to the grounding point (Figure 5),
please implement the following check on resistance of
Figure 5 grounding point of vehicle body, so as to identify the location of
Short circuit short circuit.
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IN (b) Check the resistance towards grounding point on vehicle

body.
1. Disconnect the connectors A and C and measure the
Figure 6
resistance.
Terminal 1 of connector A – Less than 1Ω
Sensor grounding point on vehicle body
Terminal 2 of connector A – 10 kΩ or higher
grounding point on vehicle body
Notices
While gently shaking the harness at the vertical and
horizontal directions, measure the resistance. If the
result is identical with the above specified value, then
there is short circuit between terminal 1 of connector A
and terminal 1 of connector C.
2. Disconnect the connector B and measure the resistance.
Figure 7
Terminal 1 of connector A – Less than 1Ω
Terminal 2 of connector B2 – 10 kΩ or higher
Sensor Notices
If the measurement result is identical with the above
value, then there is short circuit between terminal 1 of
connector B2 and terminal 1 of connector C.
Check and replace the EMS

Notices
− Don’t disconnect the connector from EMS.
Implement the check from rear side of harness side
connector.
− If the measurement conditions are not specified,
shut down the engine, turn the ignition switch to the
position ON (IG), and then carry out the check.
− Check and confirm that the connector fully
positioned. Check whether the conductor is
loosened, corroded or broken.
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(a) Firstly check the grounding circuit of EMS. If there is any IN

fault, please carry out repair. If normal, then maybe the EMS
is in fault. Temporarily use a EMS in good conditions to
replace the original, and then check whether the symptom
For example:
occurs. If the fault symptom disappears, then replace the
original EMS.
Ground:
1. Measure the resistance between grounding terminal of
EMS and grounding point of vehicle body.
Standard Resistance: Less than 1 Ω
2. Disconnect the EMS connector. Check the grounding

terminals on EMS side and harness side for bending,
corrosion or foreign matter. Finally, check the contact
pressure of female terminal.
ECUside
Ground
Harness side
Ground
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IN How to Identify the Fault

Notices
Carry out the elimination of fault in accordance with the following procedure. The following contents are only the
basic procedure for elimination of fault. Firstly, confirm that such fault elimination procedure is really applicable to
such circuit, and then start the elimination of fault.
Step 1 Send the vehicle to repair workshop
Next Step
Step 2 Carry out analysis on fault
(a) Ask the condition and environment when fault occurs to
customer.
Next Step
Step 3 Check the battery voltage
Standard voltage: 11~14V

Notices
If the voltage is lower than 11V, please charge or
replace the battery before further operation
Next Step
Step 4 Confirmation of symptom and check of DTC (and fixed data)
(a) Visually check the harness, connector and fuse for

broken circuit and short circuit.
(b) Make the engine run until the normal operating
temperature is reached.
(c) Confirm the fault symptom and condition, and check the
DTC.
Results Turn to
Output DTC A
No output DTC B
B Go to step 6
Step 5 DTC Table
(a) Check the results obtained in step 4. And then identify

the DTC in the table of DTC. In the column ―Location of
Fault‖, identify the circuits and/or parts which may involve
the fault.
(b) Make the engine run until the normal operating
temperature is reached.
Next Step Go to step 7
Step 6 Table of Fault Symptoms
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IN
(a) Check the results obtained in step 4. And then identify
the fault symptom in the table of fault symptoms. In the
column ―Suspected Location‖, identify the possible circuits
Next Step and/or parts which may involve the fault.
Step 7 Check on circuit or part
(a) Identify the circuit or part in fault.
Next Step
Step 8 Adjustment, repair or replacement
(a) Adjust, repair or replace the circuit or part in fault.
Next Step
Step 9 Confirmation Test
(a) After the adjustment, repair or replacement is completed,

confirm that the fault does not recur. If the fault does not
recur, carry out the confirmation test under the same
conditions as those under which the fault first occurred.
Next Step
Finish
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IN
NL-3 01/2016
Preparatory Work - Contents PP-1
PP Preparatory Work PP
JLD-4G20/24 Mechanical System .......................................................................................................... PP- 2

Special Tool ........................................................................................................................................ PP- 2
JLE-4G18TDB Mechanical System ........................................................................................................ PP- 4
Special Tool ........................................................................................................................................ PP- 4
Front Suspension .................................................................................................................................... PP- 7
Special Tool ........................................................................................................................................ PP- 7
Rear Suspension ..................................................................................................................................... PP- 9
Special Tool ........................................................................................................................................ PP- 9
Automatic Transmission....................................................................................................................... PP- 10
Special Tool ...................................................................................................................................... PP- 10
TMPS ....................................................................................................................................................... PP- 11
Special Tool ...................................................................................................................................... PP- 11
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PP-2 Preparatory Work - JLD-4G20/24 Mechanical System
PP JLD-4G20/24 Mechanical System

Special Tool
No. Diagram Tool No. Description
Installation tool for rear oil seal of

1 47Z01216B
crankshaft
Mounting tools of front oil seal of

2 47Z01217B
crankshaft
Front crankshaft oil seal

3 47Z01218B
dismantling tool
Belt pulley installing/dismantling

4 47Z01303B
tool
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Preparatory Work - JLD-4G20/24 Mechanical System PP-3

PP

5 47Z01303C
tool
6 47Z01219B Installation tool for piston
7 47Z01304A Filter spanner
Installation tool for the oil seal of

8 47Z01104B
the valve
9 47Z01305B Flywheel locking tool
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PP-4 Preparatory Work - Mechanical System JLE-4G18TDB
PP Mechanical System JLE-4G18TDB

Special Tool
Installation tool for rear oil seal of

1 47Z01216A
crankshaft
Mounting tools of front oil seal of

2 47Z01217A
crankshaft
Front crankshaft oil seal

3 47Z01218A
dismantling tool

4 47Z01303B
tool
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Preparatory work - Mechanical system JLE-4G18TDB PP-5

PP

5 47Z01303C
tool
6 47Z01219A Installation tool for piston
7 47Z01304A Filter spanner
Installation tool for the oil seal of

8 47Z01104A
the valve
9 47Z01305A Flywheel locking tool
NL-3 01/2016
PP-6 Preparatory Work - Mechanical System JLE-4G18TDB

PP
10 47Z01306 Fuel nozzle dismantling tool
Balance shaft oil seal installing

11 47Z01220
tool
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Preparatory Work - Front Suspension PP-7
Front Suspension PP
Special Tool
Front wheel hub flange

1 47Z03109A
dismantling/installing tool kit

2 47Z03109B

3 47Z03109C
Front wheel hub bearing

4 47Z03110A
NL-3 01/2016
PP-8 Preparatory work - Front suspension

PP
Front wheel hub bearing

5 47Z03110B
6 47Z03111 Ballhead dismantling tool
Front shock damper bolt

7 47Z03112
dismantling tool
NL-3 01/2016
Preparatory Work - Rear Suspension PP-9
Rear Suspension PP
Special Tool
1 47Z03113 Fuel pump cover dismantling tool
Shock damper spring

2 47Z03114
dismantling tool
3 47T03107 Brake pump resetting tool
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PP-10 Preparatory Work - Automatic Transmission
PP Automatic Transmission
Special Tool
1 47Z02122 Breather mounting tool
Differential oil seal installing

2 47Z02121
tool(left)
Differential oil seal installing

3 47Z02120
tool(right)
NL-3 01/2016
Preparatory Work - TMPS PP-11
TMPS PP
Special Tool
1 GEELY-CE-2Q Triggering tool
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PP-12 Preparatory work - TMPS
PP
NL-3 01/2016
Repair Specifications - Contents SS-1
Specifications for SS Repair

SS
JLE-4G18TDB Engine Control System ...................................................................................................... SS-5

Characteristic Parameters of EMS ..................................................................................................... SS-5
Water Temperature Sensor Characteristic Parameter........................................................................ SS-5
Resistance at end A and end C .......................................................................................................... SS-5
Characteristic Parameters of Front Oxygen Sensor ........................................................................... SS-5
Characteristic parameters of electronic throttle .................................................................................. SS-6
Characteristic parameters of knock sensor ........................................................................................ SS-7
Characteristic parameters of speed sensor ........................................................................................ SS-7
Characteristic parameters of high-voltage pressure sensor ............................................................... SS-7
Torque Specification ............................................................................................................................ SS-8
JLE-4G18TDB Intake system..................................................................................................................... SS-9
Torque Specification ............................................................................................................................ SS-9
JLE-4G18TDB Charging System ............................................................................................................. SS-10
Torque Specification .......................................................................................................................... SS-10
JLE-4G18TDB Ignition System ................................................................................................................ SS-11
JLE-4G18TDB Auxiliary Emission Control Device ................................................................................... SS-12
JLE-4G18TDB Cooling System................................................................................................................ SS-13
JLE-4G18TDB Start System .................................................................................................................... SS-15
Repair Parameters ............................................................................................................................ SS-15
JLE-4G18TDB Fuel System ..................................................................................................................... SS-17
JLE-4G18TDB Lubrication System .......................................................................................................... SS-18
JLE-4G18TDB Exhaust System ............................................................................................................... SS-19
Specifications of Key Emission Components ................................................................................... SS-19
JLE-4G18TDB Mechanical System.......................................................................................................... SS-20
JLD-4G20 24Engine Control System ....................................................................................................... SS-21
JLD-4G20 24 Intake System .................................................................................................................... SS-22
JLD-4G20 24 Fuel System ....................................................................................................................... SS-23
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SS-2 Repair Specifications - Contents

JLD-4G20 24 Exhaust System ................................................................................................................. SS-24
Specifications of Key Emission Components ................................................................................... SS-24
JLD-4G20 24 Cooling System.................................................................................................................. SS-25
JLD-4G20 24 Charging System ............................................................................................................... SS-26
JLD-4G20 24 Ignition System .................................................................................................................. SS-27
JLD-4G20 24 Lubrication System ............................................................................................................ SS-28
JLD-4G20 24 Auxiliary Emission Control Device ..................................................................................... SS-29
JLD-4G20 24 Mechanical System............................................................................................................ SS-30
Automatic Transmission ........................................................................................................................... SS-31
Manual Transmission ............................................................................................................................... SS-32
Gear Ratio ......................................................................................................................................... SS-32
Lubricating Oil and Sealant ............................................................................................................... SS-32
Dimension and Parameter Specification........................................................................................... SS-32
Brake System ........................................................................................................................................... SS-34
Brake Control............................................................................................................................................ SS-35
Suspension System.................................................................................................................................. SS-36
Repair Data ....................................................................................................................................... SS-36
NL-3 01/2016
Repair Specifications - Contents SS-3
Electrical Power Steering System ............................................................................................................ SS-38

Repair Data ....................................................................................................................................... SS-38
SS
Wheels and Tires ...................................................................................................................................... SS-39
A/C System............................................................................................................................................... SS-40
Audio Entertainment System .................................................................................................................... SS-41
Electrical Control System of Vehicle Body ............................................................................................... SS-42
On-board Network .................................................................................................................................... SS-43
Door Lock System .................................................................................................................................... SS-44
Horn System ............................................................................................................................................. SS-45
Lighting System ........................................................................................................................................ SS-46
Combination Instrument ........................................................................................................................... SS-47
Rearview Mirror ........................................................................................................................................ SS-48
Reversing Radar System ......................................................................................................................... SS-49
Seat Belt System ...................................................................................................................................... SS-50
Safety Control System.............................................................................................................................. SS-51
Sunroof System ........................................................................................................................................ SS-52
Anti-theft System ...................................................................................................................................... SS-53
NL-3 01/2016
SS-4 Repair Specifications - Contents
Windshield & Window Glass .................................................................................................................... SS-54

Wiper and Washer .................................................................................................................................... SS-55
Door .......................................................................................................................................................... SS-56
Front-end of Vehicle Body ........................................................................................................................ SS-57
Rear-end of Vehicle Body......................................................................................................................... SS-58
Interior Trim .............................................................................................................................................. SS-59
Exterior Trim ............................................................................................................................................. SS-60
Seats......................................................................................................................................................... SS-61
Instrument Panel ...................................................................................................................................... SS-62
NL-3 01/2016
Repair Specifications - JLE-4G18TDB Engine Control System SS-5
JLE-4G18TDB Engine Control System

Characteristic Parameters of EMS
Full-function operating voltage: 9-16V SS
Working Voltage Function restricted voltage: 6-9V
Overloaded voltage: 24V (power-on time ≤ 60s)
Supply current ≤ 30A
Vibration characteristic (vehicle body) ≤ 3g
Storage temperature -40-110 ℃
Working temperature -30-100℃ (high-temperature condition: wind velocity 2m/s,
voltage 14V)
Waterproof and dustproof class IP 6K9K (refer to standard DIN40050)
Product quality 675±50
Water Temperature Sensor Characteristic Parameter

Rated voltage 5V
A,C end: 0.075W
Rated power
B, earth end: 0.25W
Rated resistance at end A and end C (25 ℃±0.1 ℃) 1.825 K-2.155KΩ
Working temperature -30-+130 ℃
Shock acceleration on product ≤ 300m/s2
Resistance at end A and end C

Temperature range (℃) Resistance at end A and end C(KΩ)
-20±0.1 13.71-16.49
25±0.1 1.825-2.155
80±0.1 0.303-0.326
110±0.1 0.1383-0.1451
B, earth-end resistance (Ω)
50±0.2 176-280
80±0.2 63.4-81.4
110±0.2 24.6-30.6
Characteristic Parameters of Front Oxygen Sensor

Storage temperature -40-100 ℃
Limit value of exhaust Texhaustgas ≤ 930 ℃ (During the service life, the total service time is less than 25h; ≤
temperature 1030℃) temperature of protective sleeve of harness
Limit value of temperature on Thexagon ≤ 600 ℃(During the service life, the total service time is less than 40h;
threaded portion ≤680 ℃)
Tgrommet ≤ 250 ℃(close to end of sensor; during the service life, the total service time
Temperature of protective sleeve is less than 40h; ≤280 ℃)
of harness Tuphose ≤ 200 ℃(far away from end of sensor; during the service life, the total service
time is less than 40h; ≤ 230℃) limit value of temperature of plug-in parts
Temperature of harness and
Tcable ≤ 250 ℃ (During the service life, the total service time is less than 40h; ≤ 280℃)
insulation layer
Limit value for temperature of T connector ≤ 140℃ (During the service life, the total service time is less than 40h;
plug-in parts ≤150℃)
Limit value of exhaust
Pgas ≤ 2.5bar (Absolute pressure)
backpressure
NL-3 01/2016
SS-6 Repair Specifications - JLE-4G18TDB Engine Control System
Random vibration≤ 1000m/s2

Vibration limit value Sinusoidal vibration≤ 300m/s
Amplitude≤ 0.3mm
SS
Maximum voltage: 16.5V (it can reach 28V instantaneously, but this will occur for less than
System supply voltage 10 times during the service life)
Minimum voltage: 10.5V (function restricted voltage)
Voltage of heater VH, nom 7.5V
Power of heater PH, nom (under the condition that the thermal balance is
7.5W
maintained in air)
RH, cold=3.2±0.8Ω(room temperature under
Resistance of heater RH 25 ℃)
RH, min=1.8Ω(at ambient temperature of -40℃)
Heating time ≤ 10s (at room temperature of 20℃)
Maximum current of induction chamber when λ=1 IN, max ≤ 250 μA
Minimum reference current required
≥ 10μA
for normal work IP, ref, min
≤ 25μA (long-time operation)
Maximum reference current IP, ref,
≤ 75μA (short-time operation, and continuous
max
operation for up to 25h)
Current parameter of pump
≤ 20μA (long-time operation)
IP (voltage ≤ 2.5V)
Rated reference current IP, ref ≤ 60μA (short-time operation within 10s when the
catalytic converter is being heated up)
IP, max , rich ≥ -9mA (too rich, λ<0.65)
Actual (λ≠ 1) maximum current IP,
IP, max, lean ≤ 6mA (too thin, and normal air
max
environment)
Characteristic Parameters of Electronic Throttle
After 250 hours' bench
Description Value
test
Exhaust temperature at which the
350 ℃ 850 ℃ 350 ℃ 850 ℃
characteristic data are achieved
Voltage (mV) of sensing element at λ=0.97
840±70 840±70 710±70 710±70
(CO=1%)
Voltage (mV) of sensing element at λ=1.10 20±50 50±30 20±50 40±40
Internal resistance of the sensor element
≤ 1.0 ≤ 0.1 ≤ 1.5 ≤ 0.3
(kΩ)
Response time (ms) (from 600mV to 300mV) ＜ 200 ＜ 200 ＜ 400 ＜ 400
Response time (ms) (from 300mV to 600mV) ＜ 200 ＜ 200 ＜ 400 ＜ 400
Description Value Unit
Room temperature, the power of heating element
≥ 30 MΩ
Insulated resistance between the heating turns off
element and sensor joint of the new sensor Exhaust temperature 350 ℃ ≥ 10 MΩ
Exhaust temperature 850 ℃ ≥ 100 MΩ
Rated voltage 12 V
Continuous working voltage 12-14 V
Working voltage that can maintain at most 1% of
45 V
Supply voltage of the plug the total lifetime (exhaust temperature ≤ 350 ℃)
The operating voltage can be maintained for up
24 V
to 75 seconds (exhaust temperature ≤ 350 ℃)
Test voltage 13 V
The operating voltage is 13V when the heating current when the thermal balance is achieved
12 W
(exhaust temperature: 350℃; exhaust flowrate: about 0.7m/s)
The operating voltage is 13V when the heating current when the thermal balance is achieved
5 A
(exhaust temperature: 350℃; exhaust flowrate: about 0.7m/s)
Fuse of heating circuit 8 A
NL-3 01/2016
Repair Specifications - JLE-4G18TDB Engine Control System SS-7
Characteristic Parameters of Knock Sensor SS

Cable type
Sensitivity of new sensor to 7kHz signal 23.04-33.6 mV/g
The linearity between 5 to 15kHZ ±10% of 5kHZ value (based on 10/m/s²)
Principal resonant frequency ＞ 30 kHZ
Impedance: resistance (pin and copper sleeve) ＞ 1 MΩ
Impedance: capacitor (probe) 1150±200 pF
Leakage resistance (the resistance between two
4.9±20% MΩ
output pins of the sensor)
Sensitivity variation caused by temperature (at 9kHz) ≤ -0.04 mV/g ℃
Plug-in type
Sensitivity of new sensor to 7kHz signal 24-35 mV/g
The linearity between 5 to 15kHZ ±15% of 5kHZ value (based on 10/m/s²)
Principal resonant frequency ＞ 30 kHZ
Impedance: resistance (pin and copper sleeve) ＞ 1 MΩ
Impedance: capacitor (probe) 1150±200 pF
Leakage resistance (the resistance between two
4.9±20% MΩ
output pins of the sensor)
Sensitivity variation caused by temperature (at 9kHz) ≤ -0.04 mV/g ℃
Characteristic Parameters of Speed Sensor

Description Symbol Min Typical Max Unit
1 Supply voltage range Us 4.75 5.0 16 V
2 Supply current Is - 4.2 10 mA
3 Output current Io - - 20 mA
4 Output voltage Us, o 0 18 V
5 Output low voltage Vol 0 - 0.5 V
6 Output high voltage Voh Us, o-0.5 Us, o-0.3 V
Ascending time of output signal
7 tf - - 1 us
(high - low)
Descending time of output signal
8 tr - - 25 us
(low - high)
9 Power-on time ton - - 250 ms
Repetitional precision when
10 - - - ±0.1 deg
n=800rpm
Phase precision (descending
11 - -1 - 1 deg
edge)/800rpm
12 Air clearance AG 0.5 1.0 1.5 mm
13 Speed range - 15 - 8000 rpm
Characteristic Parameters of High-voltage Pressure Sensor
Limit data
Value
Parameters Unit
Min Typical Max
Power - - 16 V
Pressure - - 26 MPa
Shock pressure - - 200 MPa
Working temperature -40 - +130 ℃
NL-3 01/2016
SS-8 Repair Specifications - JLE-4G18TDB Engine Control System
Characteristic data
Value
parameters Unit
SS Min Typical Max
Measuring range of pressure 0 - 20 MPa
Working temperature -40 - 130 ℃
Power voltage 4.75 5.0 5.25 V
Supply current when Us=5.0V - 12 15 mA
Response time t10/90 - - 2.0 ms
Torque Specification
Torque Range
Fastener Name Model
Metric(N·m) English(lb-ft)
Exhaust side engine oil control
M5×0.8×12 6-8 4.4-5.9
valve fixing bolt
Intake side engine oil control
M5×0.8×12 6-8 4.4-5.9
valve fixing bolt
Electronic throttle body fixing
M6×1×50 9-12 6.6-8.85
bolt
Fixing bolt between intake
M6×1×20
pressure/temperature sensor 8-10 5.9-7.3
and outlet hose of intercooler
Fixing bolt between intake
pressure/temperature sensor M6×1×20 8-10 5.9-7.3
and intake manifold
Water temperature sensor
/ 11-14 8.1-10.3
fixing bolt
Camshaft phase sensor &
M6×1×16 9-12 6.64-8.85
cylinder head fixing bolt
Camshaft phase sensor &
high-pressure oil pump seat M6×1×60 9-12 6.64-8.85
assembly
Crankshaft position sensor &
M6×1×16 9-12 6.64-8.85
cylinder block fixing bolt
Knock sensor & cylinder block
M8×1.25×30 20-25 14.7-18.4
fixing bolt
Engine EMS mounting bracket
M6×1×14 8-10 5.9-7.3
fixing bolt
Electronic accelerator pedal
M6×1×16 8-10 5.84-7.73
fixing nut
NL-3 01/2016
Repair Specifications - JLE-4G18TDB Intake System SS-9
JLE-4G18TDB Intake System SS

Torque Range
Fastener Name Specification
Air filter fixing bolt M6×1×30 8-10 29.5-35.4
Fuel rail injector and intake
manifold component fastening M6×1 9-12 6.6-8.9
screw
Nuts on upper portion of Intake
M6×1 9-12 6.6-8.9
manifold
Bolt on lower portion of oil rail M6×1×12 9-12 6.6-8.9
Bolts and nuts of intake
M8×1.25 9-12 6.6-8.9
manifold bracket
Injector harness fixing bolt M6×1×16 9-12 6.6-8.9
Engine inlet pipe and
M6×1×18 8-10 29.5-35.4
suspension bracket fixing bolt
NL-3 01/2016
SS-10 Repair Specifications - JLE-4G18TDB Charging System
JLE-4G18TDB Charging System

SS
Torque Range
Generator fixing bolt M8×1.25×60 20-26 14.8-19.2
Nut of positive cable of battery M6×1×16 6-12 4.4-8.9
Nut of negative cable of battery M8×1.25×20 6-12 4.4-8.9
Fixing bolt of battery tray M6×1 19-21 14.0-15.5
Fixing bolt between lower
bracket of battery and vehicle M8×1.25×20 20-26 14.8-19.2
body
Fixing bolt of battery pressure
M6×1×16 6-12 4.4-8.9
plate
NL-3 01/2016
Repair Specifications - JLE-4G18TDB Ignition System SS-11
JLE-4G18TDB Ignition system SS

Torque specification
Torque Range
Ignition coil fixing bolt M6×1×25 7-10 5.2-7.4
Spark plug / 28 - 32 20.7-23.6
NL-3 01/2016
SS-12 Repair Specifications - JLE-4G18TDB Auxiliary Emission Control Device
JLE-4G18TDB Auxiliary Emission Control Device

SS
Torque Range
Fixing bolt between right
bracket of carbon canister and M6×1×16 7-9 4.4-6.6
carbon canister
Fixing bolt between left bracket
of carbon canister and carbon M6×1×16 7-9 4.4-6.6
canister
Fixing bolt between left
mounting bracket of carbon M6×1×16 7-9 4.4-6.6
canister and chassis
mounting bracket of carbon M6×1×16 7-9 4.4-6.6
canister and chassis
Fixing bolt of guard plate on
M6×1×20 7-9 4.4-6.6
bottom of carbon canister
Front oxygen sensor fastening
/ 40-50 29.5-36.9
bolt
Rear oxygen sensor fastening
/ 40-50 29.5-36.9
bolt
NL-3 01/2016
Repair Specifications - JLE-4G18TDB Cooling System SS-13
JLE-4G18TDB Cooling System SS

Torque Range
Water Pump Component Bolts M6×1×20 9-12 6.6-8.85
Fixing bolt of the water pump
/ 11-15 8.1-11
drive wheel
Fixing bolt between thermostat
M6×1×50 9 6.64
cover and thermostat casing
Fixing bolt between radiator M6×1×16
8-10 5.9-7.3
and condenser
Fixing bolt between radiator
M8×1.25×20 20-26 14.8-19.2
and vehicle
Left oil cooler fixing bolt M6×1×25 5-7 3.7-5.2
Right oil cooler fixing bolt M6×1×25 5-7 3.7-5.2
Connecting bolt between gas
outlet pipe of supercharger and M6×1×18 8-10 5.9-7.3
cylinder block
NL-3 01/2016
SS-14 Repair Specifications - JLE-4G18TDB Cooling System
SS
NL-3 01/2016
Repair Specifications - JLE-4G18TDB Start System SS-15
JLE-4G18TDB Start System SS

Repair Parameters
Repair items Repair parameters
6MT: Anticlockwise direction
Rotation direction (viewed from driving end)
6AT: Anticlockwise direction
Current of unloaded test 6AT：100A max (11.5V)
6MT：12V,1.4KW
Idle test power consumption
6AT: Rated output 12V,1.4KW
Drive gear speed 1,500rpm Min
Current of retention coil (12.2V) of starter (electromagnetic
36A
switch)
Current of suction coil (12.2V) of starter (electromagnetic
13A
switch)
Torque Range
Starter motor fixing bolt (for MT
M10×1.5×35 35-45 25.9-33.2
vehicle)
Starter motor fixing bolt (for AT
M10×1.5×35 35-45 25.9-33.2
vehicle)
NL-3 01/2016
SS-16 Repair Specifications - JLE-4G18TDB Start System
SS
NL-3 01/2016
Repair Specifications - JLE-4G18TDB Fuel System SS-17
JLE-4G18TDB Fuel system SS

Torque Range
Fixing screw of fuel filter M6×1×16 8-10 5.9-7.8
Fuel tank fixing bolt M10×1.5×35 40-50 29.5-36.9
Fixing bolt between oil filling
pipe and wheel cover on M6×1 5-7 3.7-5.2
vehicle body
M6×1×20
Filler tube fixing bolt 7-9 5.2-6.6
Oil filter grounding line fixing

M6×1×16 8-10 5.9-7.8
bolt
NL-3 01/2016
SS-18 Repair Specifications - JLE-4G18TDB Lubrication System
JLE-4G18TDB Lubrication System

SS
Torque Range
Oil drain plug fixing bolt / 35 25.8
Bolts of the oil filter / 20-25 14.8-18.5
Oil pan fixing bolts M6×1×16 9-12 6.6-8.9
M8×1.25×40 20-25 14.7-18.4
Engine oil pump fixing bolt
M8×1.25×65 20-25 14.7-18.4
Filter fixing bolt M6×1×20 9-12 6.6-8.9
Oil baffle plate bottom fixing M6×1×20 9-12 6.6-8.9
bolt M6×1×30 9-12 6.6-8.9
Engine oil pump chain
/ 10.5 7.7
tensioner fixing bolt
Engine oil pressure alarm
/ 18-22 13.3-16.2
fixing bolt
NL-3 01/2016
Repair Specifications - JLE-4G18TDB Exhaust System SS-19
JLE-4G18TDB Exhaust System SS

Specifications of Key Emission Components
Information about engine assembly
Engine Model Manufacturer Service life
10 years or
JLE-4G18TDB Zhejiang Geely Automobile Co., Ltd.
300,000km
Information about three-way catalytic converter (front)
Model of three-way
Engine Model Exhaust Manufacturer Service life
catalytic converter
Faurecia Exhaust
JLE-4G18TDB National V JL Control Technology 5 years or 160,000 km
(Ningbo) Co., Ltd.
Information about three-way catalytic converter (rear)
Model of three-way
catalytic converter
Faurecia Exhaust
JLE-4G18TDB National V JL Control Technology 5 years or 160,000 km
(Ningbo) Co., Ltd.
Information about oxygen sensor
Model of oxygen
Items Engine Model Manufacturer Service life
sensor
United Automotive 15 years or
Front Oxygen Sensor JLE-4G18TDB 0 258 017 269
Electronics Co., Ltd. 250,000km
Rear Oxygen Sensor JLE-4G18TDB LSF 4.2
Torque Range
Nut of water outlet pipe bracket
M12×1.75 72-88 53.1-64.9
of supercharger
Fixing nut of thermal baffle of
M6×1 8-10 5.9-7.4
exhaust pipe
M6×1 8-10 5.9-7.4
middle muffler
M6×1 8-10 5.9-7.4
rear muffler
Fixing bolt between preliminary
converter bracket and
M8×1.25×16 22-28 16.2-20.7
mounting point of catalytic
converter bracket
Fixing bolt between catalytic
converter and mounting point / 22-28 16.2-20.7
of suspension
Three-way catalytic converter
/ 45-55 33.2-40.6
bolt
Middle muffler assembly fixing
M10×1.5 45-55 33.2-40.6
nut
Rear muffler assembly fixing
M10×1.5 45-55 33.2-40.6
nut
NL-3 01/2016
SS-20 Repair Specifications - JLE-4G18TDB Mechanical System
JLE-4G18TDB Mechanical System

SS
Torque Range
Fixing bolt between left vibration isolating pad assembly of
M10×1.25×45 72-88 53.1-65.0
engine and left longitudinal beam of vehicle body
Fixing nut of left vibration isolating pad assembly of engine and
M10×1.25 72-88 53.1-65.0
vehicle body
M12×1.75×50 72-88 53.1-65.0
engine and transmission
Fixing bolt between engine left bracket and transmission fixing
M12×1.75×45 54-66 39.8-48.7
bolt
M12×1.75×50 90-110 66.4-81.1
engine and left bracket of engine
Fixing bolt between right vibration isolating pad assembly of
M10×1.25×45 63-77 46.5-56.8
engine and right longitudinal beam of vehicle body
M10×1.25×50 63-77 46.5-56.8
engine and vehicle body
Fixing nut of right vibration isolating pad assembly of engine and
M10×1.25 63-77 46.5-56.8
vehicle body
Fixing nut between right vibration isolating pad assembly of
M12×1.75 92-108 67.9-79.7
engine and mounting bracket of engine
M12×1.75×60 92-108 67.9-79.7
Fixing bolt between supporting arm of right vibration isolating pad
M12×1.75×70 90-110 66.4-81.1
assembly of engine and mounting bracket of engine
Fixing bolt between rear vibration isolating pad assembly of
M10×1.25×65 63-77 46.5-56.8
engine and subframe
Fixing nut between rear vibration isolating pad assembly of
M10×1.25 63-77 46.5-56.8
engine and subframe
M12×1.75×105 81-99 59.7-73.0
engine and rear bracket of engine
Fixing bolt between rear bracket of engine and transmission M12×1.75×50 54-66 39.8-48.7
Fixing bolt between front vibration isolating pad assembly of
M10×1.25×25 63-77 46.5-56.8
engine and front crossbeam
M12×1.75×90 81-99 59.7-73.0
engine and front bracket of engine
Fixing nut between front vibration isolating pad assembly of
M12×1.75 81-99 59.7-73.0
Fixing bolt between front bracket of engine and transmission M12×1.75×30 54-66 39.8-48.7
Left engine mounting bracket fixing bolt M10×25×20 63-77 46.5-56.8
NL-3 01/2016
Repair Specifications - JLD-4G20 24Engine Control System SS-21
JLD-4G20 24Engine Control System SS

Torque Range
Exhaust side engine oil control valve fixing bolt M5×0.8×12 6-8 4.4-5.9
Intake side engine oil control valve fixing bolt M5×0.8×12 6-8 4.4-5.9
Electronic throttle body fixing bolt M6×1×50 9-12 6.6-8.85
Fixing bolt between intake pressure/temperature
M6×1×20 8-10 5.9-7.3
sensor and outlet hose of intercooler
Fixing bolt between intake pressure/temperature
M6×1×20 8-10 5.9-7.3
sensor and intake manifold
Water temperature sensor fixing bolt / 11-14 8.1-10.3
Camshaft phase sensor & cylinder head fixing bolt M6×1×16 9-12 6.64-8.85
Camshaft phase sensor & high-pressure oil pump seat
M6×1×60 9-12 6.64-8.85
assembly
Crankshaft position sensor & cylinder block fixing bolt M6×1×16 9-12 6.64-8.85
Knock sensor & cylinder block fixing bolt M8×1.25×30 20-25 14.7-18.4
Engine EMS mounting bracket fixing bolt M6×1×14 8-10 5.9-7.3
Electronic accelerator pedal fixing nut M6×1×16 8-10 5.84-7.73
NL-3 01/2016
SS-22 Repair Specifications - JLD-4G20 24 Intake System
JLD-4G20 24 Intake System

SS
Torque Range
Air filter fixing bolt M6×1×30 8-10 29.5-35.4
Connecting bolt between upper
cover component of intake M8×1.25×75 22-28 16.2-20.6
manifold and intake manifold
Connecting bolt between lower
cover component of intake M8×1.25×35 22-28 16.2-20.6
manifold and intake manifold
Fixing bolt of intake air
pressure and temperature M6×1×20 8-10 5.9-7.3
sensor
Intake manifold assembly
M6×1×65 22-28 16.2-20.7
fixing bolt
Intake manifold assembly
M6×1 22-28 6.6-8.9
fixing nut
Intake hose of engine and
/ 4-6 3.0-4.4
throttle hoop
NL-3 01/2016
Repair Specifications - JLD-4G20 24 Fuel System SS-23
JLD-4G20 24 Fuel System SS

Torque Range
Fixing bolt of fuel filter M6×1×16 8-10 5.9-7.8
Fuel tank fixing bolt M10×1.5×35 40-50 29.5-36.9
Fixing bolt between oil filling
pipe and wheel cover on M6 5-7 3.7-5.2
vehicle body
Filler tube fixing bolt M6×1×20 7-9 5.2-6.6
Oil filter grounding line fixing
M6×1×16 8-10 5.9-7.8
bolt
NL-3 01/2016
SS-24 Repair Specifications - JLD-4G20 24 Exhaust System
JLD-4G20 24 Exhaust System

Specifications of Key Emission Components
SS
Information about engine assembly
Engine Model Manufacturer Service life
10 years or
JLD-4G20 Zhejiang Haoqing Automotive Manufacturing Co., Ltd.
300,000km
Information about three-way catalytic converter (front)
Model of three-way
catalytic converter
Faurecia Exhaust
JLD-4G20 National V JL Control Technology 5 years or 250,000 km
(Ningbo) Co., Ltd.
Information about three-way catalytic converter (rear)
Model of three-way
catalytic converter
Faurecia Exhaust
JLD-4G20 National V JL Control Technology 5 years or 250,000 km
(Ningbo) Co., Ltd.
Information about oxygen sensor
Model of oxygen
Items Engine Model Manufacturer Service life
sensor
Front Oxygen Sensor JLD-4G20 LSF 4.2
Rear Oxygen Sensor JLD-4G20 LSF 4
Torque Range
Nut of water outlet pipe bracket
M12×1.75 72-88 53.1-64.9
of supercharger
M6×1 8-10 5.9-7.4
exhaust pipe
M6×1 8-10 5.9-7.4
middle muffler
M6×1 8-10 5.9-7.4
rear muffler
Fixing bolt between preliminary
converter bracket and
M8×1.25×16 22-28 16.2-20.7
mounting point of catalytic
converter bracket
Fixing bolt between catalytic
converter and mounting point / 22-28 16.2-20.7
of suspension
Three-way catalytic converter
/ 45-55 33.2-40.6
bolt
Middle muffler assembly fixing
M10×1.5 45-55 33.2-40.6
nut
Rear muffler assembly fixing
M10×1.5 45-55 33.2-40.6
nut
NL-3 01/2016
Repair Specifications - JLD-4G20 24 Cooling System SS-25
JLD-4G20 24 Cooling System SS

Torque Range
Water pump fixing bolt and nut M6×1×20 9-12 6.6-8.9
Fixing nut of water inlet seat of
M6×1×16 9 6.6
engine
Fixing bolt between radiator
M6×1×16 8-10 5.9-7.3
and condenser
Right radiator fixing bolt M6×1×12 5-7 3.7-5.2
Left radiator fixing bolt M6×1×12 5-7 3.7-5.2
Connecting bolt between A/C
M6×1×16 8-10 5.9-7.3
pipeline and condenser
Fixing bolt between oil cooler
M6×1×28 5-7 3.7-5.2
and front-end module
NL-3 01/2016
SS-26 Repair Specifications - JLD-4G20 24Charging System
JLD-4G20 24Charging System

SS
Torque Range
Alternator fixing bolt M8×1.25×60 20-26 14.8-19.2
Nut of positive cable of battery M6×1×16 6-12 4.4-8.9
Nut of negative cable of battery M8×1.25×20 6-12 4.4-8.9
Fixing bolt of battery tray M8×1.25×25 19-21 14.0-15.5
Fixing bolt of battery pressure
M6×1×16 6-12 4.4-8.9
plate
Fixing bolt between lower
bracket of battery and vehicle M8×1.25×20 20-26 14.8-19.2
body
NL-3 01/2016
Repair Specifications - JLD-4G20 24 Ignition System SS-27
JLD-4G20 24 Ignition System SS

Torque Range
Ignition coil fixing bolt M6×1×25 8-10 5.9-7.3
Spark plug fixing bolt / 22-28 16.2-20.7
NL-3 01/2016
SS-28 Repair Specifications - JLD-4G20 24 lubrication System
JLD-4G20 24 Lubrication System

SS
Torque Range
Oil drain plug fixing bolt / 35 25.8
Bolts of the oil filter / 20-25 14.8-18.5
Oil pan fixing bolts M6×1×16 9-12 6.6-8.9
M8×1.25×40 20-25 14.7-18.4
Engine oil pump fixing bolt
M8×1.25×65 20-25 14.7-18.4
Filter fixing bolt M6×1×20 9-12 6.6-8.9
Oil baffle plate bottom fixing M6×1×20 9-12 6.6-8.9
bolt M6×1×30 9-12 6.6-8.9
/ 10.5 7.7
tensioner fixing bolt
/ 18-22 13.3-16.2
fixing bolt
NL-3 01/2016
Repair Specifications - JLD-4G20 24 Auxiliary Emission Control Device SS-29
JLD-4G20 24 Auxiliary Emission Control Device SS

Torque Range
Connecting bolt between left
carbon canister
Connecting bolt between right
carbon canister
Fixing bolt between left bracket
M6×1×16 7-9 4.4-6.6
of carbon canister and chassis
chassis
Fixing bolt of protective plate
M6×1×20 7-9 4.4-6.6
on bottom of carbon canister
Fixing bolt between PCV valve
component and valve chamber 5-7 3.7-5.2
cover
Fixing bolt of front oxygen
/ 40-50 29.5-36.9
sensor
Fixing bolt of rear oxygen
/ 40-50 29.5-36.9
sensor
NL-3 01/2016
SS-30 Repair Specifications - JLD-4G20 24 Mechanical System
JLD-4G20 24 Mechanical System

SS
Torque Range
M10×1.25×45 72-88 53.1-65.0
engine and left longitudinal beam of vehicle body
Fixing nut of left vibration isolating pad assembly of engine and
M10×1.25 72-88 53.1-65.0
vehicle body
M12×1.75×50 72-88 53.1-65.0
engine and transmission
Fixing bolt between engine left bracket and transmission fixing
M12×1.75×45 54-66 39.8-48.7
bolt
M12×1.75×50 90-110 66.4-81.1
engine and left bracket of engine
M10×1.25×45 63-77 46.5-56.8
engine and right longitudinal beam of vehicle body
M10×1.25×50 63-77 46.5-56.8
engine and vehicle body
Fixing nut of right vibration isolating pad assembly of engine and
M10×1.25 63-77 46.5-56.8
vehicle body
Fixing nut between right vibration isolating pad assembly of
M12×1.75 92-108 67.9-79.7
M12×1.75×60 92-108 67.9-79.7
Fixing bolt between supporting arm of right vibration isolating pad
M12×1.75×70 90-110 66.4-81.1
assembly of engine and mounting bracket of engine
M10×1.25×65 63-77 46.5-56.8
engine and subframe
Fixing nut between rear vibration isolating pad assembly of
M10×1.25 63-77 46.5-56.8
engine and subframe
M12×1.75×105 81-99 59.7-73.0
engine and rear bracket of engine
Fixing bolt between rear bracket of engine and transmission M12×1.75×50 54-66 39.8-48.7
M10×1.25×25 63-77 46.5-56.8
engine and front crossbeam
M12×1.75×90 81-99 59.7-73.0
Fixing nut between front vibration isolating pad assembly of
M12×1.75 81-99 59.7-73.0
Fixing bolt between front bracket of engine and transmission M12×1.75×30 54-66 39.8-48.7
Left engine mounting bracket fixing bolt M10×25×20 63-77 46.5-56.8
NL-3 01/2016
Repair Specifications - Automatic Transmission SS-31
Automatic Transmission SS
Repair Parameters
Transmission model DSI575F6
1st gear 4.155
2nd gear 2.375
3rd gear 1.522
Transmission ratio 4th gear 1.144
5th gear 0.859
6th gear 0.676
Reverse gear 3.178
Main reduction ratio 3.810
Oil type Fuchs FES 209-3292
Weight (including oil) (Reference) 97.22±0.45kg
Transmission oil volume(dry) 7.5L
Torque Range
Fastener Name
Inspection plug of transmission oil
25-30 18.4-22.1
level
Front cooling pipe and transmission
Max 13 Max 9.6
joint
Rear cooling pipe and transmission
Max 13 Max 9.6
joint
Connecting bolt of torque convertor
40-42 29.5-31.0
and drive plate
Connecting nut of transmission
14-20 10.3-14.8
gearshift lever and transverse shaft
Nut of oil sump of transmission 7-8 5.1-5.9
NL-3 01/2016
SS-32 Repair Specifications - Manual Transmission
Manual Transmission
Gear Ratio
SS
Tooth number of Tooth number of Main tooth number
Gear position Speed ratio
output shaft input shaft of differential
1st gear 41 11 / 3.727
2nd gear 43 21 / 2.048
3rd gear 38 28 / 1.357
4th gear 32 31 / 1.032
5th gear 39 32 / 0.821
6th gear 29 42 / 0.69
Reverse gear 42 11 / 3.818
Main reduction ratio 15 / 64 4.267
Lubricating Oil and Sealant

Transmission model 6MT-1E
Filling capacity of transmission lubricating oil ( manual transmission) (L) 1.665+/-0.065 L
Viscosity of transmission lubricating oil (manual transmission) SAE75W-92
Class of transmission lubricating oil (manual transmission) API quality class: GL-4
Bonding face between transmission casing and clutch casing (sealant) WSS-M4G323-A10
Spline of input shaft (lubricating oil) WSS-M1C273-A
Needle bearing, tapered roller bearing, and roller bearing (lubricating oil) BOT350M3
Between gear and shaft without bearing (lubricating oil) BOT350M3
Dimension and Parameter Specification

Specification
Dimension parameters
Metric(mm) English(in×10×1/1,000)
Axial clearance of 1st gear / /
Axial clearance of 2nd gear / /
Axial clearance of 3rd gear D3=0.48-0.13 D3=0.35-0.09
Axial clearance of 4th gear D4=0.52-0.15 D4=0.38-0.11
Axial clearance of reverse gear DR=0.42-0.11 DR=0.31-0.08
Adjustment gasket 0.2±0.02 0.14±0.001
Adjustment gasket 1±0.02 0.74±0.01
NL-3 01/2016
Repair Specifications - Manual Transmission SS-33
Specification SS
Dimension parameters
Metric(mm) English(in×10×1/1,000)
Torque Range
Fastener Name Specifications
Oil drain/oil filling bolt M16X1.5 31-39 22.9-28.8
Connecting bolt M4X0.7 2.5-3.5 1.8-2.6
Locking bolt of input shaft M16X1.5 105-115 77.4-84.8
Bonding face bolt M8X1.25 18 13.3
Gear shift lever component
M8X30 20-28 14.8-20.7
bolt
Bearing bracket bolt M8X19 17.5-22.5 12.9-16.6
NL-3 01/2016
SS-34 Repair Specifications - Brake System
Brake System
SS
Torque Range
Fastener Name
Install the fixing clamp for connecting
8-10 6-7.3
tube of vacuum booster
Fix the hose bracket 20-26 14.8-19.1
Install the brake hose onto caliper 28-34 20.7-25.1
Fix the caliper 94-114 69.3-84
Fix the rear axle head seat 94-114 69.3-84
Fix the dust cover 9-11 6.6-8.1
NL-3 01/2016
Repair Specifications - Brake Control SS-35
Brake Control SS
Torque Range
Fix the ESP module mounting M8×1.25×16 21-25 15.5-18.4
bracket M8 21-25 15.5-18.4
Fix the bracket assembly of
left/right wheel speed sensors 2 M6×16 8-10 6-7.3
and 3
Fix the left/right front wheel speed
sensor bracket assembly and M6×1×20 21-25 15.5-18.4
left/right front brake hose
NL-3 01/2016
SS-36 Repair Specifications - Suspension System
Suspension System
Repair Data
SS
Type McPherson independent suspension
Maximum turning angle of front wheel
37.7°/31.6°
(inner/outer)
Front wheel alignment (half-loaded
Toe-in of front wheel 0°±7.5′
state of vehicle)
Front wheel camber -0°20′±30′
Kingpin inclination 11°30′±30′
Kingpin caster 5°45′±30′
Type Multi-link independent suspension
Rear wheel alignment (half-loaded
Camber -0°30′±30′
state of vehicle)
Toe-in 0°±7.5′
Torque Range
Front column assembly and steering knuckle M17×2.5×65 215-265 158.5-195
Front column assembly and steering knuckle M17 215-265 158.5-195
Fixing nut between front column assembly and
M10 45-55 33.2-40
vehicle body
Fixing bolt between subframe and vehicle body M14×2×95 170-190 125.4-140.1
Fixing nut between subframe and vehicle body M14×2 134-150 98.8-110.6
Fixing nut between front swing arm assembly
M16×1.5 254-286 187.3-210.9
and subframe assembly
Fixing nut between front resonance block of
M10×1.25 55-65 40.6-47.9
subframe and subframe
Fixing bolt between front swing arm assembly
M16×2×100 254-286 187.3-210.9
and subframe assembly
Fixing nut between lower swing arm ballhead of
M14×2 110-140 81.1-103.3
front suspension and steering knuckle
Fixing bolt between longitudinal beam of front
M10×1.5×60 45-55 33.2-40
suspension, front crossbeam and subframe
Fixing bolt between front crossbeam and
M12×1.25×103 90-110 66.4-81.1
vehicle body
Fixing bolt between reinforcing plate of front
M12×1.25×30 90-110 66.4-81.1
suspension and vehicle body
Connecting nut among connecting rod of
M12×1.25 68-82 50.2-60.5
stabilizer bar, stabilizer bar and front column
Connecting bolt between stabilizer bar bracket
M12×1.25×30 90-110 66.4-81.1
and subframe
Connecting bolt between front point of rear
M14×2×100 145-175 106.9-129.1
subframe and vehicle body
Connecting nut between rear point of rear
M14×2 134-150 98.8-110.6
subframe assembly and vehicle body
Connecting bolt between external point of rear
M12×1.25×100 105-125 77.4-92.2
upper swing arm and steering knuckle
Connecting nut between internal point of rear
M12×1.25 105-125 77.4-92.2
upper swing arm and subframe
Connecting nut between external point of rear
M12×1.25 105-125 77.4-92.2
upper swing arm and steering knuckle
NL-3 01/2016
Repair Specifications - Suspension System SS-37
Torque Range SS
Left and Rear Axle Head Support Mounting Bolt / 94-114 69.3-84.1
Brake Caliper Bracket Mounting Bolt / 94-114 69.3-84.1
Connecting nut between external point of swing
M12×1.25 105-125 77.4-92.2
arm 1 and steering knuckle
Connecting nut between upper point of rear
M12×1.25 105-125 77.4-92.2
vibration damper and subframe
Connecting nut between lower point of rear
M12×1.25 105-125 77.4-92.2
vibration damper and vibration damper base
Connecting bolt between internal point of rear
M12×1.25×65 105-125 77.4-92.2
upper swing arm and subframe
Fixing bolt between internal point of swing arm
M12×1.25×75 120-140 88.5-103.3
1 and subframe
Connecting nut between internal point of swing
M12×1.25 120-140 88.5-103.3
arm 2 and subframe
Connecting nut between internal point of swing
M12×1.25 120-140 88.5-103.3
arm 1 and subframe
Connecting bolt between external point of swing
M12×1.25×85 105-125 77.4-92.2
arm 2 and steering knuckle
Fixing bolt between rear swing arm 2 assembly
M12×1.25×95 120-140 88.5-103.3
and subframe
Connecting bolt between front bracket of rear
M12×1.25×33 105-125 77.4-92.2
longitudinal arm and vehicle body
Connecting bolt between rear longitudinal arm
M14×1.5×80 168-192 123.9-141.6
and rear longitudinal arm
Connecting bolt between rear point of rear
M16×1.5×60 184-216 135.7-159.3
longitudinal arm and steering knuckle
Connecting nut between front end of rear
longitudinal arm and front mounting bracket of M14×1.5 168-192 123.9-141.6
rear longitudinal arm
Connecting bolt between lower mounting base
M12×1.25×25 105-125 77.4-92.2
of rear vibration damper and steering knuckle
Connecting bolt between upper point of rear
M12×1.25×65 105-125 77.4-92.2
vibration damper and subframe
Connecting bolt between lower point of rear
vibration damper and mounting base of rear M12×1.25×70 105-125 77.4-92.2
vibration damper
Rear suspension limiter and vehicle body M8×1.5×45 29-35 21.4-25.8
Connecting nut between rear stabilizer bar
M12×1.25 90-110 66.4-81.1
fixing clamp and rear subframe assembly
Connecting nut between connecting rod
assembly of rear stabilizer and rear stabilizer
bar assembly M12×1.25 68-82 50.2-60.5
Connecting nut between connecting rod
assembly of rear stabilizer and swing arm 2
NL-3 01/2016
SS-38 Repair Specifications - Electrical Power Steering System
Electrical Power Steering System

Repair Data
SS
Specification
Applications
Metric(mm) English (in)
Free play of steering wheel 30 1.18
Torque Range
Upper installation point nut of
electrical power steering column M8×1.25 20-26 14.8-19.1
and crossbeam bracket
Lower installation point of electrical
power steering column and M8×1.25×80 33 24.3
crossbeam bracket
Middle shaft assembly and input
/ 30-36 22.1-26.5
shaft of steering gear
Steering gear and sub-frame M14 125-145 92.2-107
Steering gear & steering knuckle M12 42--48 30.9-35.4
NL-3 01/2016
Repair Specifications - Wheels and Tires SS-39
Wheels and Tires SS

Repair Parameters
Tire size 225/65 R17 102H , 225/60 R18 100H
Spare tire T155/85R18 115M ;18×4.5J, Steel wheel
Cold pressure (front/rear) 220±10kPa
Rim 17×7J/18×7J, aluminum alloy wheel
Maximum radial runout of tire 0.02 mm (Metric) 0.0008 in(English)
Unbalance of tire 20mm
Torque Range
Wheel assembly and brake
M12 100-120 3.8-88.5
assembly
NL-3 01/2016
SS-40 Repair Specifications - A/C System
A/C System
SS
Torque Range
A/C assembly bolt M6×1×16 6-8 4.5-5.9
A/C pipeline - expansion
M6××120 8-10 5.9-7.4
valve bolt
Fixing bolt of expansion
M×16 8-10 5.9-7.4
valve
Compressor bolts M8×100 21-25 15.5-18.5
Compressor bolts M8×90 21-25 15.5-18.5
A/C pipeline --
M8×20 21-25 15.5-18.5
compressor bolt
A/C pipeline -- condenser
M6××120 8-10 5.9-7.4
bolt
Fixing bolt between side
face of condenser and M6×1×16 8-10 5.9-7.4
upper face of radiator
Nut on connection of
high/low pressure pipe M6×1 8-10 5.9-7.4
assembly
A/C pipeline -- bolt on wheel
M6×1×16 8-10 5.9-7.4
cover of vehicle body
Self-tapping screw of
ST4.8×16 4.5-5.5 3.3-4.1
defrosting pipe bracket
ventilation pipe mounting ST4.8×16 4.5-5.5 3.3-4.1
bracket
Nut of vent hose assembly
M6 6-12 4.4-8.8
in front of rear seat
Self-tapping screw of left
ST4.2×16 3-4 2.2-3
wind outlet assembly
Self-tapping screw of right
ST4.2×16 3-4 2.2-3
Self-tapping screw of middle
ST4.2×16 3-4 2.2-3
Self-tapping screw of wind
outlet assembly of auxiliary ST4.2×16 3-4 2.2-3
instrument panel
Self-tapping screw (front) of
vent pipe assembly of ST4.8×16 4.5-5.5 3.3-4.1
auxiliary instrument panel
NL-3 01/2016
Repair Specifications - Audio Entertainment System SS-41
Audio Entertainment System SS

Torque Range
Radio & CD player
assembly self-tapping ST4.8×16 2-3 1.5-2.3
screw
Audio player bolt M6×1×16 9-10 6.7-8.1
Antenna amplifier assembly
M6×1×16 7-9 5.2-6.6
bolt
Tweeter self-tapping screw ST4.2×9.5 1-2 0.7-1.5
Low-tone speaker rivet Φ4×15 5-7 3.7-5.2
Self-tapping screw of liquid
ST4.8×16 2-3 1.4-2.2
crystal screen
GPS antenna self-tapping
ST4.8×16 2-3 1.4-2.2
screw
NL-3 01/2016
SS-42 Repair Specifications - Electrical Control System of Vehicle Body
Electrical Control System of Vehicle Body

SS
Torque Range
Central controller assembly
M6×1 3-4 2.2-2.9
& IP bracket nut
NL-3 01/2016
Repair Specifications - On-board Network SS-43
On-board Network SS
Torque Range
Gateway & gateway
M6×1×12 7-9 5.2-6.6
bracket bolt
NL-3 01/2016
SS-44 Repair Specifications - Door Lock System
Door Lock System

SS
Torque Range
Countersunk screw of door
M6×1×16 4.5-5.5 3.3-4.1
lock
M8×1.25×22 18-22 13.3-16.2
lock catch
M6×1×16 4.5-5.5 3.3-4.1
lock
M8×1.25×22 18-22 13.3-16.2
lock catch
M6×1×16 4.5-5.5 3.3-4.1
lock
M8×1.25×22 18-22 13.3-16.2
lock catch
M8×1.25×22 18-22 13.3-16.2
lock catch
M6×1×16 4.5-5.5 3.3-4.1
lock
Tail door locking bolt M6×1×12 8-10 5.9-7.4
Countersunk screw of lock
M8×1.25×22 18-22 13.3-16.2
catch of tail door
Engine hood lock bolt M8×1.25×50 16-20 11.8-14.8
Engine hood lock latch bolt M6×1×12 8-10 5.9-7.4
NL-3 01/2016
Repair Specifications - Horn System SS-45
Horn System SS
Torque Range
High/low-tone horn
M6×1×16 20-26 14.8-19.2
assembly bolt
NL-3 01/2016
SS-46 Repair Specifications - Lighting System
Lighting System
SS
Torque Range
Front combination lamp bolt M6×1×30 4-5 3.0-3.7
Self-tapping screw of front
ST4.9×16 2-3 1.5-2.2
combination lamp
Self-tapping screw of rear
ST5.5×19 2-3 1.5-2.2
combination lamp
Rear combination lamp nut M5 3-4 2.2-3.0
Self-tapping screw of front
ST4.8×16 1-2 0.7-1.5
fog lamp
Self-tapping screw of rear
ST4.8×16 1-2 0.7-1.5
fog lamp
Fixing screw for atmosphere
/ 1-2 0.7-1.5
lamp on central console
High-mounted brake lamp
M5 3-4 2.2-3.0
assembly nut
NL-3 01/2016
Repair Specifications - Combination Instrument SS-47
Combination Instrument SS
Torque Range
combination instrument & ST4.8×16 2-4 1.5-2.9
IP frame
NL-3 01/2016
SS-48 Repair Specifications - Rearview Mirror
Rearview Mirror
SS
Torque Range
Left exterior rearview mirror
M6×1 8-10 5.9-7.4
nut
Right exterior rearview
M6×1 8-10 5.9-7.4
mirror nut
NL-3 01/2016
Repair Specifications - Reversing Radar System SS-49
Reversing Radar System SS

Torque Range
Reversing radar machine
M6×1×16 2-4 1.5-2.9
bolt
Millimetric wave radar bolt M6×1×16 8-10 5.9-7.4
NL-3 01/2016
SS-50 Repair Specifications - Seat belt System
Seat Belt System

SS
Torque Range
Self-tapping screw of seat
ST4.2×13 4 2.9
belt buckle box assembly
Fixing bolt of seat belt
M6×1 9 6.6
retractor
Fixing bolt between seat
belt and interior plate of left M6×1 9 6.6
middle column
Fixing nut of seat belt
M10 45 33.2
height adjuster
Fixing bolt in trim panel on
M10 45 33.2
fixing point of seat belt
Front seat belt height
M6×1 9 6.6
adjuster fixing bolt
Front seat belt buckle fixing
M10 45 33.2
bolt
Upper fixing bolt of rear left
M6×1 9 6.6
seat belt retractor
Lower fixing bolt of rear left
M10 45 33.2
seat belt retractor
Fixing bolt between rear left
seat belt and front interior M10 45 33.2
plate of left rear column
Rear left seat belt buckle
M10 45 33.2
fixing bolt
Rear middle seat belt fixing
M10 45 33.2
bolt
Rear left middle seat belt
M10 45 33.2
buckle fixing bolt
Rear right middle seat belt
M10 45 33.2
buckle fixing bolt
NL-3 01/2016
Repair Specifications - Safety Control System SS-51
Safety Control System SS

Torque Range
Airbag controller fixing bolt M6×1×16 8-10 5.9-7.3
Frontal collision sensor
M6×1×20 7-9 5.2-6.6
fixing bolt
Fixing bolt of lower bracket
M6×1×6 8-10 5.9-7.3
of passenger airbag
Lap airbag fixing nut M6×1 8-10 5.9-7.3
Curtain airbag fixing bolts M6×1 8-10 5.9-7.3
Fixing bolt of guide plate of
side curtain airbag in rear M6×1 8-10 59-7.3
column
NL-3 01/2016
SS-52 Repair Specifications - Sunroof System
Sunroof System
SS
Torque Range
Sunroof assembly
M6×1×20 5-7 3.7-5.2
(panoramic) bolt
Bolt of left/right connecting
plate of reinforcing plate of M6×1×16 7-9 5.2-6.6
top sunroof
NL-3 01/2016
Repair Specifications - Anti-theft System SS-53
Anti-theft System SS
Torque Range
PEPS bracket & IP
M6×1 6-12 4.4-8.8
hexagonal flange nut
NL-3 01/2016
SS-54 Repair Specifications - Windshield & Window Glass
Windshield & Window Glass

SS
Torque Range
Left rear fixed window glass
M5×0.8 5-7 3.7-5.2
assembly nut
Self-tapping screw for left
front window switch and ST2.9×13 0.6--1.0 4.4-8.7
panel
Lifter bolt M6×1×10 7-9 5.2-6.6
Lifter motor fixing bolt M6×1×10 7-9 5.2-6.6
Fixing screw of mounting
bracket of interior trim panel ST4.8×16 4.5-5.5 3.3-0.4
for door
NL-3 01/2016
Repair Specifications - Wiper and Washer SS-55
Wiper and Washer SS

Torque Range
Rear wiper arm & blade
M8×1.25 14-16 10.3-11.8
assembly fixing nut
Fixing bolt for three
installation points of M6×1×16 6-12 4.4-8.9
washing liquid reservoir
Back door wiper & back
M6×1 6-12 4.4-8.9
door fixing nut
NL-3 01/2016
SS-56 Repair Specifications - Door
Door
SS
Torque Range
Limiter fixing bolt M8×1.25×20 22-26 16.2-19.2
Limiter fixing nut M8×1.25 8-10 5.9-7.4
Upper hinge bolt of door M8×1.25×30 30-38 22.1-28.0
Lower hinge bolt of door M8×1.25×30 30-38 22.1-28.0
NL-3 01/2016
Repair Specifications - Front-end of Vehicle Body SS-57
Front-end of Vehicle Body SS

Torque Range
Engine hood hinge bolt M8×1.25×16 38-42 28.0-31.0
Engine hood hinge & body
M8×1.25 23-27 17.0-19.9
fixing nut
Engine hood handle bolt M8×1.25×20 20-24 14.8-17.7
Connecting bolt between
engine hood and vehicle M8×1.25×20 38-42 29.4-6.5
body
Engine hood hinge & front
M8×1.25×20 8-10 5.9-7.4
fender fixing bolt
Engine hood air spring
M8×1.25 20-26 14.8-19.2
bracket fixing bolt
NL-3 01/2016
SS-58 Repair Specifications - Rear-end of Vehicle Body
Rear-end of Vehicle Body

SS
Torque Range
Tail door hinge bolt M8×1.25×16 20-26 14.8-19.2
Bolt of connecting part of air
M6×1×16 8-12 5.9-8.9
spring
NL-3 01/2016
Repair Specifications - Interior Trim SS-59
Interior Trim SS
Torque Range
Fixing screw for upper trim
M6×1×16 1.5-3.5 1.1-2.6
panel of column B/C
panel of column C and ST4.8×16 4.5-5.5 3.3-4.1
metal sheet of vehicle body
panel of column B/C and M6×1×16 1.5-3.5 1.1-2.6
metal sheet of vehicle body
Seat belt buckle box &
/ 0.5-2.5 0.4-1.8
ceiling fixing screw
Sunvisor, and sunvisor
/ 7-12 5.2-8.9
hook fixing screw
Safety handle fixing screw / 3-4 2.2-3.0
Safety handle bracket fixing
/ 6-12 4.4-8.9
screw
Interior door handle fixing
ST4.8×16 2-3 1.5-2.2
screw
Door handle base fixing
ST4.8×16 4.5-5.5 3.3-4.1
screw
Door handle box &
mounting bracket fixing ST4.8×16 4.5-5.5 3.3-4.1
screw
Door mounting bracket
ST4.8×16 4.5-5.5 3.3-4.1
fixing screw
NL-3 01/2016
SS-60 Repair Specifications - Exterior Trim
Exterior Trim
SS
Torque Range
Fixing bolt for upper and
lower bodies of front M6×1×20 7-9 5.2-6.6
bumper
Fixing bolt of protective
beam foe lower small leg of M6×1×20 7-9 5.2-6.6
front bumper
Front crossbeam &
M10×1.5×60 45-55 33.2-40.6
longitudinal beam fixing bolt
Front crossbeam &
M10×1.5×25 45-79 33.2-58.3
front-end module fixing bolt
Bolt for front reinforcing
M6×1×30 7-9 5.2-6.6
beam of radiator
Radiator cover bolt M6×1×20 7-9 5.2-6.6
Radiator baffle fixing bolt M6×1×20 7-9 5.2-6.6
Fixing bolt for upper/lower
M6×1×20 7-9 5.2-6.6
body of rear bumper
Front-end module fixing bolt M8×1.25×20 20-26 14.8-24.6
Luggage rack mounting
/ 8-10 5.9-7.4
bracket fixing nut
Rear spoiler fixing nut / 8-10 5.9-7.4
NL-3 01/2016
Repair Specifications - Seats SS-61
Seats SS
Torque Range
Seat foot pad fixing bolt M10×1.5×30 40-50 29.5-36.9
Rear seat backrest bolt M10×1.5×30 40-50 29.5-36.9
Fixing bolt for rear portion
M6×1×25 10-12 7.4-8.9
of seat cushion
Backrest hook and side
mounting bracket & vehicle M10×1.25×20 18-22 13.3-16.2
body fixing bolt
NL-3 01/2016
SS-62 Repair Specifications - Instrument Panel
Instrument Panel
SS
Torque Range
Auxiliary instrument switch
ST4.8×16 1-2 0.7-1.5
fixing screw
combination instrument &
instrument frame fixing ST4.8×16 2-4 1.5-3.0
screw
Instrument panel body
/ 2-3 1.5-2.2
fixing screw
Glove box body fixing screw / 2-3 1.5-2.2
Fixing screw of lower
protective plate of / 2-3 1.5-2.2
instrument panel
M6×1×16 6-12 4.4-8.8
fixing bolt
Glove box body fixing bolt M6×1×16 6-12 4.4-8.8
M6×1 6-12 4.4-8.8
fixing nut
Left wind outlet fixing screw ST4.2×16 3-4 2.2-3.0
Glove box handle fixing
ST4.2×13 2-3 1.5-2.2
screw
Glove box damper
mounting bracket fixing ST4.8×16 1.5-2.5 1.1-1.8
screw
Instrument panel bracket
ST4.8×16 4.5-5.5 3.3-4.0
fixing screw
Ventilation pipe bracket
ST4.8×16 4.5-5.5 3.3-4.0
fixing screw
Defrosting pipe mounting
ST4.8×16 4.5-5.5 3.3-4.0
bracket screw
Auxiliary instrument panel
ST4.8×16 4.5-5.5 3.3-4.0
handle cover fixing screw
Fixing screw of decorative
strip of front panel of ST4.8×16 4.5-5.5 3.3-4.0
auxiliary instrument panel
Fixing screw of middle left
decorative strip of ST4.8×16 4.5-5.5 3.3-4.0
instrument panel
Fixing bolt of left/right
mounting bracket for
/ 20-28 14.8-20.7
crossbeam of instrument
panel
Fixing bolt of middle
supporting rod of
/ 20-28 14.8-20.7
crossbeam of instrument
panel
Curtain frame fixing screw ST4.2×13 3-4 2.2-3.0
Curtain decorative strip/trim
ST4.2×9.5 3-4 2.2-3.0
cover mounting bracket
NL-3 01/2016
JLD-4G20/24 Engine Control System - Contents ES - 1
ES JLD-4G20/24 Engine Control System
Electronic Fuel Injection System..................................................................................................ES - 4 ES

Precautions ................................................................................................................................................................ ES - 4
Component Position................................................................................................................................................... ES - 5
System Diagram ........................................................................................................................................................ ES - 7

System Description .................................................................................................................................................... ES - 9
How to Carry Out the Analysis for Elimination of Fault............................................................................................. ES - 10

Intermittent Fault Inspection..................................................................................................................................... ES - 12
Table of Fault Symptoms ......................................................................................................................................... ES - 15

EMS Terminal........................................................................................................................................................... ES - 22
Diagnostic System ................................................................................................................................................... ES - 28

Inspection/troubleshooting for DTC of Components ................................................................................................ ES - 28
DTC P000A64 P000A77 P001013 P001277 ........................................................................................................... ES - 36

DTC P001621 P001622 P001678............................................................................................................................ ES - 43
DTC P003013 P003111 P003212 P00531E ............................................................................................................ ES - 46

DTC P003613 P003711 P003812 P00541E ............................................................................................................ ES - 52
DTC P010525 P010629 P010711 P010812 ............................................................................................................ ES - 58

DTC P011100 P011317 P011216............................................................................................................................. ES - 65
DTC P011600 P011817 P011716 ............................................................................................................................ ES - 70

DTC P012129 P012216 P012317............................................................................................................................ ES - 76
DTC P013029 P013116 P013217 P013300 P013413 P219500 P219600............................................................... ES - 82

DTC P013629 P013716 P013817 P014013 P227024 P227123.............................................................................. ES - 88
DTC P017000 P017100 P017200............................................................................................................................ ES - 94

DTC P020113 P020213 P020313 P020413 ............................................................................................................ ES - 97
DTC P021900 ........................................................................................................................................................ ES - 102
DTC P022129 P022216 P022317.......................................................................................................................... ES - 106
DTC P030022 P030021 P030029 P030122 P030121 P030129 P030222 P030221 P030229 P030322 P030321
P030329 P030422 P030421 P030429................................................................................................................... ES - 118
DTC P032200 ........................................................................................................................................................ ES - 125

DTC P032700 ........................................................................................................................................................ ES - 129
DTC P042000 ........................................................................................................................................................ ES - 139

DTC P044413 P045811 P045912 .......................................................................................................................... ES - 142
DTC P048113 P048013 ......................................................................................................................................... ES - 147

DTC P069111 P069212 ......................................................................................................................................... ES - 151
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ES - 2 JLD-4G20/24 Engine Control System - Contents
DTC P069311 P069412 ......................................................................................................................................... ES - 155
DTC P050129 ........................................................................................................................................................ ES - 159

DTC P050600 P050700 ......................................................................................................................................... ES - 161
DTC 56000 P056200 P056300 .............................................................................................................................. ES - 164

DTC P057129 P05711C ........................................................................................................................................ ES - 170
DTC P060100 P060611 P060612 P060443 P060543 ........................................................................................... ES - 174

DTC P060694 P060692 P060664 P060661 P060667 P060696 P06061C P060655 P060600 P060662 P060663
P060648 P060647 P060675 P060649................................................................................................................... ES - 176

DTC P062713 P062811 P062912 .......................................................................................................................... ES - 180
DTC P064513 P064611 P064712 .......................................................................................................................... ES - 187

DTC P068881 ........................................................................................................................................................ ES - 197
DTC P133600 P210612 P210619 P210692 P210613 P210629............................................................................ ES - 200

DTC P154500 P154522 P154521 P155900 P155929 P156400 P156500 P156800 P157900 .............................. ES - 204
DTC P161000 P161100 P161200 P161300 P161400 ........................................................................................... ES - 208

DTC P208811 P208912 ......................................................................................................................................... ES - 210
DTC P212216 P212317 ......................................................................................................................................... ES - 217

DTC P212716 P212817 ......................................................................................................................................... ES - 222
DTC P213800 P213829 ......................................................................................................................................... ES - 227

DTC P217700 P217800 P218700 P218800 .......................................................................................................... ES - 229
DTC U007300 U010182 U010183 U010387 U012282 U012283 U012287 U013187 U014087 U014187
U015182 U015183 U015187 P168386 .................................................................................................................. ES - 233
DTC U300385 U300384 ........................................................................................................................................ ES - 233

DTC P070400 ........................................................................................................................................................ ES - 240
Engine Fault Indicator Lamp (MIL)/immediate repair indicator lamp of vehicle is not working properly. ................ ES - 243
Crankshaft rotation is normal, but the engine cannot start ..................................................................................... ES - 247
Electronic Throttle Control (ETC) Self-adaptive Learn Program ............................................................................ ES - 252

Learning of speed sensor (CKP) ............................................................................................................................ ES - 253
OCV valve ................................................................................................................................ES - 254

Component ............................................................................................................................................................ ES - 254
Removal................................................................................................................................................................. ES - 256
Check..................................................................................................................................................................... ES - 257
Clean ..................................................................................................................................................................... ES - 258

Installation.............................................................................................................................................................. ES - 259
Electronic throttle body ..........................................................................................................ES - 260

Component ............................................................................................................................................................ ES - 260
Removal................................................................................................................................................................. ES - 262
Check..................................................................................................................................................................... ES - 263
Installation.............................................................................................................................................................. ES - 264
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JLD-4G20/24 Engine control system - Contents ES - 3
Intake pressure/temperature sensor......................................................................................ES - 265

ES
Component ............................................................................................................................................................ ES - 265
On-board dismantlement ....................................................................................................................................... ES - 268
Check..................................................................................................................................................................... ES - 269
On-board installation .............................................................................................................................................. ES - 269
Water temperature sensor ......................................................................................................ES - 270

Component ............................................................................................................................................................ ES - 270
Removal................................................................................................................................................................. ES - 272
Check..................................................................................................................................................................... ES - 273
Phase sensor ..........................................................................................................................ES - 275

Component ............................................................................................................................................................ ES - 275
Check..................................................................................................................................................................... ES - 277
Installation.............................................................................................................................................................. ES - 277
Crankshaft position sensor ....................................................................................................ES - 279

Component ............................................................................................................................................................ ES - 279
Removal................................................................................................................................................................. ES - 281
Check..................................................................................................................................................................... ES - 282
Installation.............................................................................................................................................................. ES - 282
Knock sensor ..........................................................................................................................ES - 284

Component ............................................................................................................................................................ ES - 284
Check..................................................................................................................................................................... ES - 288
Engine ECU ........................................................................................................................................................... ES - 289

Component ............................................................................................................................................................ ES - 289
On-board check ..................................................................................................................................................... ES - 290

Removal................................................................................................................................................................. ES - 290
Accelerator pedal ................................................................................................................................................... ES - 292

Component ............................................................................................................................................................ ES - 292
On-board check ..................................................................................................................................................... ES - 293

Removal................................................................................................................................................................. ES - 293
Check..................................................................................................................................................................... ES - 294
Installation.............................................................................................................................................................. ES - 294
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ES - 4 JLD-4G20/24 Engine Control System - Electronic Fuel Injection System
Electronic Fuel Injection System

ES
Precautions
1. Notices for Operation of Airbag System
a. When replacing the EMS controller, TCU controller or BCM controller, please implement the initialization operation.
b. This vehicle is equipped with airbags. If the repair is not carried out in correct sequence, the airbag may be deployed
unexpectedly in the course of repair. This may cause serious accident. Before the repair (including check, replacement,
dismantlement or installation of part), be sure to read the notices about airbag system.
2. Notices for CAN Communication System
a. When sending out the DTC of CAN communication system, please eliminate the fault of communication line. Be sure to
eliminate the fault of EMS only after it is confirmed that the CAN communication system is normal.
b. Since the CAN communication line has its own length and route, it is impossible to carry out repair temporarily by using
bypass harness.
3. Cooling Fan System
a. When the power mode is in the state OFF and the engine temperature is too high, the cooling fan may run continuously for
about 3 minute. After operating the power switch so as to set the power mode in the state OFF, be sure to keep your hands
and other articles away from the running fan.
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JLD-4G20/24 Engine Control System - Electronic Fuel Injection System ES - 5
Component Position
Position Diagram of Components of Engine Control System
ES
Fuel distribution pipe and fuel

injector assembly Phase Sensor
OCV solenoid valve
Electronic throttle valve body

Ignition Coil
Air intake
temperature/pres
sure sensor
Knock sensor Engine speed sensor
Engine water temperature sensor
Rear Oxygen Sensor

Front Oxygen Sensor
NL-3 01/2016
Position Diagram of Components of Engine Control System (continued)
ES
OBD diagnostic interface Electronic Accelerator Pedal
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System Diagram
ES
EMS Control System
Battery supply
Ignition Coil
Power supply of PEPS switch

Fuel injector
Intake pressure/temperature
sensor
Electronic throttle motor
Gear switch signal
Brake vacuum pump relay
Cruise switch
Fuel pump relay
Accelerator pedal position sensor
Carbon canister solenoid valve
Throttle position sensor
OCV solenoid valve
Coolant temperature sensor
Main Relay
Crankshaft position sensor
A/C clutch relay

Camshaft position sensor
A/C controller
A/C pressure switch signal
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ES
Low-speed cooling fan relay
High-speed cooling fan relay
Knock sensor Power switch
Power signal
Brake switch
Clutch pump
Front Oxygen Sensor
Rear Oxygen Sensor

Gateway
NL-3 01/2016
System Description
ES
This engine adopts the combined electronic control system, and is mainly composed of engine management system (EMS),
EMS circuit, and system input/output components. Located on left side in engine compartment, the EMS is the control center
of engine control system. It constantly detects signals from various sensors and controls various systems affecting the vehicle
performance. The engine control module also implements the system diagnosis function, and it can identify the operation
faults, remind the driver through fault indicator lamp (MIL), and store the fault code which indicates the location of fault, so as
to facilitate the repair carried out by repair personnel. If the engine control module damages, the module interior has no single
component for repair. EMS shall be replaced in its entirety.
Information input components:
Speed sensor, camshaft position sensor (CMP), intake temperature/pressure sensor [intake temperature sensor (IAT),
including intake pressure sensor (MAP)], knock sensor (KS), electronic throttle [ throttle position sensor (TPS)], water
temperature sensor (ECT), front oxygen sensor (HO2S), rear oxygen sensor (HO2S), neutral position switch, electronic
accelerator pedal [accelerator pedal position sensor], clutch master cylinder sensor, A/C pressure switch, power steering
switch, brake lamp switch, high beam relay, CAN information input, and serial data line input.
Output component:
Electronic throttle [throttle control motor], fuel nozzle for cylinders 1-2-3-4, ignition coil for cylinders 1-2-3-4, carbon canister
solenoid valve (EVAP), variable valve timing solenoid valve (OCV), starter relay, A/C compressor relay, main relay, fuel pump
relay, low speed cooling fan relay, and high speed cooling fan relay.
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How to Carry out the Analysis for Elimination of Fault

ES
Control System Inspection
Diagnostic steps:
Step 1 Customer mentioned fault analysis
Next Step
Step 2 Connect fault diagnostic scanner

(a) Install fault diagnostic scanner.
(b) Power on the fault diagnostic scanner.
(c) Whether the fault diagnostic scanner is power on.
No Go to step 11
Yes
Step 3 Make the fault diagnostic scanner communicate with engine management system.
(a) Operate the power switch so as to set the power mode in

the state ON.
(b) Try to build up the communication with engine
management system (EMS).
(c) Confirm whether there is communication between fault
diagnostic scanner and engine management system.
No Go to step 14
Yes
Step 4 If the engine is able to be started?
(a) If the engine is able to be started?
No Intermittent fault inspection
Yes
Select the fault code reading function for engine management system, and confirm whether there is
Step 5
fault code for the system.
(a) If the engine is able to be started?
Yes
Step 6 After recording the fault diagnosis code, clear it.
Next Step
Step 7 Confirm whether the fault will recur.
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(a) Confirm whether the fault will recur.

ES
No Go to step 9
Yes
Step 8 Fault diagnosis simulation.
Next Step
Step 9 Check whether the control system has fault diagnosis code.
(a) Check whether the control system has fault diagnosis
code.
Yes
Step 10 Carry out repair on the basis of fault diagnosis code.
Next Step
Step 11 Use a normal vehicle, connect the fault diagnostic scanner to check whether it can start?
(a) Use a normal vehicle, connect the fault diagnostic
scanner to check whether it can start?
For fault diagnostic scanner fault, please

No
replace the fault diagnostic scanner with a
new one.
Yes
Step 12 Check the power supply of fault diagnostic interface.
Next Step
Step 13 Carry out the integrity diagnosis for CAN bus.

(a) Carry out the integrity diagnosis for CAN bus. Please
refer to the section about integrity test of CAN (fault codes
U003788, U005588, U002888, U004688, U003887,
U002987 and U004787).
Next Step
Step 14 Conduct confirm test.
Next Step
Step 15 End.
NL-3 01/2016
Intermittent Fault Inspection

ES
Notices
− Clear the DTC.
− Carry out the simulation test.
− Check and shake the harness and terminal of connection box.
Carry out preliminary inspection firstly before carrying out fault diagnosis according to engine fault symptoms.
1. Check whether engine fault indicator lamp works normally;
2. Check and confirm that there is no fault information record with fault diagnosis scanner.
3. Check whether the fault symptom complained by car owner exists and determine the conditions if the fault occurs.
When the fault can't be confirmed via DTC inspection, the fault only occurs occasionally during operation At this point you
should confirm all circuits and components that can possibly lead to the fault. Under most conditions, rapidly locate the faulty
element via executing the basic inspection in the following flow chart. Especially for harness connector poor contact and other
faults.
Fault definition: the fault is not available at present; the fault diagnosis log shows this fault in history. Or the customer reports
this fault, however, the fault is not related to the fault diagnosis code and the fault symptoms can't be recreated.
Diagnostic steps:
Step 1 Check whether the battery voltage is normal.
(a) Operate the starter switch to turn the power supply mode
to OFF state.
(b) Measure the voltage of battery.
(c) Implement the corresponding step on the basis of
measured value.
Results Go to Step
11~14V Yes
Less than 11V No
Check the battery

No
Yes
Step 2 Visual physical inspection

If the following phenomenon exists, please firstly carry out
repair for such fault; otherwise the subsequent fault
diagnosis will be affected.
(a) Check whether the harness is broken, worn, peeling off,
etc
(b) Check where there is leakage on fuel pipeline.
(c) Check whether the layout of harness is incorrect. It is
prohibited to make harness close to the following
high-voltage or high-current devices: ignition coil, ignition
conductor, starter motor and generator. The operation of
these components will generate bigger electromagnetic
interference, thus influencing correct signal transmission and
leading to system operation anomaly.
(d) Check whether the high-voltage line system is aged,
broken, flattened or damaged.
(e). Check whether the vacuum hose ruptures, damages or
twisted. Confirm line connection and arrangement
correctness.
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(f) Check whether the engine management system (EMS)

grounding point and body grounding point is loose, ES
oxidized and corrosive, etc. The grounding point position
of control system can not be changed optionally, it will
affect normal work of control system.
(g) Check whether the positive and negative cable
connection of battery is reliable, loose, oxidized and
corrosive, etc.
Next Step
Step 3 Check the harness and connectors

(a) Plentiful intermittent faults are caused by the movement
of harness and connector due to vibration, distortion,
uneven road or component operation.
(b) Too huge circuit resistance may cause component
operation anomaly Use the fault diagnostic scanner to
forcibly drive the actuator. If it can’t work normally, check
whether the relevant circuit has the fault such as too high
resistance.
Next Step
Step 4 Make the fault appear again and use the instrument to record data of the engine control unit.
(a) Connect a fault diagnostic scanner and use the data
record function to record road test data during the
occurrence of the intermittent fault. After pressing the button
for the vehicle data recorder, record engine control module
data during intermittent fault. The data is used to clarify fault
component.
(b)Another diagnostic method is when the vehicle is running,
connect a digital multimeter to the suspicious circuit. The
abnormal reading of the digital multimeter may indicate the
faulty position.
Next Step
Step 5 Fault indicator lamp lights intermittently, however, the system doesn't set the fault code.
(a) The following conditions may cause intermittent lighting
of the fault indicator lamp. However, the system will not set
fault diagnosis code:
(b) The electromagnetic interference is caused by solenoid
valve or switch which is controlled by abnormally-working
relay or engine management system.
(c) Non original or installed accessories after sale, such as
onboard telephone, alarm, lamp, wireless equipment
mounting not correct
(d) Intermittent short circuit to ground of the fault indicator
lamp control circuit.
(e) The grounding point of engine management system is
Next Step
loosened.
Step 6 Other inspections.
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(a) Test whether the circuit between the diodes on both

ES ends of the A/C compressor clutch and other diodes is
broken
(b) Check whether the charging system has the following
conditions:
• Alternator rectifier fault may possibly lead to AC signal
interference in the electric system.
(c) Whether the alternator output voltage is correct If the
alternator output voltage is less than 9V or higher than
14.5V, repair the charging system.
Next Step
Step 7 Enter into the table of fault symptoms.
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Table of Fault Symptoms

ES
Hints:
 The table below can help identify the cause of fault. The descending sequence is used to indicate the possibility of
causes of fault. Check every suspected location in accordance with the sequence. If necessary, repair, replace or adjust
the part which has failed.
 Before checking the following suspected locations, please check the fuses and relays relating to the system.
Symptoms Suspected Parts: Measures/Reference
1. EMS power circuit Refer to DTC 56000 P056200 P056300
Refer to DTC P010500 P010621
2. Intake pressure (MAP) sensor P010622 P010684 P010685 P010716
Slow, reduced and unsteady speed P010817
Fault definition: depress the 3. Fuel pressure anomaly
Diagnosis of fuel system
acceleration pedal, there is no instant 4. Nozzle operation anomaly
response. At any speed, this fault may Refer to DTC P022129 P022216
5. Throttle position sensor 2
occur. During initial start of the vehicle P022317
(e.g. start after parking), the fault is 6. Ignition system: spark plug or ignition
usually more obvious Under serious conductor anomaly
Diagnosis of ignition system
condition, such fault may possibly lead 7. Longer delay of the ignition of the
to engine speed loss. knock sensor (KS) system
8. Wheel speed sensor Refer to DTC P032200
9. Acceleration pedal position sensor 1 Refer to DTC P212216 P212317
10. Acceleration pedal position sensor 2 Refer to DTC P212716 P212817
1. A/C signal circuit A/C diagnosis
Engine stalls only when A/C is working. Refer to DTC P154500 P154522
Fault Definition: when A/C is working, 2. Electronic Throttle Body P154521 P155900 P155929 P156400
engine speed is not stable or engine P156500 P156800 P157900
stalls. Please refer to the section about engine
3. EMS
ECU
High fuel consumption, poor fuel 2. Intake temperature pressure sensor P010711 P010812, DTC P011100
economy P011317 P011216
Fault definition: the oil consumption via 3. Air filter element blockage Please refer to “Air filter”
the actual road test obviously exceeds 4. Poor fuel quality, fuel contamination
the expected value. In addition, the fuel 5. Fuel pressure anomaly Diagnosis of fuel system
consumption is also significantly higher 6. Nozzle operation anomaly
than the previous road test. Refer to DTC P154500 P154522
7. Electronic Throttle Body P154521 P155900 P155929 P156400
P156500 P156800 P157900
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ES 8. The use has any of the following driving
habits: The A/C or defroster mode is always
activated, the tire pressure is incorrect, the
vehicle is overloaded, or the acceleration is
carried out too quickly or too frequently
9. Air leakage in intake system and
crankcase system
10. Blockage of the forced ventilation valve of
the crankcase
11. Longer delay of the ignition of the knock
sensor (KS) system
12. Spark plug: incorrect calorific value,
moistening, crack, incorrect clearance,
Ignition system check
ablation, too much carbon deposit,
contamination by fuel
High fuel consumption, poor fuel 13. Spark plug conductor broken
economy 14. Ignition coil broken
Fault definition: the oil 15. Engine coolant level too low, thermostat
Cooling system check
consumption via the actual road fault
test obviously exceeds the 16. Too much oil inside the combustion
expected value. In addition, the chamber or valve seal leakage
fuel consumption is also 17. Incorrect cylinder compression pressure
significantly higher than the 18. Valve blockage or leakage, valve spring
previous road test. broken, valve timing incorrect Mechanical system check
19. Too much carbon deposit in the
combustion chamber
20. Vacuum hose rupture or twisting,
unreliable connection
21. Exhaust not smooth: three-way catalytic
Please refer to “Exhaust system”
converter blockage, silencer interior damage
22. Brake system delay or operation anomaly Please refer to “Brake system”
23. Electromagnetic interference (EMI) in the
voltage circuit may possibly lead to engine
misfiring fault. The fault diagnostic scanner
may be used to monitor the engine speed
parameter. If the engine speed parameter
increases suddenly but the actual engine
speed remains unchanged, this means that
there is electromagnetic interference.
Lack of fuel supply, Misfiring 1. EMS power circuit Refer to DTC 56000 P056200 P056300
Fault definition: after the engine 2. Air filter element blockage Replacement of air filter element
speed increases, there is 3. Fuel pressure anomaly
Please refer “Fuel system”
continuous pulsation, or jitter, 4. Nozzle operation anomaly
usually even more noticeable Refer to DTC P012129 P012216
with the engine load increasing. 5. Throttle position sensor 1
P012317
When the engine speed is above
1,500 rpm, the fault does not 6. Throttle position sensor 2
P022317
appear.
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7. Longer delay of the ignition of the knock ES
sensor (KS) system
Please refer “Ignition system”
9. Spark plug conductor broken
Lack of fuel supply, Misfiring 10. Ignition coil broken
Fault definition: after the engine 11. Wheel speed sensor Refer to DTC P032200
speed increases, there is 12. Too much oil inside the combustion
continuous pulsation, or jitter, chamber or valve seal leakage
usually even more noticeable 13. Incorrect cylinder compression pressure
with the engine load increasing. 14. Valve stagnant or leakage
When the engine speed is above 15. Camshaft convex corner wear
1,500 rpm, the fault does not 16. Valve timing incorrect Please refer to “Diagnosis of engine”
appear. 17. Valve spring broken
combustion chamber
19. Camshaft, cylinder lid, piston, link rod and
bearing anomaly
20. The emission of exhaust is not smooth:
The information and steps of diagnosis
The three-way catalytic converter is blocked
of exhaust system.
up, The muffler is internally damaged
Poor, unsteady, incorrect idle 2. Air filter element blockage Replace air filter element
speed or stall 3. Fuel pressure anomaly
Fault definition: unsteady engine 4. Fuel contamination Please refer to “Fuel system”
operation during idle speed In 5. Injector operation anomaly
extreme cases, the engine or the Refer to DTC P154500 P154522
vehicle will tremble. With a 6. Electronic Throttle Body P154521 P155900 P155929 P156400
certain throttle opening, the P156500 P156800 P157900
engine idle speed may fluctuate. 7. Electronic accelerator pedal position Refer to DTC P212216 P212317, DTC
Any of these circumstances is sensor P212716 P212817
likely to be serious enough to 8. Positive crankcase ventilation
Please refer to “Auxiliary emission
make the engine stall. 9. Evaporative Emission (EVAP) Canister
system”
Solenoid Valve
NL-3 01/2016

ES 10. Longer delay of the ignition of the knock
sensor (KS) system
Please refer to “Ignition system”
13. Ignition coil broken
15. Too much oil inside the combustion
Poor, unsteady, incorrect idle
chamber or valve seal leakage
speed or stall
16. Incorrect cylinder compression pressure
Fault definition: unsteady engine
17. Valve blockage or leakage, valve spring
operation during idle speed In
broken, valve timing incorrect
extreme cases, the engine or the
vehicle will tremble. With a
combustion chamber
certain throttle opening, the
19. Check engine bracket
engine idle speed may fluctuate.
Any of these circumstances is 12. Spark plug conductor broken
likely to be serious enough to 20. Electromagnetic interference (EMI) in the
voltage circuit may possibly lead to engine Please refer to “Engine”
make the engine stall.
misfiring fault. Usually, the fault diagnostic
scanner can be used to detect
electromagnetic interference via monitoring
engine speed parameter. When the engine
speed suddenly increases and the actual
engine speed almost remains unchanged. It
means the electromagnetic interference is
available. In case of fault, inspect whether the
ignition control circuit has the high voltage
component nearby.
2. Incorrect fuel number
Combustion and ignition knock 3. Fuel pressure anomaly
Please refer to “Fuel system”
Fault definition: the knock sound 4. Nozzle operation anomaly
aggravates during accelerate 5.Mixture too thin
With variation of the throttle 6. Longer delay of the ignition of the knock
opening, the engine will sensor (KS) system Please refer to “Ignition system”
generate sharp metal strike 7. Spark plug's calorific value not correct
sound. 8. Cooling system: level too low, engine
coolant not correct, engine coolant leakage, Please refer to “Cooling system”
cooling fan not operating
Combustion and ignition knock 9. Too much oil inside the combustion
Fault definition: the knock sound chamber or valve seal leakage
aggravates during accelerate 10. Cylinder compression pressure too high
With variation of the throttle 11. Too much carbon deposit in the Please refer to “Engine”
opening, the engine will combustion chamber
generate sharp metal strike 12. Camshaft, cylinder lid, piston, link rod and
sound. bearing anomaly
NL-3 01/2016

1. Too much oil inside the combustion ES
Please refer to “Engine”
combustion chamber
3. Timing assembly not correct
Engine difficult to start 5. Fuel pump relay, fuel pump, injector, fuel
Fault definition: normal operation contamination
of the engine crankshaft, while 6. Ignition system: ignition leads, spark plug,
can’t be started for a long time. ignition coil
The engine may finally start and Please refer to DTC 56000 P056200
7. EMS power circuit
may immediately flameout P056300
8. Engine coolant temperature sensor Please refer to “Cooling system”
9. Electronic Throttle Body P154521 P155900 P155929 P156400
P156500 P156800 P157900
10. Electronic accelerator pedal position Refer to DTC P212216 P212317 DTC
sensor P212716 P212817
2. Fuel pressure anomaly
3. Fuel contamination Please refer to “Fuel system”
4. Injector operation anomaly
Backfire, blast 5. Air leakage in the intake system and
Fault definition: the not fully crankcase
system”
combusted gas in the 6. Positive crankcase ventilation
combustion chamber enters the 7. Longer delay of the ignition of the knock
intake manifold or exhaust sensor (KS) system
system for ignition, it generates 8. Spark plug: incorrect calorific value,
very big blast sound. moistening, crack, incorrect clearance,
NL-3 01/2016

ES 1. EMS power circuit Refer to DTC 56000 P056200 P056300
2. A/C compressor Please refer to “A/C system”
3. Heating type oxygen sensor anomaly Replace the oxygen sensor
4. Poor fuel quality, fuel contamination
5. Fuel pressure anomaly Please refer to “Fuel system”
6. Nozzle operation anomaly
Surge Refer to DTC P154500 P154522
Fault definition: engine power 7. Electronic Throttle Body P154521 P155900 P155929 P156400
varies when the throttle P156500 P156800 P157900
stabilizes. The vehicle speed 8. Smart changeable valve timing system
changes while the acceleration 9. Vacuum hose rupture or twisting, unreliable Please refer to “Engine”
pedal position does not change. connection
2. Air filter element blockage Replace the air filter element
4. Fuel pressure anomaly Please refer to “Fuel system”
Power inadequate, bonding or Refer to DTC P154500 P154522
soft 6. Electronic Throttle Body P154521 P155900 P155929 P156400
Fault definition: engine output P156500 P156800 P157900
power less than the expected 7. Longer delay of the ignition of the knock
value When half depressing the sensor (KS) system
acceleration pedal, little or no 8. Spark plug: incorrect calorific value,
speed increase at all. moistening, crack, incorrect clearance,
NL-3 01/2016

12. Too much oil inside the combustion ES
Power inadequate, bonding or
soft
Fault definition: engine output Please refer to “Engine”
broken, valve timing incorrect
power less than the expected
value When half depressing the
combustion chamber
acceleration pedal, little or no
16. Smart changeable valve timing system
speed increase at all.
17. Exhaust not smooth: three-way catalytic
converter blockage, silencer interior damage
1. Battery
No operation of the engine 2. Starter Please refer to “Power system and
Definition of fault: When the 3. Start relay charging system”
power switch is in the state ST, 4. Ignition switch
the engine crankshaft does not 5. BCM Check the BCM system
rotate. Please refer to the section about
6. Engine Anti-theft System
intelligent entry & start system
Engine does not start, no sign of 2. Wheel speed sensor Refer to DTC P032200
the vehicle starting. Refer to DTC P001621 P001622
3. Camshaft position sensor
Fault Definition: When start P001678 DTC P034178
switch in the ST position, the 4 Ignition system Please refer to “Ignition system”
engine crankshaft rotates, but no 5. Fuel pump control circuit
sign of the vehicle starting. 6. Fuel injector operation circuit
7. EMS Please refer to “Engine ECU”
NL-3 01/2016
EMS Terminal
ES
CA45 Engine Management System Harness Connector 1
CA45 Engine management system harness connector 1
Notices
− UB is the battery voltage.
− If there is no description, GND is 0 V or close to 0 V.
Terminal Name Terminal Description State Specified condition
The power mode is in the
1 B.D.CANH CAN-H
state ON
2 - - - -
3 - - - -
4 - - - -
5 O.S.HR Main Relay All
6 - - - -
The electronic accelerator pedal The power mode is in the
7 G.R.PEDPOS1
sensor 1 is earthed state ON
8 - - - -
9 - - - -
10 - - - -
I.S.CLUTCH Switch on top of clutch pump (for MT
11 - -
TOP vehicle)
NL-3 01/2016

Reference voltage for vacuum The power mode is in the state ES
12 I.A.PVAC -
sensor ON
13 - - - -
14 - - - -
Non-interrupted power supply The power mode is in the state
15 V.V.UBR -
for main relay ON
Non-interrupted power supply The power mode is in the state
16 V.V.UBR -
for main relay ON
The power mode is in the state
17 B.D.CANL CAN-H -
ON
18 B-D-DIAK Diagnostic line - -
19 O.V.PRESS Vacuum sensor signal -
ON
20 V.V.UBD Constant power supply All -
21 I.A.LSDOWN Rear oxygen sensor signal - -
22 - - - -
23 I.S.BR Brake lamp switch When the brake is depressed -
24 I.S.PSW A/C pressure switch On or Off -
25 I.S.BL Brake lamp -
ON
26 - - - -
27 - - - -
28 I.S.ACSW A/C pressure switch On or Off -
29 L.F.CAMIN Phase sensor signal - -
Electronic accelerator pedal The power mode is in the state
30 I.A.PEDPOS2 -
sensor 2 signal ON
31 O.S.FAN2 Cooling fan high speed relay - -
32 I-S-IMMO The engine is locked up -
ON
33 - - - -
34 O.V.CAM Power supply of phase sensor - -
35 I.S.ON The power switch is turned on -
ON
36 O.V.PEDPOS2 5V Power 2 -
ON
37 O.V.PEDPOS1 5V Power 1 -
ON
38 O.S.KOS A/C compressor relay The A/C switch is turned on - -
39 - - - -
40 - - - -
41 - - - -
42 - - - -
The rear oxygen sensor is The power mode is in the state
43 G.R.LSDOWN -
earthed ON
NL-3 01/2016

ES I.S.CLUTCH The power mode is in the
44 Clutch pedal position -
TOP state ON
45 I.A.PEDPOS1 -
46 - - - -
47 G-R-PRESS Vacuum sensor grounding -
state ON
48 O.T.LSHDOWN Rear oxygen sensor heating -
state ON
49 O.S.FPR Fuel pump relay -
state ON
50 - - - -
51 - - - -
52 - - - -
53 - - - -
54 - - - -
55 - - - -
The water temperature
56 O.S.FAN1 Cooling fan Low speed relay reaches the opening -
temperature
57 - - - -
58 - - - -
59 G.R.PEDPOS2 -
60 - - - -
61 - - - -
62 - - - -
63 G.G.GNDPOW2 EMS grounding All -
NL-3 01/2016
EG24 Engine Management System Harness Connector 2

ES
EG24 Engine management system harness connector 2
Notices
− UB is the battery voltage.
− If there is no description, GND is 0 V or close to 0 V.
1 - - - -
2 - - - -
3 O.T.IV4 Injector 3 When the engine is running
4 O.T.IV1 Injector 4 When the engine is running -
5 - - - -
6 - - - -
7 O.T.CVVT1 Variable valve timing valve When the engine is running
Front oxygen sensor heating
9 O.T.LSHUP In the course of heating -
signal
11 O.T.ETCPOS Throttle actuator -
ON
12 O.P.ICC3 Ignition Coil 1 When the engine is running
NL-3 01/2016
Terminal Description Terminal Description State Specified condition

ES The power mode is in the state
13 I.A.TPS1 Throttle position sensor -
ON
14 I.A.TPS2 Throttle position sensor -
ON
15 - - - -
The front oxygen sensor is
16 G.R.LSUP When the engine is running -
earthed
17 - - - -
18 - - - -
19 - - - -
20 - - - -
21 G.R.TGROUND Sensor grounding -
ON
22 G.R.THROTPOS Sensor grounding When the engine is running -
23 O.T.ETCNEG Throttle actuator -
ON
24 O.P.ICC4 Ignition Coil 3 When the engine is running -
25 I.A.KSB Knock sensor signal B When the engine is running -
26 I.A.KSA Knock sensor signal A When the engine is running -
Air intake
27 I.A.MAINFOLD When the engine is running -
temperature/pressure sensor
28 - - - -
29 I.F.CAMIN Camshaft position sensor When the engine is running -
30 O.S.CPV Carbon canister control valve When the engine is running -
31 G.R.CAM Sensor grounding When the engine is running -
Engine speed sensor terminal
32 I.F.DGA When the engine is running -
A
Engine speed sensor terminal
33 I.F.DGB When the engine is running -
B
34 O.V.CAM When the engine is running -
signal
Engine water temperature
37 I.A.TMOT When the engine is running -
sensor
38 I.A.TAIR Air intake pressure sensor When the engine is running -
39 - - - -
40 I.A.LSUP Front oxygen sensor signal When the engine is running -
41 - - - -
The clutch pump is turned off The power mode is in the state
42 I.F.CLUTCH -
(for MT vehicle) ON
Throttle position sensor power The power mode is in the state
43 O.V.THROTPOS -
supply ON
44 - - - -
NL-3 01/2016

Intake pressure sensor 5 V The power mode is in the state ES
45 O.V.MAINFOLD -
power supply ON
46 - - - -
NL-3 01/2016
Diagnostic System
ES
1. Instructions
When eliminating a fault on the vehicle equipped with
multi-channel on-board diagnostic system, the vehicle shall
IP12 OBD diagnostic interface be connected to the intelligent tester. And then various data
from EMS can be read.
The OBD specifications require that, the on-board computer
shall light the MIL on instrument panel when a fault is found
in any of the following components:
1) Emission control system/component
2) control components of drive train (which affect the
emission of vehicle)
3) In addition, the corresponding DTC will be recorded in
EMS memory. If the fault does not recur within 3
consecutive cycles, then the MIL will go out automatically,
but the DTC will still be recorded in EMS memory.
Notices:
Before measuring the resistance, don’t operate the
vehicle for at least 1 minute, and don’t operate the
power switch, any other switch or door. If the result
does not meet the specified value, maybe the
diagnostic interface fails. Repair or replace the harness
connector.
4) Connect the fault diagnostic scanner to the diagnostic
interface, and operate the power switch so as to set the
power mode in the state ON. If the display screen indicates
that there is communication error, then the problem is not in
the vehicle, but in the diagnostic scanner.
Notices:
If the communication is normal when the diagnostic
scanner is connected with another vehicle, please
check the diagnostic interface on original vehicle. If the
communication still can’t be built up when the
diagnostic scanner is connected with another vehicle,
maybe the problem exists in diagnostic scanner. Refer
to the user’s manual for the scanner or contact the
manufacturer.
Inspection/troubleshooting for DTC of 1. Check the DTC
1) Connect the fault diagnostic scanner to the diagnostic
components
interface.
2) Operate the power switch so as to set the power mode in
the state ON.
3) In accordance with the instructions given on display of
diagnostic scanner, read the value of DTC.
2. Clear DTC
1) Connect the fault diagnostic scanner to the fault
diagnostic interface.
2) Operate the power switch so as to set the power mode in
the state ON.
3) In accordance with the instructions given on display of
diagnostic scanner, delete the DTC.
NL-3 01/2016
Table of Active Test

Items displayed by the ES
Test component Control range Diagnosis descriptions
fault diagnostic scanner
The carbon canister valve Enable active carbon When the command is for the state ON, the
0%, 50%, 100%
controls the duty ratio. canister solenoid valve solenoid valve will be opened/closed within 3-5s.
Carry out this test only when the vehicle speed is
equal to zero the vehicle and vehicle speed
sensor has no fault.
State of oil pump relay Enable the fuel pump ON/OFF
The function can control fuel pump relay. The
fuel pump relay will connect/disconnect within
3-5s.
Note: Only in the conditions when the engine
coolant temperature is lower than 100 ℃（212℉)
and A/C switch is off, can this function test be
State of low-speed fan Enable low speed
ON/OFF executed.
relay cooling fan
This function can control low speed cooling fan
relay. When receiving the connection instruction,
the cooling fan will start 5s at low speed.
Note: Only in the conditions when the engine
coolant temperature is lower than 100℃（212℉)
and A/C switch is off, can this function test be
State of high-speed fan Enable high speed
ON/OFF executed.
relay cooling fan
This function can control high speed cooling fan
relay. When receiving the connection instruction,
the cooling fan will start 5s at high speed.
Throttle valve opening When the command is for the state ON, the
Open the throttle ON/OFF
degree throttle will be opened/closed within 3-5s.
When the command is for the state ON, the
Activate the intake
Control of intake camshaft 0%, 50%, 100% intake camshaft will be opened/closed within
camshaft
3-5s.
When the command is for the state ON, the
Control of exhaust Activate the exhaust
0%, 50%, 100% exhaust camshaft will be opened/closed within
camshaft camshaft
3-5s.
When the command is for state ON, the air
Activate the air
Air pressure solenoid valve 0%, 50%, 100% pressure solenoid valve will be opened/closed
pressure solenoid valve
within 3-5s.
This function can control the pressure release
Activate the pressure valve of turbocharger. When the function is
Pressure release valve of
release valve of ON/OFF activated on the basis of the command received,
turbocharger
turbocharger the turbocharger pressure release valve will be
opened
This function can control the coolant pump.
Activate the coolant When the function is activated on the basis of the
Coolant pump ON/OFF
pump command received, the coolant pump will be
opened
This function can control the flowrate control
Activate the flowrate valve. When the function is activated on the basis
Flow Control Valve ON/OFF
control valve of the command received, the flowrate control
valve will be opened
This function can control the idle control function.
Activate the idle control When the function is activated on the basis of the
Idle-speed control ON/OFF
valve command received, the idle control will be
activated
NL-3 01/2016
Table of DTCs
ES Diagnostic
Description Diagnosis procedure
Trouble Code
P000A64 Operating fault of intake VVT (delay)
Refer yo DTC P000A64 P000A77
P000A77 Operating fault of intake VVT (jamming)
P001013 P001277
P001013 The intake VVT circuit is broken
P001277 The locked position of intake camshaft is unreasonable
P001621 The intake camshaft position is advanced Refer to DTC P001621 P001622
P001622 The intake camshaft position is delayed P001678
P001678 The intake camshaft position runs out
P003013 Upstream oxygen sensor heating control circuit open
P003111 Upstream oxygen sensor heating control circuit short to ground
Upstream oxygen sensor heating control circuit short to power
P003212 P003212 P00531E
supply
P00531E Upstream oxygen sensor heating resistance not reasonable
P003613 Downstream oxygen sensor heating control circuit open
P003711 Downstream oxygen sensor heating control circuit short to ground
Downstream oxygen sensor heating control circuit short to power
P003812 P003812 P00541E
supply
P00541E Downstream oxygen sensor heating resistance not reasonable
P010525 Intake air pressure sensor signal with no change
P010629 Intake pressure sensor not reasonable Refer to DTC P010525 P010629
P010711 Air intake pressure sensor circuit voltage is too low P010711 P010812
P010812 Air intake pressure sensor circuit voltage is too high
P011100 Air intake temperature sensor signal circuit fails unexpectedly
P011317 The voltage of intake manifold temperature sensor is too high
P011216
P011216 The voltage of intake manifold temperature sensor is too low
P011600 Engine coolant temperature sensor signal not reasonable
P011817 The engine coolant temperature sensor circuit voltage is too high
P011716
P011716 The engine coolant temperature sensor circuit voltage is too low
P012129 Signal of electronic throttle position sensor 1 not reasonable
Signal circuit voltage of electronic throttle position sensor 1 is too
P012216 Refer to DTC P012129 P012216
low
P012317
P012317
high
NL-3 01/2016
Diagnostic
Trouble Code ES
P013029 Upstream oxygen sensor signal not reasonable
P013116 Upstream oxygen sensor signal circuit voltage is too low
P013217 Upstream oxygen sensor signal circuit voltage is too high Refer to DTC P013029 P013116
P013300 Upstream oxygen sensor aging P013217 P013300 P013413
P013413 Upstream oxygen sensor circuit signal fault P219500 P219600
P219500 Upstream oxygen sensor aging-signal constantly thick
P219600 Upstream oxygen sensor aging-signal constantly thin
P013629 Downstream oxygen sensor signal not reasonable
P013716 Downstream oxygen sensor signal circuit voltage is too low
P013817 Downstream oxygen sensor signal circuit voltage is too high
P013817 P014013 P227024
P014013 Downstream oxygen sensor circuit signal fault
P227123
P227024 Downstream oxygen sensor aging- signal constantly thin
P227123 Downstream oxygen sensor aging- signal constantly thick
Air/fuel ratio closed-loop control: offline test shows self-learning is
P017000
not reasonable
Air/fuel ratio closed-loop control: offline test shows thin mixture Refer to DTC P017000 P017100
P017100
after self-learning P017200
Air/fuel ratio closed-loop control: offline test shows thick mixture
P017200
after self-learning
P020113 Cylinder 1 injector control circuit open
P020213 Cylinder 2 fuel injector control circuit open Refer to DTC P020113 P020213
P020313 Cylinder 3 injector control circuit open P020313 P020413
P020413 Cylinder 4 injector control circuit open
P021900 The engine speed is too high Refer to DTC P021900
P022129 Signal of electronic throttle position sensor 2 not reasonable
P022216 Refer to DTC P022129 P022216
low
P022317
P022317
high
P026111 Control circuit of cylinder 1 fuel injector undervoltage
P026212 Control circuit of cylinder 1 fuel injector overvoltage
P026411 Cylinder 2 fuel injector control circuit voltage undervoltage
P026512 Cylinder 2 fuel injector control circuit voltage overvoltage
P026411 P026512 P026711
P026711 Cylinder No.3 fuel injector control circuit voltage undervoltage
P026812 P027011 P027112
P026812 Cylinder No.3 fuel injector control circuit voltage overvoltage
P027011 Cylinder No.4 fuel injector control circuit voltage undervoltage
P027112 Cylinder No.4 fuel injector control circuit voltage overvoltage
NL-3 01/2016
Diagnostic
ES Description Diagnosis procedure
Trouble Code
P030022 Multi-cylinder misfire
P030122 Cylinder No.1 Misfires
P030029 P030122 P030121
P030222 Cylinder No. 2 misfire
P030129 P030222 P030221
P030229 P030322 P030321
P030329 P030422 P030421
P030429
P030422 Cylinder 4 misfires
P032200 Speed sensor fault Refer to DTC P032200
P032700 The knock sensor circuit fails Refer to DTC P032700
P034178 Intake camshaft position sensor signals are unreasonable Refer to DTC P034178
The oxygen storing ability of three-way catalytic converter is
P042000 Refer to DTC P042000
reduced
P044413 Carbon canister control valve control circuit open
P045811 Carbon canister control valve control circuit voltage too low
P045912
P045912 Carbon canister control valve control circuit voltage too high
P048013 Cooling fan relay control circuit open (low speed)
P048113 Cooling fan relay control circuit open (high speed)
P069111 Cooling fan relay control circuit short to ground (low speed)
P069212 Cooling fan relay control circuit short to power supply (low speed)
P069311 Cooling fan relay control circuit short to ground (high speed)
Cooling fan relay control circuit short to power supply (high Refer to DTC P069311 P069412
P069412
speed)
The signal of vehicle speed sensor is incorrect. Please refer to
DTC P050129
P050600 Controlled idling speed is lower than the target idling speed
P050700 Controlled idling speed is higher than the target idling speed
P055716 The voltage of brake vacuum pressure sensor signal is too low -
NL-3 01/2016
Diagnostic Trouble
Code ES
P055817 The voltage of brake vacuum pressure sensor signal is too high -
P056000 System battery voltage signal is not reasonable
Refer to DTC 56000 P056200
P056200 System battery voltage is too low
P056300
P056300 System battery voltage is too high
P057129 The signal of two brake switches is not synchronous
Refer to DTC P057129 P05711C
P05711C The brake lamp switch signal circuit fails
Any cruise control button is seized or has been pressed down
U040582
and held for too long time (for AT vehicle) Please refer to “Cruise system”
P057900 The cruise circuit fails (for AT vehicle)
P060100 The calculation of checksum for EEPROM fails
P060612 The voltage of ambient pressure sensor signal is too high
P060611 The voltage of ambient pressure sensor signal is too low
P060612 P060443 P060543
P060443 Electronic control unit RAM fault
P060543 Electronic control unit ROM fault
Fault of electronic throttle security monitoring function (second
P060694
layer torque monitoring fault)
P060692 The second-level safety monitoring fails (speed sensor)
The safety monitoring function for electronic throttle fails (The
P060664
second-level load signal monitoring fails)
P060661
second-level ignition angle signal monitoring fails)
Fault of electronic throttle security monitoring function (ECU
P060667
erroneous response monitoring fault)
Fault of electronic throttle security monitoring function (AD
P060696
converter monitoring fault)
P06061C P060664 P060661 P060667
second-level throttle body signal monitoring fails)
P060696 P06061C P060655
Fault of electronic throttle security monitoring function
P060655 P060600 P060662 P060663
(deformation code monitoring fault)
P060648 P060647 P060675
P060600 The second-level safety monitoring fails (safety oil cutoff)
P060649
The second-level safety monitoring fails (electronic accelerator
P060662
pedal)
P060663 Fault of electronic throttle security monitoring function
P060648
(monitoring erroneous response fault)
P060647
(monitoring model feedback fault)
Fault of electronic throttle security monitoring function (path test
P060675
off fault)
P060649
(monitoring model inquiry fault)
NL-3 01/2016
Diagnostic Trouble
ES Description Diagnosis procedure
Code
P062713 The fuel pump relay control circuit open
P062811 Fuel pump relay control circuit short to ground or open
P062912
P062912 Fuel pump relay control circuit short to power supply
P064513 A/C compressor replay control circuit open
P064611 A/C compressor replay control circuit short to ground
P064712
P064712 A/C compressor replay control circuit short to power supply
Refer to “Engine Fault Indicator
Lamp (MIL)/immediate repair
P070000 The external request MIL fails
indicator lamp of vehicle is not
working properly”.
P070400 The signal of clutch pedal switch is incorrect (for MT vehicle) Refer to DTC P070400
P068881 Fault of main relay output voltage signal Refer to DTC P068881
P133600 Safety monitor torque of electronic throttle limits the function
P210612 Power drive level fault of electronic throttle (short)
Power drive level fault of electronic throttle (overheat or Refer to DTC P133600 P210612
P210619
overcurrent) P210619 P210692 P210613
P210692 Power drive level fault of electronic throttle (SPI bus or signal) P210629
P210613 Power drive level fault of electronic throttle (open)
P210629 Load monitoring fault
P154500 The position of electronic throttle is incorrect
P154522 The PID position control for electronic throttle fails
P154521 The PID position control for electronic throttle fails
P155900 The self-learning for electronic throttle fails
The repeated self-learning for mechanical bottom dead center Refer to DTC P154500 P154522
P155929
of electronic throttle fails P154521 P155900 P155929
System pressure cannot meet the requirements for electronic P156400 P156500 P156800
P156400
throttle self-learning P157900
The initial self-learning for bottom dead center of electronic
P156500
throttle fails
P156800 The check on electronic throttle spring fails
P157900 Electronic throttle self-learning requirement is not met
P161000 The SecretKey of EMS is the default value
P161100 The SecurityCode of EMS is the default value
The certification reply of PEPS is incorrect, and the anti-theft Refer to DTC P161000 P161100
P161200
certification fails P161200 P161300 P161400
P161300 EMS does not receive the certification reply from PEPS
P161400 The transmission of certification message fails
P208811 Intake VVT valve circuit is short to ground.
P208912 Intake VVT valve circuit is short to power supply
NL-3 01/2016
Diagnostic Trouble
Code ES
Electronic accelerator pedal position sensor 1 signal
P212216
undervoltage
P212317
overvoltage
P212716
undervoltage
P212817
overvoltage
The signal of electronic accelerator pedal position sensor is
P213800 unreasonable (test on displacement of pedal when the engine is
running at a speed close to neat idle) Refer to DTC P213800 P213829
Electronic accelerator pedal position sensor signal
P213829
unreasonable
The air fuel ratio close loop control self-learning value is beyond
P217700
the upper limit
P217800
the lower limit Refer to DTC P217700 P217800
The air fuel ratio close loop control self-learning value is beyond P218700 P218800
P218700
the upper limit (low load area)
P218800
the lower limit (low load area)
U007300 CAN communication related diagnosis
U010182 The counter of TCU message 0x118 is wrong
U010183 The check digit of TCU message 0x118 is wrong
U010187 The communication between ECU and TCU is lost
U010387 The communication with BCM is lost or the signal is abnormal
U012282 The counter of ESP message 0x025 is wrong Refer to DTC U007300 U010182
U012283 The check digit of ESP message 0x025 is wrong U010183 U010387 U012282
U012287 The communication with ESP controller fails U012283 U012287 U013187
U013187 The communication with BCM is lost or the signal is abnormal U014087 U014187 U015182
U014087 The communication with BCM is lost or the signal is abnormal U015183 U015187 P168386
U014187 The communication with HVAC is lost or the signal is abnormal
U015182 The counter of ACU message 0x268 is wrong
U015183 The check digit of ACU message 0x268 is wrong
P168386 Airbag signal unreasonable
U015187 Communication with ACU is interrupted
U300385 The battery voltage is too high
Refer to DTC U300385 U300384
U300384 The battery voltage is too low
NL-3 01/2016
DTC P000A64 P000A77 P001013 P001277

ES
1. Fault Code Description
DTC Fault code description
The intake air camshaft position (CMP) actuator is connected to the intake air camshaft and operated via hydraulic pressure.
The hydraulic pressure is provided by the engine fuel pump to alter the intake air camshaft's angle relative to CKP. The intake
VVT solenoid valve is supplied with power by the main replay. ECM controls grounding via pulse width modulation signal. It
thus controls the engine oil flow to the camshaft position actuator. The engine oil pressure makes the safety slide valve inside
the camshaft position actuator fixed to the front of the camshaft move. When the safety slide valve moves, the engine oil is
soaked into the camshaft position actuator to turn the camshaft. Therefore, the valve timing which is most suitable for the state
of engine will be provided, so as to improve the torque at any speed, enhance the fuel economy and reduce the exhaust gas.
2. Fault code setting and faulty position:
DTC setting condition
DTC NO. DTC detection strategy Fault position
(control strategy)
- In every VVT diagnosis& test
cycle, the difference between
maximum position angle
P000A64
reached by VVT and position
angle of VVT at beginning of
test is more than 3
- Connection circuit of intake
- In every VVT diagnosis& test
VVT
cycle, the difference between - VVT solenoid valve
maximum position angle - VVT actuator assembly
P000A77
reached by VVT and position - Solenoid valve circuit
angle of VVT at beginning of - EMS
test is less than 3
P001013 - The circuit is open
- The difference between
- During startup, whether the actual angle of intake VVT
P001277 intake VVT is at the locked during startup and default
position position angle (start time) is)
more than 10 KW
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3. Circuit diagram:
ES
Main Relay
ER05
Variable valve timing

valve (intake )
4. Diagnostic Steps:
Notice: prior to executing this diagnosis procedure, observe the data table of the fault diagnostic scanner and
analyze data accuracy for quick troubleshooting!
Check and make sure that there is no fault code of control system, except for P000A64, P000A77 and
Step 1
P001013.
(a) Connect the fault diagnostic scanner to the diagnosis
interface.
(b) Operate the power switch so as to set the power mode in
the state ON.
(c) Press the power supply button of the fault diagnostic
scanner.
(d) Select the following menu: engine/reading fault code.
(e)Read DTC codes.
(f) Confirm that there is no other fault code
Displayed DTC Go to Step
DTC other than P000A64,
No
P000A77, P001013
P000A64, P000A77,
Yes
P001013
No Please refer to “Table of fault codes”
Yes
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Step 2 Check the following items.

ES (a) Whether the engine viscosity and cleanness are normal.
(b) Observe the engine oil level and it shall be within the
operation scope.
(c) Whether the engine oil is not timely replaced, with
additive or the viscosity is not correct.
Replace the engine oil and the engine

No oil filter element, if necessary, wash
the engine lubrication system.
Yes
Step 3 Check whether the timing system is normal and whether the OCV actuator is normal.
(a) Please refer to the section about timing chain.
(b) Check whether the OCV actuator assembly is normal.
(c) Confirm whether the above parts are normal.
Replace the engine oil and the engine

No oil filter element, if necessary, wash
the engine lubrication system.
Yes
Step 4 Measure the resistance of the OCV solenoid valve assembly.

to OFF state.
(b) Disconnect the battery negative cable.
(c) Disconnect the OCV solenoid valve harness connector
EG15.
(d) Connect two conductors to terminals 1 and 2 of OCV
solenoid valve.
(e) Measure the resistance between terminals 1 and 2 of
OCV solenoid valve.
Standard value: 7.5-8.5Ω at 20℃ (68℉)
(f) Remove the OCV solenoid valve assembly, connect the
terminals 1 and 2 to positive and negative poles of battery
respectively, and check whether the OCV solenoid valve
works normally; if the OCV solenoid valve works
abnormally, just clean up the OCV solenoid valve, and
please refer to the section about OCV valve; reconnect the
battery, and check whether the OCV solenoid valve works
normally.
(g) Install the solenoid valve, and connect the OCV solenoid
valve harness connector.
(h) Confirm whether the resistance meets the standard
value, and confirm whether the OCV solenoid valve works
normally after being cleaned up.
Replace the OCV solenoid valve

No assembly and go to Step 14.
Yes
Step 5 Measure OCV solenoid valve power supply.
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to OFF state. ES
(b) Disconnect the OCV solenoid valve harness connector
EG15 variable valve timing valve (intake)
EG15.
Wiring harness connector
(c) Operate the starter switch to turn the power supply mode
to ON state.
(d) Measure the voltage between terminal 1 of the harness
connector EG15 and reliable grounding.
Standard voltage: 11~14 V
(e) Re-connect the OCV solenoid valve harness connector
EG15.
(f) Confirm whether the voltage meets the standard value.
No Go to step 11.
Yes
Step 6 Check the OVC solenoid valve fuse EF10.

Engine compartment fuse relay box

to OFF state.
(b) Pull out the OVC solenoid valve fuse EF10, and check
whether the fuse has blown out.
Rated capacity of fuse: 15A
No Replace the fuse, so as to eliminate

the fault.
Yes
Step 7 Check the power circuit of OVC solenoid valve.

to OFF state.
EG15 Variable valve timing valve (intake) harness (b) Disconnect the OCV solenoid valve harness connector
connector EG15.
(c) Measure the resistance between solenoid valve fuse
EF10 and terminal 1 of OVC solenoid valve connector
EG15.
Standard resistance value: Less than 1 Ω
No Go to step 9.
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Yes
ES Step 8 Check where there is voltage on pins 30 and 85 of main relay ER05.
Engine compartment fuse relay box to OFF state.
(c) Remove the main relay ER05, and connect the negative
cable of battery.
(d) Operate the power switch so as to set the power mode in
the state ON.
(e) Measure the voltage between pins 30 and 85 of main
relay ER05 and reliable grounding point.
Standard voltage: 11~14 V
(f) Confirm whether the voltage meets standard value
Replace the main relay ER05, so as to

No
eliminate the fault.
Yes
Step 9 Check the power circuit of main relay ER05.

to OFF state.
Connect the EG38 to electrical box in engine compartment. (c) Remove main relay ER05.
(d) Measure the resistance between B+ of battery and the
circuit between power terminal of main relay ER05 and
terminal 1 of EG38.
Standard resistance: less than 1 Ω.
No Repair or replace the harness, so as to

Yes
Step 10 Check the control circuit of main relay ER05.
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Engine compartment fuse, relay box to OFF state. ES
(b) Disconnect the negative battery cable.
(c) Disconnect the EMS harness connector CA45.
(d) Remove main relay ER05.
(e) Measure the resistance value between the terminal 5 of
EMS harness connector CA45 and the port 86 of main relay
ER05.
(f) Confirm whether the resistance meets the standard value.
No Overhaul or replace the harness.
CA45 Engine management system harness connector
Yes
Step 11 Check the control circuit of intake variable valve timing valve.
to OFF state.
(b) Disconnect the harness connector EG15 of intake variable
EG15 Variable valve timing valve (intake) harness valve timing valve.
(c) Disconnect engine EMS harness connector EG24.
connector
(d) Measure the resistance value between the terminal 2 of
EG15 and the terminal 7 of EG24. As for standard value,
please refer to the table below.
(e) Measure the resistance value between terminal 2 of
exhaust VVT valve harness connector EG15 and grounding
with a multimeter, the standard valve is shown in table below.
(f) Turn ignition switch to “ON” position (note: connectors
EG24 and EG15 must be disconnected at this moment), and
measure voltage value between terminal 2 of harness
connector EG15 of exhaust variable valve timing valve to
grounding with multimeter. The standard value is shown in
table below.
Tester connection Standard value
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Resistance between
Less than 1 Ω
ES EG15(2) and EG24(7)
EG24 Engine management system harness connector 2 EG15(2)- Grounding
10kΩ or higher
resistance
EG15(2)- Grounding
0V
voltage
(g) Measure whether the value meets the standard value.
No Repair or replace the harness.
Yes
Step 12 Check the power supply and grounding of EMS.

(a) Check whether EMS power supply circuit is normal.
(b) Check whether EMS grounding circuit is normal.
No Repair fault position.
Yes
Step 13 Replace the EMS.

(a) Replace the EMS, and carry out the learning for engine
speed sensor.
Next Step
Step 14 Determine whether the DTC is saved again via the fault diagnostic scanner.
(a) Connect fault diagnostic scanner to diagnostic test
interface.
(b) Operate the starter switch to turn the power supply mode
to ON state.
(c) Clear DTCs.
(d) Start and run the engine at idle speed to warm up the
engine for 5min at least.
(e) Vehicle road test for 10min at least.
(f) Read the DTC of the control system again and confirm the
system has no DTC output.
Intermittent fault, refer to "Check of
No intermittent fault for intermittent fault".
Yes
Step 15 Diagnosis is finished.
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DTC P001621 P001622 P001678

ES
1. DTC description
DTC Fault description
P001621 The intake camshaft position is advanced
P001622 The intake camshaft position is delayed
P001678 The intake camshaft position runs out
The engine control module (EMS) uses speed (CKP) sensor and camshaft position (CMP) sensor pulse signal to detect the
correlation between crankshaft position and camshaft position. When the crankshaft rotates, it drives speed sensor signal disc
to rotate together. The teeth on the signal disc will cut the magnetic line of force of the sensor. This change in the magnetic flux
will produce the output signal voltage of certain frequency at both the sensor coil ends, which is then output to the engine
control module (EMS). The output signals can represent the speed and position of the crankshaft. Camshaft position sensor is
installed on the rear right side of the cylinder head. When the crankshaft rotates, it drives the camshaft and the signal wheel on
the camshaft to rotate together through the timing chain. The camshaft rotates one revolution when the crankshaft rotates
every two revolutions, while the camshaft position sensor generates a voltage which is output to EMS under the action of the
signal wheel.
2. DTC set and fault position:
DTC setting condition (control
DTC No. DTC detection strategy Fault position
strategy)
- Difference between learned
P001621
- Difference between value and set value <-24KW - 1. Timing chain tensioner
synchronized learned value - Difference between learned - 2. Timing chain
P001622
and reference value of value and set value >24 KW - 3. Crankshaft sprocket
crankshaft and camshaft - Difference between learned - 4. EMS
P001678
value and set value >20KW
NL-3 01/2016
3. Circuit diagram:
ES
Engine speed
sensor
Main relay
ER05
Phase sensor
4. Diagnostic steps:
Notice: Prior to executing this diagnostic procedure, observe the data list of the fault diagnostic scanner and analyze
data accuracy for quick troubleshooting!
Step 1 Check the conditions of engine oil.
(a) Whether the engine oil viscosity and cleanliness are
normal.
(b) Check the engine oil level and it shall be within the
working scope.
(c) Check engine oil pressure, if engine oil pressure is too
low, you should identify the causes and repair engine
lubrication if necessary.
(d) Whether the engine oil is not timely replaced, with additive
or the viscosity is not correct.
(e) Confirm that the above are normal.
Replace the engine oil and the oil filter
No element, if necessary, clean the engine
lubricating system.
Yes
Step 2 Check valve timing system.

(a) Check whether the camshaft, crankshaft and timing chain
are correct.
(b) Check whether the timing chain tension is normal.
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No Go to step 6.
ES
Yes

No Repair the fault position.
Yes

(a) Replace the EMS, refer to “Engine ECU”.
Next Step
Step 5 Adjust and maintain mechanical timing system.

(a) Inspect the vehicle maintenance records to see whether
the recent repairs involve the timing chain, camshaft or
crankshaft, and whether engine oil change interval is too
long.
(b) Check whether the engine oil is contaminated or contains
impurities, and find out the cause. Check whether the timing
chain tensioner works normally and whether the fuel inlet is
blocked up, and carry out replacement if necessary. Please
refer to “Timing chain”. Remove timing chain, camshaft
position actuator, and sprocket. Refer to "Timing chain".
Remove intake camshaft OCV solenoid valve strainer, check
the strainer and oil channels for impurities, clean the strainer
and replace it if necessary. Please refer to "OCV valve".
Next Step
interface.
to ON state.
(c) Clear DTCs.
engine for 5 min at least.
(e) Vehicle road test at least 10 min.
Yes
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DTC P003013 P003111 P003212 P00531E

1. DTC description:
ES
P003212 Upstream oxygen sensor heating control circuit short to power supply
P00531E Upstream oxygen sensor heating internal resistance is not reasonable
The function of the oxygen sensor is to convert the difference of the oxygen ion condensation inside and outside the sensing
ceramic tube into voltage signal output. When the sensing ceramic tube's temperature reaches 350℃(662 °F), it will own
solid electrolyte's characteristics. The oxygen ions can pass through the ceramic tube freely because of its special texture.
The concentration difference can be changed into potential difference and then forms electrical signal output just due to this
characteristic. If the gas mixture is a little richer, the concentration difference of the oxygen ions inside and outside the ceramic
tube is higher, the potential difference is higher, a lot of oxygen ions move from the inside to the outside, and the output voltage
is higher (nearly 800mV-1000mV); if the gas mixture is a little thinner, the concentration difference of the oxygen ions inside
and outside the ceramic tube is lower, the potential difference is lower, only a small quantity of oxygen ions move from the
inside to the outside, and the output voltage is lower (nearly 100 mV). The signal voltage mutates near the theoretical
equivalent air-fuel ratio （λ=1）. The working voltage of the heating coil of the upstream oxygen sensor is provided by EMS
controlled main relay, i.e. when the starter switch turns to “ON”, the sensor terminal 1 of the harness connector EG05 has
battery voltage. EMS controls the heater working duration via terminal 9 of harness connector EG24.
DTC setting conditions
(control strategy)
P003013 - Open circuit
P003111 - Circuit short to ground
- Hardware circuit check
- Circuit short to power - 1. Sensor circuit
P003212
supply - 2. Sensor
- Monitor the internal - 3. EMS
- The resistance is higher
P00531E resistance of front oxygen
than threshold value
sensor
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3. Circuit diagram:
ES
Main relay
ER05
Front oxygen Rear oxygen

sensor sensor
Step 1 Preliminary check.
Check whether the following conditions are available that
affect the working of the heated oxygen sensor:
(a) Exhaust system leakage or blockage.
(b) Heated oxygen sensor connector incoming with water.
(c) Connect the diagnosis instrument, and check whether
there is any fault code other than P003013, P003111,
P003212 and P00531E.
Yes Refer to "Table of DTC".
No
Step 2 Check the upstream oxygen sensor heater resistance value.
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to OFF state.
ES (b) Disconnect the negative battery cable.
(c) Disconnect the upstream oxygen sensor harness
connector EG05.
(d) Measure the heater resistance value between terminals 1
and 2 of the upstream oxygen sensor.
(e) Measure the resistance value between the terminals 1
and 2 of upstream oxygen sensor.
Standard resistance value: 1~6 Ω
(f) Connect the upstream oxygen sensor harness connector.
(g) Confirm whether the resistance value meets the standard
value.
No Replace the upstream oxygen sensor.
Yes
Step 3 Check the control circuit of upstream oxygen sensor.
to OFF state.
(b) Disconnect upstream oxygen sensor harness connector
EG05.
EG05 Upstream oxygen sensor harness
connector (c) Disconnect the engine EMS harness connector EG24.
(e) Use a multimeter to measure the resistance value
between the terminal 2 of upstream oxygen sensor harness
connector EG05 and the grounding. As for standard value,
measure voltage between terminal 2 of harness connector
EG15 of upstream oxygen sensor to grounding with
EG24 Engine management system harness
connector 2
multimeter. The standard value is shown in table below.
Resistance between
Less than 1 Ω
EG05(2) and EG24(9)
EG05(2)- Grounding
10kΩ or higher
resistance
EG05(2)- Grounding
0V
voltage
Yes
Step 4 Check the heater fuse EF11 of the upstream oxygen sensor.
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(b) Pull out the upstream oxygen sensor heater fuse EF11,
and check whether the fuse has blowout.
Replace the fuse, so as to eliminate the
Yes fault.
No
Step 5 Check the heater power supply circuit of the upstream oxygen sensor.
to OFF state.
EG05 Upstream oxygen sensor harness (c) Disconnect the upstream oxygen sensor harness
connector
connector EG05.
(d) Measure the resistance value between upstream oxygen
sensor harness connector EG05 terminal 1 and fuse EF11,
and the standard value is shown in the table below.
(e) Measure resistance between terminal 1 of upstream
oxygen sensor harness connector EG05 and reliable
grounding; the standard value is shown in the following table.
(f) Operate the starter switch to turn the power supply mode
to ON state. Measure voltage between terminal 1 of upstream
oxygen sensor harness connector EG05 and reliable
grounding; the standard value is shown in the following table.
EG05(1)- The fuse EF11 Less than 1 Ω
EG05(1)- Grounding
10kΩ or higher
resistance
EG05(1)- Grounding
11~14V
voltage
Yes
Step 6 Check where there is voltage on pins 30 and 85 of main relay ER05.
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ES Engine compartment fuse relay box
to OFF state.
battery cable.
the state ON.
Standard voltage value: 11~14 V
(f) Confirm whether the voltage meets standard value.
No
Yes
Engine compartment fuse, relay box
to OFF state.
EMS harness connector CA45 and the socket 86 of main
relay ER05.
Standard resistance value: less than 1 Ω
(e) Confirm whether the voltage meets standard value.
CA45 Engine management system harness

connector 1
Yes
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(b) Check whether EMS grounding circuit is normal. ES
Yes
(a) Replace the EMS.
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes
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DTC P003613 P003711 P003812 P00541E

1. DTC description:
ES
P003812 Downstream oxygen sensor heating control circuit short to power supply
P00541E Downstream oxygen sensor heating internal resistance is not reasonable
ceramic tube into voltage signal output. When the sensing ceramic tube's temperature reaches 350℃(662 °F), it will own solid
electrolyte's characteristics. The oxygen ions can pass through the ceramic tube freely because of its special texture. The
concentration difference can be changed into potential difference and then forms electrical signal output just due to this
characteristic. If the gas mixture is a little richer, the concentration difference of the oxygen ions inside and outside the ceramic
tube is higher, the potential difference is higher, a lot of oxygen ions move from the inside to the outside, and the output voltage
is higher (nearly 800mV-1000mV); if the gas mixture is a little thinner, the concentration difference of the oxygen ions inside
and outside the ceramic tube is lower, the potential difference is lower, only a small quantity of oxygen ions move from the
inside to the outside, and the output voltage is lower (nearly 100 mV). The signal voltage mutates near the theoretical
equivalent air-fuel ratio （λ=1）. The working voltage of the heating coil of the downstream oxygen sensor is provided by EMS
controlled main relay, i.e. when the starter switch turns to “ON”, the sensor terminal 1 of the harness connector EG04 has
battery voltage. EMS controls the heater working duration via terminal 48 of harness connector CA45.
(control strategy)
P003711 - Circuit short to ground
- Hardware circuit check
- Circuit short to power - 1. Sensor circuit
P003812
supply - 2. Sensor
- Monitor the internal - 3. EMS
- The resistance is higher
P00541E resistance of rear oxygen
than threshold value
sensor
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3. Circuit diagram:
ES
Main relay
ER05
sensor sensor
(c) Connect the diagnosis instrument, and check whether
there is any fault code other than P003613, P003711,
P003812 and P00541E.
No
Step 2 Check the downstream oxygen sensor heater resistance value.
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to OFF state.
(c) Disconnect downstream oxygen sensor harness
connector EG04.
(d) Measure the heater resistance value between terminals 1
and 2 of the downstream oxygen sensor.
(e) Measure the resistance value between the terminals 1
and 2 of downstream oxygen sensor.
(f) Connect the upstream oxygen sensor harness connector.
value.
Replace the downstream oxygen
No sensor.
Yes
Step 3 Check the control circuit of downstream oxygen sensor.
to OFF state.
(b) Disconnect downstream oxygen sensor harness
connector EG04.
EG04 Downstream oxygen sensor harness
(c) Disconnect engine EMS harness connector CA45.
connector
EG04 and the terminal 48 of CA45. As for standard value,
(e) Use a multimeter to measure the resistance value
between the terminal 2 of downstream oxygen sensor
harness connector EG04 and the grounding . As for standard
value, please refer to the table below.
(f) Set the power mode in the state ON (Note: the CA45 and
EG04 connectors shall be disconnected), and use a
multimeter to measure the voltage value between the
terminal 2 of downstream oxygen sensor harness connector
EG04 and the grounding. As for standard value, please refer
connector 1
to the table below.
Resistance between
Less than 1 Ω
EG04(2) and CA45(48)
EG04(2)- Grounding
10kΩ or higher
resistance
EG04(2)- Grounding
0V
voltage
Yes
Step 4 Check the heater fuse EF11 of downstream oxygen sensor.
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Engine compartment fuse, relay box ES
to OFF state.
(b) Pull out the downstream oxygen sensor heater fuse EF11,
and check whether the fuse has blowout.
Replace the fuse, so as to eliminate the
Yes fault.
No
Step 5 Check downstream oxygen sensor heater power supply circuit.
to OFF state.
EG04 Downstream oxygen sensor harness (c) Disconnect downstream oxygen sensor harness
connector
connector EG04.
(d) Measure the resistance value between downstream
oxygen sensor harness connector EG04 terminal 1 and fuse
EF11, and the standard value is shown in the table below.
(e) Measure resistance value between terminal 1 of
downstream oxygen sensor harness connector EG04 and
reliable grounding; the standard value is shown in the
following table.
to ON state. Measure voltage value between terminal 1 of
reliable grounding; the standard value is shown in the
following table.
EG04(1)- The fuse EF11 Less than 1 Ω
EG04(1)- Grounding
10kΩ or higher
resistance
EG04(1)- Grounding
11~14V
voltage
Yes
Step 6 Check whether there is voltage on sockets 30 and 85 of main relay ER05.
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ES to OFF state.
battery cable.
the state ON.
(e) Measure the voltage between sockets 30 and 85 of main
No
Yes
to OFF state.
relay ER05.

connector 1
Yes
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Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes
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DTC P010525 P010629 P010711 P010812

1. DTC description:
ES
P010525 Intake air pressure sensor signal with no change
P010629 Intake air pressure sensor is not reasonable
P010711 Intake air pressure sensor circuit voltage is too low
P010812 Intake air pressure sensor circuit voltage is too high
Intake air pressure sensor responds to the pressure variation inside intake manifold. Pressure varies according to the engine
load. The sensor circuit is composed of the following:
• 5V reference voltage circuit.
• Low reference voltage circuit.
• Sensor signal circuit.
EMS provides low reference voltage for terminal 4 of the sensor harness connector EG17 via terminal 27 of harness connector
EG24. and, provides 5 V reference voltage through EG24 terminal 38 to EG17 terminal 2. The sensor provides a signal to the
terminal 45 of EMS harness connector EG24 via terminal 3 of the signal circuit EG17. The signal is related to the intake
manifold pressure variation. When the intake pressure is low, EMS detected signal voltage will be low, e.g. during idle speed or
deceleration. When the intake pressure is higher, EMS detected signal voltage shall be higher, e.g. when the starter switch
connects and the engine is shut down or the throttle is fully opening. The sensor is also used to determine atmospheric
pressure. When the starter switch connects and the engine closes, the condition will occur. As long as the engine running
under the throttle fully opening, the atmospheric pressure reading will also update. EMS detects sensor signal to determine
whether the voltage exceeds the normal range.
(control strategy)
- Signal check: The pressure
- The pressure drop after the
P010525 does not drop after the
engine is started <20hpa
engine is started
- Pressure indicated on
pressure sensor (which - 1. Sensor circuit
P010629 - The signal is unreasonable
depends on speed of engine - 2. Sensor
and opening of throttle) - 3. EMS
-Circuit check, exceeding the -Pressure sensor voltage <
P010711
lower limit 0.20V
-Circuit check, exceeding the - Voltage of pressure
P010812
upper limit sensor >4.88 V
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3. Circuit diagram:
ES
Main relay
ER05
Intake temperature
and pressure
sensor
Notice: Connecting the 5V reference voltage circuit of the intake temperature and pressure sensor with other vehicle
components is strictly prohibited. Or else, it will damage the sensor and EMS.
Check whether the following conditions are available:
(a) Sensor housing damage, vacuum tubes broken.
(b) Sensor seal damage.
(c) Sensor looseness or incorrect installation.
(d) Sensor vacuum tube blockage.
Yes Repair or replace faulted components.
No
Step 2 Measure 5V reference voltage of intake pressure sensor.
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ES to OFF state.
(b) Disconnect the intake temperature and pressure sensor
EG17 Intake pressure and temperature sensor
harness connector eg17.
harness connector
to ON state.
(e) Measure voltage between terminal 2 of intake
temperature and pressure sensor harness connector EG17
and reliable grounding.
Standard voltage value: 5 V
(e) Connect intake temperature and pressure sensor harness
connector eg17.
No Go to step 6.
Yes
Step 3 Measure the sensor signal circuit.
(a) Connect the intake temperature and pressure sensor

harness connector eg17, and turn the digital multimeter to DC
voltage position, with the black probe reliably grounded and
the red probe connected to the terminal 1.
harness connector
(b) Start the engine.
(c) Under the condition that the engine is running at idle
speed, measure the voltage between terminal 1 and reliable
grounding point.
(d) Under the engine empty load state, slowly open the
throttle, and observe whether the voltage at terminal 1
changes.
(e) Quickly open the throttle, to observe whether the voltage
at terminal 1 can instantly reach 4V and then drop to 1.5 V.
(f) Confirm whether the above measurement is normal.
No Go to step 7.
Yes
Step 4 Measure the intake temperature and pressure sensor grounding circuit.
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to OFF state. ES
(c) Disconnect the intake temperature and pressure sensor
harness connector
harness connector EG17.
(d) Operate the starter switch to turn the power supply mode
to ON state.
(e) Measure resistance between terminal 4 of intake
(f) Connect intake temperature and pressure sensor harness
connector EG17.
(g) Confirm whether the measured value meets the standard
value.
No Go to step 8.
Yes
Step 5 Replace intake pressure and temperature sensor.
(h) Replace the intake pressure/temperature sensor. Please

refer to “Intake pressure/temperature sensor”.
No Go to step 11.
Yes
Step 6 Check the circuit between intake temperature and pressure sensor and EMS.
NL-3 01/2016
to OFF state.
ES
harness connector (c) Disconnect the intake temperature and pressure sensor
harness connector EG17 and EMS harness connector EG24.
(d) Measure the resistance value between terminal 2 of intake
and terminal 38 of EMS harness connector EG24. Check
whether any circuit is open. Otherwise, repair the fault
position. The standard value is given in the table below.
(e) Measure resistance value between terminal 2 of intake
and reliable grounding. Check whether any circuit is short to
ground. Otherwise, repair the fault position. The standard
EG24 engine management system harness
connector 2 value is given in the table below.
(f) Measure voltage value between terminal 2 of intake
power supply. Otherwise, repair the fault position. Refer to
the table below for standard values.
Resistance between
Less than 1 Ω
EG17(2) and EG24(38)
EG17(2)- Grounding
10kΩ or higher
resistance
EG17(2)- Grounding
0V
voltage
Yes
Step 7 Check the intake temperature and pressure sensor signal circuit.
to OFF state.
harness connector (c) Disconnect the intake temperature and pressure sensor
harness connector EG17 and EMS harness connector EG24.
(d) Measure the resistance between terminal 1 of intake
position. Refer to the table below for standard values.
ground. Otherwise, repair the fault position. Refer to the table
below for standard values.
NL-3 01/2016
(f) Measure voltage between terminal 1 of intake temperature

EG24 Engine management system harness and pressure sensor harness connector EG17 and reliable
connector 2
grounding. Check whether any circuit is short to power ES
supply. Otherwise, repair the fault position. Refer to the table
Resistance between
Less than 1 Ω
EG17(1) and EG24(21)
EG17(1)- Grounding
10kΩ or higher
resistance
EG17(1)- Grounding
0V
voltage
Yes
Step 8 Check sensor grounding circuit.
to OFF state.
EG24 engine management system harness
connector 2
(d) Disconnect the EMS harness connector EG24.
(e) Measure the resistance between terminal 4 of intake
position.
(f) Measure voltage between terminal 4 of intake temperature
and pressure sensor harness connector EG17 and reliable
grounding. Check whether any circuit is short to power
supply. Otherwise, repair the fault position.
harness connector Tester connection Standard value
EG17(4)-EG24(27)
Less than 1 Ω
resistance
EG17(4)- Grounding
0V
voltage
Yes
Step 9 Check the power circuit of EMS.
NL-3 01/2016

ES Handle fault of EMS power supply
No
circuit.
Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes
NL-3 01/2016
DTC P011100 P011317 P011216

1. Fault code description:
ES
P011100 Air intake temperature sensor signal circuit fails unexpectedly
P011317 The voltage of intake manifold temperature sensor is too high
P011216 The voltage of intake manifold temperature sensor is too low
The sensor is integrated in the engine intake temperature and pressure sensor to measure the temperature of air entering the
engine. EMS provides EMS internal low reference voltage circuit to terminal 4 of sensor harness connector EG17 through
terminal 27 of harness connector EG24, and also provides 5 V reference voltage to terminal 2 of sensor EG17 through
terminal 38 of EG24. When the intake temperature and pressure sensor is in cold state, the thermal sensitive resistance for
measuring temperature is higher. When the air temperature increases, the resistance decreases. When the resistance is
higher, EMS will detect the voltage of the signal circuit is higher. With the reduced resistance, the voltage of intake temperature
signal circuit detected by EMS also reduces.
(control strategy)
- The measured value of
- The measured value of intake manifold temperature
intake manifold temperature sensor depends on
sensor is too high, and temperature of engine
P011100 exceeds the threshold value - In a driving cycle, the
- The temperature of intake difference between
manifold is abnormal and maximum and minimum
remains unchanged temperature of intake
manifold is <5℃ - 1. Sensor circuit
- The leaping voltage of - 2. Sensor
- The leaping voltage of
intake manifold temperature - 3. EMS
intake manifold temperature
sensor
sensor >0.2979V
P011317 - The voltage exceeds the
- The voltage of intake
upper limit, and there is short
manifold temperature
circuit or open circuit to
sensor >4.5020V
power supply
- The voltage exceeds lower - The voltage of intake
P011216 limit and there is short circuit manifold temperature
to the earth. sensor >1.0010 V
NL-3 01/2016
3. Circuit diagram:
ES
Main relay
ER05
Intake temperature
and pressure
sensor
Notice: Connecting the 5V reference voltage circuit of the intake temperature and pressure sensor with other vehicle
components is strictly prohibited. Or else, it will damage the sensor and EMS.
(a) Sensor housing damage, vacuum pipe rupture.
(b) Sensor seal damage.
(c) Sensor looseness or incorrect installation.
(d) Sensor vacuum tube blockage.
No
Step 2 Measure intake temperature sensor resistance.
NL-3 01/2016
to OFF state.
(b) Disconnect the negative battery cable. ES
EG17 Intake pressure and temperature sensor (c) Disconnect the intake temperature and pressure sensor
harness connector harness connector EG17.
(d) Measure the resistance value between intake temperature
sensor terminal 3 and terminal 4.
Standard value: As for specific parameters, please refer to
the JLE-4G18TDB intake system.
(e) Connect intake temperature and pressure sensor harness
connector EG17.
Yes
Step 3 Check intake air temperature sensor signal circuit.
to OFF state.
harness connector harness connector EG17 and EMS harness connector EG24.
(d) Measure the resistance value between terminal 3 of intake
position. Refer to the table below for standard values.
ground. Otherwise, repair the fault position. Refer to the table
power supply. Otherwise, repair the fault position. Refer to
the table below for standard values.
Resistance between
EG24 Engine management system harness Less than 1 Ω
connector 2 EG17(3) and EG24(45)
EG17(3)- Grounding
10kΩ or higher
resistance
EG17(3)- Grounding
0V
voltage
Yes
NL-3 01/2016
Step 4 Check intake temperature sensor working voltage.
ES (a) Operate the starter switch to turn the power supply mode
to OFF state.
harness connector
to ON state.
Standard voltage value: 4.5~5 V
(f) Connect the intake temperature and pressure sensor
connector EG17.
value.
No Go to step 6.
Yes
Step 5 Check intake temperature sensor working voltage.
to OFF state.
harness connector
(e) Measure the resistance value between terminal 4 of intake
position.
EG24 Engine management system harness power supply. Otherwise, repair the fault position.
connector 2
value.
EG17(4)-EG24(27)
Less than 1 Ω
resistance value
EG17(4)- Grounding
0V
voltage
Yes
NL-3 01/2016
(a) Check whether EMS power supply circuit is normal. ES

Handle fault of EMS power supply
No circuit.
Yes
(a) Replace the EMS. Please refer “Replacement of engine

management system”.
Next Step

interface.
to ON state.
(c) Clear DTCs.
No
intermittent fault for intermittent fault".
Yes
NL-3 01/2016
DTC P011600 P011817 P011716

ES
P011600 Unreasonable faults of engine coolant temperature sensor signal
P011817 Engine coolant temperature sensor circuit voltage is too high
P011716 Engine coolant temperature sensor circuit voltage is too low
Engine water temperature sensor is a rheostat with negative temperature coefficient to measure the water temperature. EMS
provides 5V voltage to the terminal 1 of the engine water temperature sensor harness connector EG23 via terminal 37 of EMS
harness connector EG24, and provides EMS internal low reference voltage circuit to the terminal 3 of the engine water
temperature sensor connector EG23 via terminal 21 of EG24. EMS interior will always record the length of time of the starter
switch off. If the time reaches the set starter switch off time when the starter switch is started, the engine control module will
compare the engine water temperature and intake temperature in order to determine whether the temperature difference is
within the normal working range.
(control strategy)
- The voltages of water - The jump of voltage of
P011600 temperature sensor jumps water temperature
unreasonably sensor >1.0010V
- The voltage of water - The measured voltage of - 1. Sensor circuit
P011817 temperature sensor exceed water temperature - 2. Sensor
the upper limit sensor >4.9023 V - 3. EMS
- The voltage of water - The measured voltage of
P011716 temperature sensor exceeds water temperature sensor
the lower limit <0.0977V
NL-3 01/2016
3. Circuit diagram:
ES
Main relay
ER05
Water temperature
sensor
Notice: Never use the combustible anti-freezer under any circumstance, such as alcohol. The combustible anti-freeze
may lead to serious fire accident.
(a) Check whether the engine coolant temperature sensor
has erosion sign or the engine coolant leakage through the
sensor.
(b) Check whether the engine coolant level in the cooling
system storage tank is correct.
No
Step 2 Check the engine coolant temperature sensor resistance.
NL-3 01/2016
to OFF state.
EG23 Water temperature sensor harness (c) Disconnect the water temperature sensor harness
connector
connector EG23.
(d) Measure the resistance value between terminals 1 and 3
of connector EG23.
Standard value: For specific parameters, please refer to
JLE-4G18TDB intake system.
(e) Connect water temperature sensor harness connector
EG23.
Replace the water temperature sensor.
No Go to Step 9.
Yes
Step 3 Check water temperature sensor signal circuit.
to OFF state.
EG23 Water temperature sensor harness (c) Disconnect the intake temperature and pressure sensor
connector harness connector EG23.
to ON state.
(f) Connect the intake temperature and pressure sensor
connector EG23.
value.
No Go to step 7.
Yes
Step 4 Check water temperature sensor grounding circuit.
to OFF state.
EG23 Water temperature sensor harness (c) Disconnect engine water temperature sensor harness
connector connector EG23.
(e) Measure the resistance between the terminal 3 of water
temperature sensor harness connector EG23 and the
terminal 21 of EMS harness connector EG24.
(e) Connect engine water temperature sensor harness
connector EG23.
(g) Connect the EMS harness connector EG24.
(h) Confirm whether the resistance meets the standard value.
No Go to step 6.
NL-3 01/2016
Yes
ES
Step 5 Check engine coolant temperature sensor signal circuit.
to OFF state.
EG23 Water temperature sensor harness
connector (c) Disconnect the water temperature sensor harness
connector EG23.
(d) Measure the resistance value between terminal 1 of
engine water temperature sensor harness connector EG23
and terminal 37 of EMS harness connector EG24; check
whether there is open circuit. Otherwise, repair the fault
position.
(e) Measure the voltage value between terminal 1 of engine
water temperature sensor harness connector EG23 and
connector 2 reliable grounding; check whether there is short circuit to
power supply. Otherwise, repair the fault position.
value.
EG23(1)-EG24(37)
Less than 1 Ω
resistance value
EG23(1)- Grounding
10kΩ or higher
resistance
EG23(1)- Grounding
0V
voltage
No Go to step 6.
Yes
Step 6 Check water temperature sensor grounding circuit fault.
NL-3 01/2016
ES to OFF state.
connector 2 (b) Disconnect the negative battery cable.
(c) Disconnect the water temperature sensor harness
connector EG23.
engine water temperature sensor harness connector EG23
and terminal 21 of EMS harness connector EG24; check
whether there is open circuit. Otherwise, repair the fault
position.
(f) Measure the voltage value between terminal 3 of engine
water temperature sensor harness connector EG23 and
reliable grounding; check whether there is short circuit to
power supply. Otherwise, repair the fault position.
value.
EG17 Intake pressure and temperature sensor Tester connection Standard value
harness connector EG233)-EG24(21)
Less than 1 Ω
resistance value
EG23(3)- Grounding
0V
voltage
Yes

No circuit.
Yes
(a) Replace the EMS, refer to “Engine ECU”
Next Step

interface.
to ON state.
(c) Clear DTCs.
NL-3 01/2016

(f) Read the DTC of the control system again and confirm the ES
Yes
NL-3 01/2016
DTC P012129 P012216 P012317

ES
P012129 Signal of electronic throttle position sensor 1 unreasonable
P012216 Electronic throttle position sensor 1 signal circuit voltage too low
P012317 Electronic throttle position sensor 1 signal circuit voltage too high
The actual throttle position will be compared to the throttle position determined by the engine load. The engine control module
(EMS) determines the engine load via the intake temperature and pressure sensor (MAP) signal. Through further contrast, it
may judge whether the sensor has fault and set the corresponding DTC.
• EMS provides 5V reference voltage for terminal 3 of the electronic throttle position sensor harness connector EG22 via
• Electronic throttle position sensor 1 provides the sensor signal voltage for terminal 13 of EMS harness connector EG24
through terminal 6 of EG22.
• EMS provides EMS grounding circuit to terminal 2 of the electronic throttle position sensor harness connector EG22 through
terminal 22 of harness connector EG24.
(control strategy)
P012129 - Rationality check - |TPS1-TPS2| >6.27 V
- TPS1 The signal voltage - 1. Sensor circuit
P012216 - Exceed the lower limit
TPS1 <0.176 V - 2. Sensor
- TPS1 The signal voltage - 3. EMS
P012317 - Exceed the upper limit
TPS1 >4.629 V
NL-3 01/2016
3. Circuit diagram:
ES
Main relay
ER05
Electronic
throttle
(a) Check whether the following conditions are available:
(b) Check whether the sensor harness connector is loose.
(c) Check whether the appearance of the sensor is damaged.
No
Step 2 Check to confirm the control system has no other DTC output.
(a) Connect the fault diagnostic scanner to the diagnostic

interface.
to ON state.
scanner.
(d) Read DTC.
(e) Confirm there is no other DTCs.
NL-3 01/2016
Refer to "Table of DTC".

ES No
Yes
Step 3 Check throttle position sensor signal output circuit.
(a) (Connect electronic throttle harness connector EG22)

Turn the digital multimeter to DC voltage position, with the
EG22 Electronic throttle harness connector
black probe connected to terminal 2 and the red probe to
terminal 6.
(c) Under engine idling state, measure the voltage between
terminal 6 and terminal 2.
Standard voltage value: 0.3~0.7 V
(d) Fully open throttle, and measure voltage between terminal
6 and terminal 2.
Standard voltage value: 4.45~4.85 V
(e) Confirm whether the above is normal.
No Go to step 7.
Yes
Step 4 Check 5V reference voltage of throttle position sensor.
to OFF state.
(b) Disconnect the electronic throttle harness connector
EG22.
to ON state.
(d) Measure the voltage between terminal 3 of electronic
throttle harness connector EG22 and reliable grounding.
(e) Connect the electronic throttle harness connector EG22.
(f) Confirm whether the measured value meets the standard
value.
No Go to step 6.
Yes
Step 5 Check throttle position sensor grounding circuit.
NL-3 01/2016
to OFF state.
ES
EG22 Electronic throttle harness connector (b) Disconnect the negative battery cable.
(c) Disconnect the electronic throttle harness connector
EG22.
(d) Measure the resistance between terminal 2 of electronic
(e) Connect the electronic throttle harness connector EG22.
Replace the throttle body assembly.
No Please refer to “Electronic throttle body”.
Yes
Step 6 Check the throttle position sensor reference voltage circuit.
to OFF state.
EG22 Electronic throttle harness connector (b) Disconnect the electronic throttle harness connector
EG22.
(c) Disconnect the EMS harness connector EG24.
electronic throttle harness connector EG22 and terminal 43 of
EMS harness connector EG24, and check for open circuit,
otherwise repair the fault position.
electronic throttle harness connector EG22 and reliable
grounding; check whether there is short circuit to ground,
otherwise, repair the fault position.
(f) Measure the resistance value between terminal 3 of
connector 2
value.
EG22(3)-EG24(43)
Less than 1 Ω
resistance value
EG22(3)- Grounding
10kΩ or higher
resistance
EG22(3)- Grounding
0V
voltage
Yes
Step 7 Check the throttle position sensor signal circuit.
NL-3 01/2016
ES to OFF state.
EG22.
(f) Measure the voltage value between the terminal 6 of
EG24 Engine management system harness grounding, and check whether there is short circuit to power
connector 2
supply, otherwise repair the fault position.
value.
EG22(6)-EG24(13)
Less than 1 Ω
resistance value
EG22(6)- Grounding
10kΩ or higher
resistance
EG22(6)- Grounding
0V
voltage
Yes
Step 8 Check throttle position sensor grounding circuit.
to OFF state.
EG22 Electronic throttle harness connector (c) Disconnect the electronic throttle harness connector
EG22.
grounding, and check whether there is short circuit to power
supply, otherwise repair the fault position.
value.
NL-3 01/2016

EG22(2)-EG24(22) Less than 1 Ω ES
connector 2 resistance value
EG22(2)- Grounding 0V
voltage
Yes

No
circuit.
Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes
NL-3 01/2016
DTC P013029 P013116 P013217 P013300 P013413 P219500 P219600

1. DTC description:
ES
P013029 Upstream oxygen sensor signal is not reasonable
P013217 Upstream oxygen sensor signal circuit voltage is too high
P013300 Upstream oxygen sensor aging
P013413 Upstream oxygen sensor circuit signal fault
P219500 Upstream oxygen sensor aging - signal constantly thick
P219600 Upstream oxygen sensor aging - signal constantly thin
ceramic tube into voltage signal output. When the sensing ceramic tube's temperature reaches 350℃, it will own
solid electrolyte's characteristics. The oxygen ions can pass through the ceramic tube freely because of its special
texture. The concentration difference can be changed into potential difference and then forms electrical signal output just due
to this characteristic. If the gas mixture is a little richer, the concentration difference of the oxygen ions inside and outside the
ceramic tube is higher, the potential difference is higher, a lot of oxygen ions move from the inside to the outside, and the
output voltage is higher (nearly 800mV-1000mV); if the gas mixture is a little thinner, the concentration difference of the
oxygen ions inside and outside the ceramic tube is lower, the potential difference is lower, only a small quantity of oxygen ions
move from the inside to the outside, and the output voltage is lower (nearly 100 mV). The signal voltage mutates near the
theoretical equivalent air-fuel ratio （λ=1）. The working voltage of the heating coil of the upstream oxygen sensor is provided
by EMS controlled main relay, i.e. when the starter switch turns to “ON”, the sensor terminal 1 of the harness connector EG05
has battery voltage. EMS controls the heater working duration via terminal 9 of harness connector EG24.
(control strategy)
- Output voltage of upper
-Oxygen sensor voltage is downstream oxygen sensor
within the specified low Front oxygen: >0.06V and
voltage for a long time <0.40V; rear oxygen: >0.50V
- The voltage of sensor - Output voltage of upper
P013029
voltage leaks to power downstream oxygen sensor
- 1. Sensor circuit
supply Front oxygen: >0.06V and
- 2. Sensor
- There is coupling between <1.20 V; rear oxygen: >0.10V
- 3. EMS
signal line and heating line - Difference of voltage on
front oxygen>2.0020V
-Signal short to ground - Output voltage of upstream
P013116
during cold state oxygen sensor < 0.06V
- The voltage of front oxygen - Output voltage of upstream
P013217
sensor is too high oxygen sensor > 1.20 V
NL-3 01/2016

(control strategy) ES
- The delay time of filtered
- The delay time of filtered
upstream signal period is
P013300 upstream signal period >
higher than the threshold
0.7000 s
value
- The signal circuit is open
- 1. Sensor circuit
- The common grounding - Voltage range of upstream
- 2. Sensor
point involves open circuit oxygen sensor 0.40V-0.60V
- 3. EMS
when the fuel supply is cut - Voltage of front rear oxygen
P013413
off sensor >1.20V
- High temperature and - Internal resistance of
resistance of the oxygen oxygen sensor >20000Ohm
sensor
3. Circuit diagram:
Main relay
ER05

sensor sensor
(a) Check whether the following conditions are available that
(b) Exhaust system leakage or blockage.
(c) Heated oxygen sensor connector incoming with water.
NL-3 01/2016
Repair or replace faulty parts.

ES Yes
No
Step 2 Check upstream oxygen sensor data.
(a) Connect fault diagnostic scanner, and start the engine.

(b) Keep the engine speed at around 2,500 rpm for
more than 2 minutes to warm up the engine, until the
engine water temperature reaches 80℃ (176 °F).
(c) Read the upstream oxygen sensor voltage data with the
fault diagnostic scanner.
(d) Observe the oxygen sensor output voltage and the data
stream display shall fluctuate within the 0.1 - 0.9V scope.
Please refer to "Check of intermittent
Yes fault for intermittent fault".
No
Step 3 Test the upstream oxygen sensor signal.
(a) If the data stream shows the voltage is constantly lower

than 0.45V (mixture too thin), execute the check procedure
according to the following steps:
– Proper amount of propane gas will be injected in the inlet.
– Observe whether there is significant change on the
upstream oxygen sensor data stream voltage; the signal
voltage will increase rapidly.
(b) If the data stream shows the voltage is constantly higher
than 0.45V (mixture too rich), execute the check procedure
– Make the transmission at the neutral gear.
- Pull up the EPB switch.
- Depress the acceleration pedal so that the engine speed
suddenly increases to 4000rpm and then suddenly release
the acceleration pedal.
– Repeat more than three times as per the above procedure.
– Observe whether there is obvious change on the upstream
oxygen sensor data stream voltage; the signal voltage will
decrease rapidly.
When executing the above test, the upstream oxygen sensor
signal voltage shall significantly vary with the test.
(c) Confirm whether there are significant changes in voltage
generation.
Refer to “Table of fault symptom” to
No check reasons for engine air-fuel ratio
too thin/rich.
Yes
NL-3 01/2016

interface. ES
to ON state.
(c) Read the fault diagnostic code, and check whether there
is any fault code other than P013029, P013116, P013217,
P013300, P013413, P219500 and P219600.
No
Step 5 Measure the output signal of upstream oxygen sensor.
(a) Start the engine, under idling state, when the

oxygen sensor reaches its working temperature of
350℃ (662 °F).
(b) Measure the change in voltage signal of the upstream
oxygen sensor within 10s.
Signal changes: more than 8 times.
(c) Confirm whether the voltage signal change is normal.
Yes Go to step 7.
No
Step 6 Replace upstream oxygen sensor.
(a) Replace the upstream oxygen sensor, refer to "Front

oxygen sensor".
(b) Replace the upstream oxygen sensor, and check whether
the fault is eliminated.
Yes Go to step 11.
No
Step 7 Check the heater power supply circuit of the upstream oxygen sensor.
to OFF state.
(c) Disconnect the upstream oxygen sensor harness
EG05 Upstream oxygen sensor harness connector
connector EG05 and the EMS harness connector EG24.
(d) Measure the resistance value, between terminal 3 of
upstream oxygen sensor harness connector EG05 and
terminal 16 of EMS harness connector EG24; check whether
there is open circuit, otherwise, repair the fault position.
ground, otherwise, repair the fault position.
NL-3 01/2016
(f) Measure the voltage value between terminal 3 of upstream

ES oxygen sensor harness connector EG05 and reliable
EG24 Engine management system harness grounding; check whether there is short circuit to power
connector 2
supply, otherwise, repair the fault position.
EG05(3)-EG24(16) Less than 1 Ω
EG05(3)- Grounding
10kΩ or higher
resistance
EG05(3)- Grounding
11~14 V
voltage
Yes
Step 8 Check the circuit between the upstream oxygen sensor and EMS.
to OFF state.
(b) Disconnect the upstream oxygen sensor harness
EG05 Upstream oxygen sensor harness connector connector EG05 and the EMS harness connector EG24.
(c) Measure the resistance value between terminal 4 of
terminal 40 of EMS harness connector EG24; check whether
there is open circuit, otherwise, repair the fault position.
(d) Measure the resistance value between terminal 4 of the
ground, otherwise, repair the fault position.
(e) Measure the voltage value between terminal 4 of
EG24 Engine management system harness reliable grounding; check whether there is short circuit to
connector 2 power supply, otherwise, repair the fault position.
EG05(4)- Grounding
10kΩ or higher
resistance
EG05(4)- Grounding
0V
voltage
(f) Measure whether the value meets the standard value
Yes
NL-3 01/2016

No Repair the power circuit of EMS.
Yes
(a) Replace the EMS, refer to "Engine ECU".
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes
NL-3 01/2016
DTC P013629 P013716 P013817 P014013 P227024 P227123

1. DTC description:
ES
P013629 Downstream oxygen sensor signal is not reasonable
P013716 Downstream oxygen sensor signal circuit voltage is too low
P013817 Downstream oxygen sensor signal circuit voltage is too high
P227024 Downstream oxygen sensor aging - signal constantly thin
P227123 Downstream oxygen sensor aging - signal constantly thick
ceramic tube into voltage signal output. When the sensing ceramic tube's temperature reaches 350℃(662 °F), it
will own solid electrolyte's characteristics. The oxygen ions can pass through the ceramic tube freely because of its
special texture. The concentration difference can be changed into potential difference and then forms electrical signal output
just due to this characteristic. If the gas mixture is a little richer, the concentration difference of the oxygen ions inside and
outside the ceramic tube is higher, the potential difference is higher, a lot of oxygen ions move from the inside to the outside,
and the output voltage is higher (nearly 800mV-1000mV); if the gas mixture is a little thinner, the concentration difference of
the oxygen ions inside and outside the ceramic tube is lower, the potential difference is lower, only a small quantity of oxygen
ions move from the inside to the outside, and the output voltage is lower (nearly 100 mV). The signal voltage mutates near the
theoretical equivalent air-fuel ratio （λ=1）. The working voltage of the heating coil of the downstream oxygen sensor is
provided by EMS controlled main relay, i.e. when the starter switch turns to “ON”, the sensor terminal 1 of the harness
connector EG04 has battery voltage. EMS controls the heater working duration via terminal 48 of harness connector CA45.
(control strategy)
- The difference in voltage of
- There is coupling between rear oxygen sensor when
P013629
signal line and heating line heating is carried out and not
carried out > 2.0020V
-Signal short to ground - Voltage signal of rear
P013716
during cold state oxygen sensor < 0.06V
-Rear oxygen voltage signal - Voltage signal of rear
P013817
is too high oxygen sensor > 1.20 V - 1. Sensor circuit
- Range of voltage signal of - 2. Sensor
- Oxygen sensor signal open
rear oxygen sensor - 3. EMS
- High temperature and
P014013 0.40V-0.50V
resistance of the oxygen
- Resistance of oxygen
sensor
sensor > 40000
-Rear oxygen voltage is - Voltage of rear oxygen
P227024
constantly higher sensor > 0.71 V
-Rear oxygen voltage is - Voltage of rear oxygen
P227123
constantly lower sensor < 0.55V
NL-3 01/2016
3. Circuit diagram:
ES
Main relay
ER05
Front oxygen sensor Rear oxygen sensor
Yes Repair the fault position.
No
Step 2 Check downstream oxygen sensor data.
(a) Connect fault diagnostic scanner, and start the engine.

(b) Keep the engine speed at around 2,500 rpm for
more than 2 minutes to warm up the engine, until the
engine water temperature reaches 80℃ (176 °F).
(c) Read the downstream oxygen sensor voltage data with
the fault diagnostic scanner.
(d) Observe the oxygen sensor output voltage and the data
stream display shall fluctuate within the 0.1 - 0.9V scope.
NL-3 01/2016
Please refer to "Check of intermittent

Yes fault for intermittent fault".
ES
No
Step 3 Test the downstream oxygen sensor signal.

- Proper amount of propane gas will be injected in the inlet.
- Observe whether there is significant change on the
downstream oxygen sensor data stream voltage; the signal
(b) If the data stream shows the voltage is constantly higher
- Make the transmission at the neutral gear.
- Pull up the EPB switch.
- Depress the acceleration pedal so that the engine speed
- Repeat more than three times as per the above procedure.
- Observe whether there is obvious change on the
downstream oxygen sensor data stream voltage; the signal
voltage will decrease rapidly.
When executing the above test, the downstream oxygen
sensor signal voltage shall significantly vary with the test.
(c) Confirm whether there are significant changes in voltage
generation.
Check reasons for engine air-fuel ratio
No too thin/rich. Refer to "Table of fault
symptoms ".
Yes

interface.
to ON state.
is any fault code other than P013029, P013116, P013217,
P013300, P013413, P219500 and P219600.
No
Step 5 Measure the output signal of upstream oxygen sensor.
(a) Check three-way catalytic converter appearance

intactness (whether sign of over temperature, sealing gasket
missing, etc. are available).
(b) Check whether the exhaust pipe appearance and sealing
gasket are intact.
NL-3 01/2016
Replace the broken component and go

Yes to step 12. ES
No
Step 6 Measure signal output of the downstream oxygen sensor.
(a) Start the engine, under idling state, when the

downstream oxygen sensor reaches its working
temperature of 350℃ (662 °F).
(b) Measure variation of voltage signal of downstream oxygen
sensor in 10s.
Signal changes: more than 8 times.
Yes Go to step 8.
No
Step 7 Replace downstream oxygen sensor.
(a) Replace the downstream oxygen sensor, refer to "Front

oxygen sensor".
(b) Check whether the fault is eliminated.
Yes System is normal.
No
Step 8 Check downstream oxygen sensor heater power supply circuit.
to OFF state.
EG04 Downstream oxygen sensor harness

(c) Disconnect the downstream oxygen sensor harness
connector connector EG04 and the EMS harness connector CA45.
terminal 43 of EMS harness connector CA45; check whether
there is open circuit, or else, repair the fault position.
the downstream oxygen sensor harness connector EG04 and
ground, or else, repair the fault position.
(f) Measure the voltage value between the terminal 3 of the
power supply, or else, repair the fault position.
NL-3 01/2016

ES EG04(3)-CA45(43) Less than 1 Ω
CA45 Engine management system harness EG04(3)- Grounding
connector 1 10kΩ or higher
resistance
EG04(3)- Grounding
0V
voltage
Yes
Step 9 Check the circuit between the downstream oxygen sensor and EMS.
to OFF state.
(b) Disconnect the downstream oxygen sensor harness
EG04 Downstream oxygen sensor harness connector EG04 and the EMS harness connector CA45.
connector
(c) Measure the resistance value between terminal 4 of
terminal 21 of EMS harness connector CA45; check whether
the downstream oxygen sensor harness connector EG04 and
ground, or else, repair the fault position.
(e) Measure the voltage value between the terminal 4 of the
CA45 Engine management system harness downstream oxygen sensor harness connector EG04 and
connector 1
power supply, or else, repair the fault position.
EG04(4)-CA45(21) Less than 1 Ω
EG04(4)- Grounding
10kΩ or higher
resistance
EG04(4)- Grounding
0V
voltage
(f) Measure whether the value meets the standard value
Yes
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No Repair the power circuit of EMS.
Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes
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DTC P017000 P017100 P017200

1. DTC description:
ES
P017000 Offline detection air-fuel ratio closed-loop control self-learning is not reasonable
P017100 Offline detection air-fuel ratio closed-loop control self-learning is too thin
P017200 Offline detection air-fuel ratio closed-loop control self-learning is too rich
The engine control module controls the closed-loop air-fuel ratio measure system to realize the best match of the handling
quality, fuel economy and emission control. In the closed-loop mode, the engine control module detects the upstream oxygen
sensor (HO2S) signal voltage and regulates the fuel supply according to it. The fuel supply variation will change long-term and
short-term fuel adjustment value. The short-term fuel adjustment value will rapidly vary with the upstream oxygen sensor
signal voltage. Such changes will fine tune the engine fuel supply. The long-term fuel adjustment value varies with the
short-term fuel adjustment trend. The long-term fuel adjustment will roughly adjust the fuel supply to go back to the short-term
fuel adjustment's center value and restore control over the short-term fuel adjustment. The ideal fuel adjustment value is
approximately 0%. The positive fuel adjustment value shows that the engine control module is increasing the fuel to
compensate too thin state of the mixture. The negative fuel adjustment value indicates that the engine control module is
reducing the fuel amount to compensate too rich state of the mixture.
(control strategy)
- Offline detection air-fuel - Fluctuation range of
ratio closed-loop control closed-loop quick correction
P017000
self-learning is not factor of gas mixture >
reasonable 0.0313
- 1. Oxygen sensor
-Offline detection air-fuel - Closed-loop quick
- 2. Fuel injector
P017100 ratio closed-loop control correction factor of gas
- 3. EMS
self-learning is too thin mixture > 1.2266
-Offline detection air-fuel - Closed-loop quick
P017200 ratio closed-loop control correction factor of gas
self-learning is too rich mixture < 0.7734
interface.
to ON state.
is any fault code other than P017000, P017100 and 017200.
No
Step 2 View intake pressure sensor data stream.
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(a) Check whether the following conditions are available that

(b) Operate the starter switch to turn the power supply mode ES
to OFF state.
(c) Connect fault diagnostic scanner.
(d) Start the vehicle.
(e) View intake pressure sensor data stream.
(f) Compare the reading of the atmospheric pressure in the
fault diagnostic scanner with Table Altitude and atmospheric
pressure correlation
(g) Confirm whether the reading of the atmospheric pressure
in the fault diagnostic scanner is normal.
Repair air pressure sensor fault, refer to
No DTC P012129 P012216 P012317
Yes
Step 3 Check electronic throttle position sensor data stream.
(a) Start the vehicle.

(b) Use the fault diagnostic scanner to view the upstream
oxygen sensor data stream.
(c) Confirm whether the throttle valve data is normal.
No Maintain throttle fault.
Yes
Step 4 View upstream oxygen sensor data stream.

(b) Warm up the engine and keep normal idle speed.
(c) Use the fault diagnostic scanner to view the upstream
Standard value: 0.1 -0.9 V
(d) Confirm whether the upstream oxygen sensor data are
normal.
No P013217 P013300 P013413 P219500
P219600 Repair of upstream oxygen
sensor.
Yes
Step 5 Observe long-term fuel correction parameter.

(c) Use the fault diagnostic scanner to view the long-term fuel
correction parameter.
(d) Confirm whether the long-term fuel correction parameter
is normal.
No
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Step 6 Check engine system and its components.
ES (a) Operate the starter switch to turn the power supply mode
to OFF state.
(b) Check vacuum hose rupture, twisting or connection
(c) Check intake manifold, throttle valve body and fuel
injection nozzle for vacuum leakage.
(d) Check crankshaft ventilation system leakage state.
(e) Check fuel contamination state.
(f) Check too thin state of the injection fuel of fuel injection
nozzle.
(g) Check too thin state of the fuel system.
(h) Check too rich state of the fuel system.
(i) Check too rich state of the injection fuel of fuel injection
nozzle .
(j) Check intake pipe for collapse or blockage.
(k) Check excessive fuel in the crankcase.
(l) Check the working state of the evaporation emission
control system.
(m) Check the working state of other fault lamps in the
instrument.
(n) Confirm whether the engine system is normal.
No
Step 7 Maintain the engine system and its components.
Next Step
NL-3 01/2016
DTC P020113 P020213 P020313 P020413

1. DTC description:
ES
P020113 Cylinder No. 1 fuel injector control circuit open
Fuel injector working voltage is provided by the main relay which is controlled by EMS. Battery voltage passes through the
main relay terminal 87 to all fuel injector connectors terminal 1. EMS controls fuel injector coil grounding through terminals 10,
8, 3 and 4 of harness connector EG24. EMS monitors the state of each fuel injector drive circuit. If EMS detects that the
voltage corresponding to the drive circuit instruction state is not correct, it will set a DTC of the fuel injector control circuit fault.
(control strategy)
P020113
- 1. Fuel injector circuit
P020213 - Check the circuit of
- The circuit is open - 2. Fuel injector
P020313 hardware
- 3.EMS
P020413
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3. Circuit diagram:
ES
Main relay
ER05 Fuel injector 1 Fuel injector 2 Fuel injector 3 Fuel injector 4
(a) Check fuel injector harness connector, whether there is
damage, poor contact, aging, loosening, etc.
No
Step 2 Measure resistance value of fuel injector assembly.
to OFF state.
(c) Disconnect the fuel injector harness connectors EG01,
EG02, EG03 and EG06 of every cylinder.
of all cylinder fuel injectors.
Standard value: 20 ℃ (68 ℉ )11.4~12.6 Ω
(e) Connect each fuel injector harness connector.
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Replace the fuel nozzle assembly, refer

No to "Fuel distributor assembly". ES
Yes
Step 3 Check the fuel injector fuse EF26.
to OFF state.
(b) Remove the fuel injector fuse EF26.
Rated capacity of the fuse: 10A
(c) Confirm whether fuse is blown.
Eliminate the fault of short circuit, and
Yes replace the fuse.
No
Step 4 Measure the working power supply of the fuel injector.
to OFF state.
(b) Disconnect the fuel injector harness connectors EG01,
Fuel injector harness connector EG02, EG03 and EG06 of every cylinder.
to ON state.
(d) Measure the voltage between terminal 1 of each cylinder
fuel injector harness connector and reliable grounding.
(e) Connect each fuel injector harness connector.
No Go to step 5.
Yes
Step 5 Check fuel injector control circuit.
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ES to OFF state.
Fuel injector harness connector (c) Disconnect the fuel injector harness connectors EG01,
(d) Connect the LED-based test lamp to terminal 1 and 2 of
each cylinder fuel injector harness connector.
(e) Start the engine.
(f) Observe whether the test lamp flashes normally.
(g) Confirm the test lamp flashes normally.
Yes Go to step 7.
No
Step 6 Check the power supply circuit of all cylinder fuel injectors.
to OFF state.
Fuel injector harness connector (c) Disconnect the fuel injector harness connectors EG01,
(d) Remove engine main relay.
(e) Measure the resistance value between terminals 1 of fuel
injector harness connectors EG01, EG02, EG03 and EG06
and terminal 87 of engine main relay ER05.
(f) Measure the resistance value between terminal 1 of fuel
injector harness connector EG01, EG02, EG03 and EG06
EG01(1)EG02(1)EG03(1)E
Less than 1 Ω
G06(1)-ER05 terminal 87
EG01(1)EG02(1)EG03(1)E
G06(1)- Grounding 10 kΩ or higher
resistance
Yes
Step 7 Check the control circuit of all cylinder fuel injectors.
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to OFF state. ES
Fuel injector harness connector
(c) Disconnect the fuel injector harness connectors EG01,
EG02, EG03 and EG06 of every cylinder as well as the EMS
(d) Measure the resistance value between terminal 2 of each
cylinder fuel injector harness connector EG01, EG02, EG03
and EG06 and corresponding terminal 10, 8, 3, 4 of EMS
harness connector EG24 separately; check whether there is
open circuit, or else, repair the fault position.
each cylinder fuel injector harness connector EG01, EG02,
EG03 and EG06 and reliable grounding separately; check
whether there is short circuit to ground, or else, repair the
EG24 Engine management system harness fault position.
connector 2 (f) Measure the voltage value between terminal 2 of each
cylinder fuel injector harness connector EG01, EG02, EG03
and EG06 and reliable grounding separately; check whether
there is short circuit to power supply, or else, repair the fault
position.
EG01(2)EG02(2)EG03(2)E
G06(2)- Grounding 10 kΩ or higher
resistance
Yes

No Maintain the power circuit of EMS.
Yes
Next Step
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ES interface.
to ON state.
(c) Clear DTCs.
Yes
DTC P021900
1. DTC description:
P021900 The engine speed is too high
The working principle of speed sensor is using magnetoelectric effect, when the crankshaft rotates, it drives the sensor signal
wheel to rotate together, the teeth on the sensor signal wheel cuts the magnetic line of force of the sensor, this change in the
magnetic flux results in an output voltage of certain frequency at the both sensor coil ends, which is output to the electronic
controller. The output signal may represent the speed and position of the crankshaft. EMS calculates ignition timing, injection
timing and knock ignition control based on the input signal of the speed sensor and camshaft position sensor. Speed sensor is
also used for detecting miss fire and speed meter display. EMS uses CAN network to send the engine speed signal to the
instrument.
(control strategy)
- 1. Sensor
- Engine speed exceeds the
P021900 - Engine speed > 7,000 rpm - 2. Sensor circuit
maximum speed, unbelievable
- 3. EMS
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3. Circuit diagram:
ES
Engine speed
sensor
Main relay
ER05
Phase
sensor
(a) Check whether the sensor harness connector EG29 has
loosening, poor contact, etc.
(b) Check whether the sensor is installed correctly.
(c) Check whether the sensor clearance is normal.
No Handle fault position and go to step 9.
Yes
Step 2 Read engine speed data with the fault diagnostic scanner.
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ES interface.
(c) Read the engine speed data displayed by the fault
diagnostic scanner.
(d) If the engine can't start, check the data when the engine is
running.
(e) If the fault diagnostic scanner shows the engine speed at
"0", it indicates the harness between the speed sensor and
EMS has open circuit or short circuit.
(f) Confirm whether the data stream conforms to the standard
value.
Yes
Step 3 Check speed sensor resistance value.
to OFF state.
EG29 Engine speed sensor harness connector

(c) Disconnect the speed sensor harness connector EG29.
(d) Measure the resistance between terminals 1 and 2 of the
speed sensor.
Standard value: 20 ℃ (68 ℉ )774~946 Ω
(e) Connect speed sensor harness connector EG29.
Replace the speed sensor, and go to
No step 9
Yes
Step 4 Check sensor terminal 1 circuit.
to OFF state.
EG29 Engine speed sensor harness connector (b) Disconnect the negative battery cable.
(c) Disconnect the speed sensor harness connector EG29
and EMS harness connector EG24.
speed sensor harness connector EG29 and terminal 32 of
EMS harness connector EG24, and check for open circuit.
(e) Measure the resistance value between terminal 1 of the
speed sensor harness connector EG24 and reliable
grounding; check whether the circuit is short to ground.
Standard value:
Measured items Standard values
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EG29(1)-EG24(32)
Less than 1 Ω
EG24 Engine management system harness resistance value ES
connector 2
Resistance between EG29(1)
10 kΩ or higher
and reliable grounding
value.
Deal with the circuit fault, and go to step
No 9.
Yes
to OFF state.

(f) Measure the voltage value between terminal 2 of the
grounding; check whether there is short circuit to power
connector 2 supply.
Standard value:
Measured items Standard value
EG29(2)-EG24(33)
Less than 1 Ω
resistance value
10 kΩ or higher
Voltage between EG29(2)
0V
value.
Deal with the sensor circuit fault, and go
No to Step 7.
Yes
Step 6 Check sensor signal disc.
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(a) Check whether the signal disc teeth has damage,

ES shortage, etc.
(b) Check whether the installation position of signal disc teeth
is correct.
No Go to step 9.
Yes

Yes
Step 8 Replace the EMS, refer to "Engine ECU".
Next Step

interface.
to ON state.
(c) Clear DTCs.
(e) Read the DTC of the control system again and confirm the
No
Yes
Step 10 The fault is eliminated.
DTC P022129 P022216 P022317

1. DTC description:
P022129 Signal of electronic throttle position sensor 2 is not reasonable
P022216 Electronic throttle position sensor 2 signal circuit voltage is too low
P022317 Electronic throttle position sensor 2 signal circuit voltage is too high
The actual throttle position will be compared to the throttle position determined by the engine load. The engine control module
(EMS) determines the engine load via the intake temperature and pressure sensor (MAP) signal. Through further contrast, it
may judge whether the sensor has fault and set the corresponding DTC.
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DTC detection DTC setting conditions (control

DTC No. Fault position
strategy strategy) ES
P022129 - Rationality check - |TPS1-TPS2| > 6.27%
- Exceed the lower - TPS2 The signal voltage TPS2 ＜ - 1. Sensor circuit
P022216
limit 0.156V - 2. Sensor
- Exceeds the upper - TPS2 The signal voltage TPS2 ＞ - 3. EMS
P022317
limit 4.883 V
3. Circuit diagram:
Main relay
ER05
Electronic
throttle
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ES data accuracy for quick troubleshooting!
(a) Check whether the sensor harness connector is loose.
(b) Check whether the appearance of the sensor is damaged.
Yes Handle fault position and go to Step 10.
No

interface.
to ON state.
scanner.
(d) Read DTC.
No Refer to "Table of DTC".
Yes
Step 3 Check the throttle position sensor 2 signal output.
(a) (Connect electronic throttle harness connector EG22)

Turn the digital multimeter to DC voltage position, with the
black probe connected to terminal 2 and the red probe to
EG22 Electronic throttle harness connector terminal 5.
(c) Under engine idling state, measure the voltage between
terminal 5 and terminal 2.
Standard value: 4.3~4.7 V
(d) Fully open throttle, and measure voltage between terminal
5 and terminal 2.
(e) Confirm whether the measured value is normal.
Yes Go to step 7.
No
Step 4 Check 5V reference voltage of throttle position sensor 2.
to OFF state.
(d) Connect the negative battery cable, and operate the
ignition switch so as to set the power mode in the state ON.
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(e) Measure the voltage between terminal 3 of electronic

Standard value: 5 V ES
(f) Connect the electronic throttle harness connector EG22.
(g) Confirm whether the voltage meets standard value.
No Go to step 6.
Yes
Step 5 Check throttle position sensor 2 grounding circuit.
to OFF state.
(c) Disconnect the electronic throttle harness connector
EG22.
Standard value: Less than 1 Ω
value.
No Go to step 8.
Yes
Step 6 Check 5V reference voltage circuit of throttle position sensor 2.
to OFF state.
(c) Disconnect the electronic throttle harness connector EG22
No Repair faulty position.
the electronic throttle harness connector EG22 and reliable
grounding, check whether the circuit is short to ground, or
else repair the fault position.
(f) Measure the voltage value between terminal 3 of electronic
throttle harness connector EG22 and reliable grounding;
check whether there is short circuit to ground, or else, repair
the fault position.
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Standard value:
ES EG24 Engine management system harness Measured items Standard value
connector 2
EG22(3)-EG24(43) resistance
Less than 1 Ω
value
10 kΩ or higher
0V
value.
Repair the faulty circuit and replace the
No harness if necessary.
Yes
Step 7 Check the throttle position sensor 2 signal circuit.
to OFF state.
electronic throttle harness connector EG22 and the terminal
14 of EMS harness connector EG24, and check whether the
circuit is broken.
Standard value:
EG24 Engine management system harness Measured items Standard value
connector 2
Less than 1 Ω
value
10 kΩ or higher
value.
Yes
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to OFF state. ES
electronic throttle harness connector EG22 and the terminal
22 of EMS harness connector EG24, and check whether the
circuit is broken.
(e) Measure the voltage value between the terminal 2 of
electronic throttle harness connector EG22 and the reliable
grounding, and check whether the circuit is short to the power
supply.
Standard value:
connector 2
Less than 1 Ω
value
0V
value.
Repair the faulty circuit and replace
No
harness if necessary.
Yes

Check and repair the EMS power circuit,
No or replace the harness.
Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
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ES system has no DTC output.
Yes

DTC P026111 P026212 P026411 P026512 P026711 P026812 P027011 P027112
1. DTC description:
P026111 Cylinder No.1 fuel injector control circuit voltage is too low
P026212 Cylinder No.1 fuel injector control circuit voltage is too high
Fuel injector working voltage is provided by the main relay which is controlled by EMS. Battery voltage passes through the
main relay terminal 87 to all fuel injector connectors terminal 1. EMS controls fuel injector coil grounding through terminals 10,
8, 3 and 4 of harness connector EG24. EMS monitors the state of each fuel injector drive circuit. If EMS detects that the
voltage corresponding to the drive circuit instruction state is not correct, it will set a DTC of the fuel injector control circuit fault.
strategy strategy)
- Check the circuit of
P026111 – Circuit short to ground
hardware
P026212 - Circuit short to power supply
hardware
hardware
- Check the circuit of - 1. Fault of fuel injector
hardware circuit
- Check the circuit of - 2. Fuel injector
hardware - 3. EMS
hardware
hardware
hardware
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3. Circuit diagram:
ES
Main relay Fuel injector Fuel injector Fuel injector Fuel injector
ER05 1 2 3 4
(a) Check whether the fuel injection nozzle harness
connector has damage, poor contact, aging, loosening, etc.
(b) Check whether the sensor harness is damaged.
No

interface.
to ON state.
scanner.
(d) Read DTC.
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Yes
ES
Step 3 Check the resistance value of the fuel injection nozzle assembly.
(a) Disconnect each cylinder fuel injection nozzle harness

connector EG01, EG02, EG03, EG06.
(b) Measure the resistance value between terminals 1 and 2
Fuel injector harness connector of all cylinder fuel injection nozzles.
Standard value: 20 (68 ℉ )11.4~12.6 Ω
℃
(c) Connect each fuel injection nozzle harness connector.
(d) Confirm whether the measured value is normal.
No Replace injection nozzle assembly.
Yes
Step 4 Check the fuel injector fuse EF26.
Engine compartment fuse, relay box to OFF state.
(c) Remove the fuse EF26.
(d) Check whether the fuse is blown out.
Eliminate the fault of short circuit, and
Yes replace the fuse.
No
Step 5 Measure the working power supply of the fuel injection nozzle.
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to OFF state. ES
(b) Disconnect the fuel injector harness connectors EG01,
Fuel injector harness connector (c) Operate the starter switch to turn the power supply mode
to ON state.
(d) Measure the voltage between the terminal 1 of fuel
injector harness connector and the reliable grounding point.
Standard value: 11~14 V
(e) Connect all cylinder fuel injection nozzle harness
connector.
No Go to step 7.
Yes
Step 6 Check the fuel injection nozzle control circuit.
to OFF state.
(c) Disconnect each cylinder fuel injection nozzle harness
(d) Connect the LED-based test lamp to terminal 1 and 2 of
each cylinder fuel injection nozzle harness connector.
(e) Connect the negative battery cable, and start the engine.
(f) Observe whether the test lamp flashes normally.
(g) Confirm the test lamp flashes normally.
Yes Go to step 8.
No
Step 7 Check the power supply circuit of all cylinder fuel injection nozzles.
to OFF state.
Fuel injector harness connector (c) Disconnect each cylinder fuel injection nozzle harness
(e) Measure the resistance value between terminals 1 of fuel
injector harness connectors EG01, EG02, EG03 and EG06
and terminal 87 of engine main relay ER05.
(f)Measure the resistance value between the terminal 1 of
each cylinder fuel injection nozzle harness connector EG01,
EG02, EG03 and EG06 and reliable grounding separately;
the fault position.
Standard value:
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ES Engine compartment fuse, relay box
EG01(1)\EG02(1)\EG03(1)\
EG06(1)-ER05 terminal 87 Less than 1 Ω
resistance value
Resistance between
EG01(1)\EG02(1)\EG03(1)\
10 kΩ or higher
EG06(1) and reliable
grounding
value.
Yes Go to step 9.
No
Step 8 Check the control circuit of all cylinder fuel injection nozzles.
to OFF state.
(c) Disconnect the fuel nozzle harness connectors EG01,
EG02, EG03 and EG06 of every cylinder as well as the EMS
(d) Measure the resistance value between terminal 2 of each
cylinder fuel injector nozzle harness connector EG01, EG02,
EG03 and EG06 and corresponding terminal 10, 8, 3, 4 of
EMS harness connector EG24 separately; check whether
each cylinder fuel injector nozzle harness connector EG01,
EG02, EG03 and EG06 and reliable grounding separately;
the fault position.
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(f) Measure the voltage value between terminal 2 of each

cylinder fuel injector nozzle harness connector EG01, EG02,
connector 2 EG03 and EG06 and reliable grounding separately; check ES
whether there is short circuit to power supply, or else, repair
the fault position.
Standard value:
value
value
Less than 1 Ω
value
value
Resistance between
EG01(1)\EG02(1)\EG03(1)\EG 10 kΩ or higher
06(1) and reliable grounding
Voltage between
EG01(1)\EG02(1)\EG03(1)\EG 0 V
06(1) and reliable grounding
value.
Repair circuit fault, and replace the
Yes

Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes
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ES
DTC P030022 P030021 P030029 P030122 P030121 P030129 P030222 P030221 P030229 P030322
P030321 P030329 P030422 P030421 P030429
1. DTC description:
EMS uses information from speed sensor and camshaft position sensor to determine whether misfire available in the engine. If
a certain cylinder doesn't work normally, EMS can detect crankshaft speed variation; the misfire of a certain cylinder is
calculated just by detecting the crankshaft speed variation during the power stroke. In case of misfire, the combustible mixture
that has not combusted in cylinder drained to the exhaust system and finally combusted in the three-way catalytic converter
(TWC). It may lead to overheating of the converter or even damage TWC. In case of overheating of the three-way catalytic
converter, the malfunction indicator lamp (MIL) will always light on or flash. Meanwhile, set the corresponding DTC.
NL-3 01/2016
DTC detection DTC setting conditions (control ES

strategy strategy)
P030022 - Misfiring fault counter relating to
P030122 damage of three-way catalytic converter
P030322 - Misfire rate of every cylinder (The threshold value of
P030422 destroying the misfiring rate caused by damage of
catalyst three-way catalytic converter depends
P030222 on operating conditions. Please refer to
the instructions on demonstration)
P030021 - 1. Ignition coil circuit
- Misfire fault counter related to
P030121 - Misfire rate - 2. Ignition coil
emissions of cylinders, the misfire rate
P030221 aggravating the - 3. EMS
threshold deteriorating the emission >
P030321 emission
2.9%
P030421
P030029 - Misfire fault counter related to
P030129 emission of cylinders in the first count
P030229 - Non-trusted error cycle after starting, the misfire rate
P030329 threshold deteriorating the emission>
P030429 2.9%.
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3. Circuit diagram:
ES
Cylinder No.1 Cylinder No.2 Cylinder No.3 Cylinder No.4

Main relay ignition coil ignition coil ignition coil ignition coil
ER05
(a) Check whether the fuel injection nozzle harness
connector has damage, poor contact, aging, loosening, etc.
(b) Check whether the sensor harness is damaged.
No

interface.
to ON state.
scanner.
(d) Read DTC.
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Yes
Step 3 Check vacuum pipe and intake system. ES
(a) Check whether the intake temperature pressure sensor

vacuum pipe connection is incorrect or air leakage.
(b) Check whether brake vacuum booster vacuum pipe
connection is incorrect or air leakage.
(c) Check whether the intake temperature and pressure
sensor vacuum pipe connection is incorrect or air leakage.
(d) Check whether the connection of positive crankcase
ventilation valve and ventilation pipe is incorrect or air
leakage.
(e) Check whether the intake system has air leakage.
(f) Check for the above faults.
No Handle fault position and go to Step 17.
Yes
Step 4 Check the spark plug.
(a) Remove the spark plug in the misfire cylinder.

(b) Check whether the spark plug clearance is too big or
small.
Standard clearance: 0.80.9 mm (0.0310.035 in)
(c) Inspect whether the spark plug's electrode eroded,
damaged.
(d) Check whether the spark plug skirt and electrode are
humid, or with serious gasoline smell.
(e) Reinstall the spark plug.
(f) Confirm whether the above faults are available
Replace the spark plug, refer to "Spark
Yes plug".
No
Step 5 Check whether the spark plug arcing is normal.
(a) Conduct spark test.

(b) Remove ignition coil of the misfire cylinder.
(c) Disconnect all cylinder fuel injector connectors.
(d) Install the spark plug to the ignition coil.
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(e) Start the engine (engine running time no more than 5s)
ES and check arcing state.
(f) Reconnect all cylinder fuel injector connectors.
(g) Install ignition coil.
(h) Confirm whether the spark plug arcing is normal.
Notice
The following conditions shall be met before executing this
procedure:
1. Must disconnect all fuel injector connectors.
2. Engine running time is no more than 5s.
No Go to step 9.
Yes
Step 6 Check compression pressure of the misfire cylinder.
(a) For detailed steps, refer to "Comprehensive check of

engine".
(b) Confirm whether the cylinder compression pressure is
normal.
Yes Go to step 10.
No
Step 7 Check the reason for the low cylinder compression pressure.
(a) Check the reason for the low cylinder compression

pressure.
(b) Check and repair the compression force of cylinder.
Next Step
Step 8 Check the fuel and the fuel injector of the misfire cylinder.
(a) Check whether the fuel injector has leakage, blockage.

(b) Check whether the fuel quality is normal.
(c) Confirm whether the above faults are available.
Notice
The following conditions shall be met before executing this
procedure:
2. Engine running time is no more than 5s.
Yes
Step 9 Replace the spark plug, and check whether the misfiring cylinder is fired.
NL-3 01/2016
(a) Remove ignition coil of the misfire cylinder.

(b) Disconnect all cylinder fuel injector connectors. ES
(c) Replace the installed spark plug with the normal spark
plug.
(d) Start the engine (engine running time no more than 5s)
and check arcing state.
(e) Connect all cylinder fuel injector connectors.
(f) Install ignition coil.
(g) Confirm whether the spark plug arcing is normal.
Check and repair the ignition coil and
No circuit.
Yes
Step 10 Check EMS control terminal voltage of the misfire cylinder fuel injector.
EG24 Engine management system harness to OFF state.
(e) Measure the voltage between terminal 3, 4, 8, 10 of EMS
harness connector EG24 and reliable grounding.
Check fuel injector nozzle circuit. Refer
No
to "Check of intermittent fault for
intermittent fault"
Yes
Step 11 Check the misfire cylinder valve clearance.
(a) Check the misfire cylinder valve clearance.

(b) Confirm whether the valve clearance is normal.
Intake: 0.22-0.28 mm (metric system) or 0.0087-0.0110 in
(imperial system);
Exhaust: 0.27-0.33 mm (metric system) or 0.0106-0.0130 in
(imperial system).
Adjust the valve clearance of misfiring
No cylinder.
Yes
(a) Check the valve timing system, refer to "Timing chain".

(b) Confirm whether the valve timing is normal.
NL-3 01/2016
Adjust valve timing and go to Step 17.

ES No
Yes
Step 13 Check fuel pressure.

(a) Check the fuel pressure, refer to "Fuel pressure detection
procedure".
(b) Check fuel pressure.
Repair fuel system: fuel pump, fuel filter,
No
fuel pipeline, fuel pressure regulator.
Yes
Step 14 Check whether the data display is normal in the list of data stream.
(a) Check intake temperature and pressure sensor data.

(b) Check the water temperature sensor data.
(c) Check electronic throttle position sensor.
(d) Confirm whether the above components are normal.
No Replace the damaged part.
Yes

Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes
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ES
DTC P032200
1. DTC description:
P032200 Speed sensor fault
The working principle of speed sensor is using magnetoelectric effect, when the crankshaft rotates, it drives the sensor signal
wheel to rotate together, the teeth on the sensor signal wheel cuts the magnetic line of force of the sensor, this change in the
magnetic flux results in an output voltage of certain frequency at the both sensor coil ends, which is output to the electronic
controller. The output signal may represent the speed and position of the crankshaft. EMS calculates ignition timing, injection
timing and knock ignition control based on the input signal of the speed sensor and camshaft position sensor. Speed sensor is
also used for detecting miss fire and speed meter display. EMS uses CAN network to send the engine speed signal to the
instrument.
strategy strategy)
- The PG signal is
detected, and the - 1. Wheel speed sensor
P032200 synchronization of - Phase signal counter ≥ 5 - 2. Sensor circuit
speed signal is not - 3. EMS
completed
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3. Circuit diagram:
ES
Engine
speed
Main relay sensor
ER05
Phase
sensor
Yes
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interface. ES
(c) Read the engine speed data displayed by the fault
diagnostic scanner.
(d) If the engine can't start, check the data when the engine is
running.
(e) If the fault diagnostic scanner shows the engine speed at
"0", it indicates the harness between the speed sensor and
EMS has open circuit or short circuit.
(f) Confirm whether the data stream meets the standard
value.
Yes
Step 3 Check speed sensor resistance value.
to OFF state.
EG29 Engine speed sensor harness connector (b) Disconnect the negative battery cable.
of the speed sensor.
Standard value: 20 ℃ (68 ℉ )774~ 946 Ω
(e) Connect speed sensor harness connector EG29.
Replace the speed sensor, and go to the
No step 9
Yes
to OFF state.
Standard value:
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Less than 1 Ω
ES EG24 Engine management system harness value
connector 2
Resistance between E29(1)
10 kΩ or higher
value.
Deal with the circuit fault, and go to Step
No 9.
Yes
Step 5 Check the circuit of sensor terminal 2.
to OFF state.
connector 2 supply.
Standard value:
Less than 1 Ω
value
10 kΩ or higher
0V
value.
No to Step 7.
Yes
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shortage, etc.
(b) Check whether the installation position of signal disc teeth ES
is correct.
No Go to step 9
Yes

Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes
DTC P032700
1. DTC description:
P032700 The knock sensor circuit fails
KS sensor's feedback signal on EMS enables EMS's control over the ignition timing at the most ideal state; the ignition system
reaches the optimum performance and meanwhile prevents the potential knock damage on the engine. Knock sensor is
located in the cylinder block under the intake manifold. The AC signal voltage generated by the knock sensor varies with the
vibration level during the running of the engine. The engine control module adjusts the ignition timing according to the
amplitude and frequency of knock sensor signal. EMS receives signals from terminals 1 and 2 of knock sensor harness
connector EG30 through terminals 25, 26 of the harness connector EG24.
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ES strategy strategy)
- Reference voltage for identification of
shock (At different speed, the threshold - 1. Sensor circuit
- Detected signal
P032700 value will be different) - 2. Sensor
scope lower
- Number of consecutive occurrences > - 3. EMS
30
3. Circuit diagram:
Main relay
ER05
Knock
sensor
(a) Check whether knock sensor has physical damage.
(b) Check whether the knock sensor is correctly installed; too
tight or loose torque will lead to set DTC.
(c) Whether knock sensor's installing surface has burr, cast
trimming and foreign substance.
(d) The knock sensor must stay away from the hose, bracket
and engine circuits.
(e) Confirm whether the above components are normal.
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Yes
ES

interface.
to ON state.
(c) Select "Engine"/"Read data stream"/"Knock sensor signal
1".
(d) Start the engine and make it to the normal working
temperature.
(e) During vehicle road test, read the engine speed data
displayed by the fault diagnostic scanner.
(f) Confirm whether the data is normal.
No Go to step 4
Yes
Step 3 Intermittent fault, refer to "Check of intermittent fault for intermittent fault".
Next Step
Step 4 Check the resistance value of knock sensor.
to OFF state.
EG30 Knock sensor harness connector
(c) Disconnect knock sensor harness connector EG30.
of the knock sensor.
Standard value: (4.9±0.98) MΩ
(e) Connect knock sensor harness connector EG30.
Replace the knock sensor, and go to the
No step 9.
Yes
Step 5 Check the circuit of terminal 1 of knock sensor.
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ES to OFF state.
(c) Disconnect the knock sensor harness connector EG30,
and the EMS harness connector EG24.
(d) Measure the resistance value between terminal 1 of knock
sensor harness connector EG30 and terminal 26 of EMS
harness connector EG24; and check for open circuit.
supply.
connector 2
Standard value:
Less than 1 Ω
value
10 kΩ or higher
0V
value.
Deal with the circuit fault, and go to Step
No 9.
Yes
Step 6 Check the circuit of sensor terminal 2.
to OFF state.
(c) Disconnect the knock sensor harness connector EG30,
(d) Measure the resistance value between terminal 2 of knock
sensor harness connector EG30 and terminal 25 of EMS
harness connector EG24; and check for open circuit.
supply.
Standard value:
NL-3 01/2016

EG24 Engine management system harness EG30(2)-EG24(25) ES
connector 2 Less than 1 Ω
resistance value
Resistance between
EG30(2) and reliable 10 kΩ or higher
grounding
0V
value.
No to Step 9.
Yes

Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes

DTC P034178
1. DTC description:
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ES P034178 Intake camshaft position sensor signals are unreasonable
Phase sensor correlates the crankshaft and camshaft position so that EMS calculates the cylinder 1 compression TDC and
finally determines the fuel injection to the corresponding cylinder at the proper time. Camshaft position sensor circuit includes
the following circuits:
- Reference voltage: EMS provides a reference voltage to terminal 3 of the camshaft position sensor harness connector EG08
through terminal 34 of harness connector EG24.
- Signal circuit: EMS receives signal voltage from terminal 2 of the camshaft position sensor harness connector EG08 via
terminal 29 of the harness connector EG24.
EMS low reference voltage circuit: EMS provides low reference voltage circuit for terminal 1 of the camshaft position sensor
harness connector EG08 via terminal 31 of the harness connector EG24.
strategy strategy)
- 1. Sensor
- The phase signal is
P034178 - Phase signal fault counter ≥1 - 2. Sensor circuit
not detected
- 3. EMS
3. Circuit diagram:
Engine speed
sensor
Main relay
ER05
Phase sensor
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data accuracy for quick troubleshooting! ES
Yes
Step 2 Measure sensor 5V reference voltage.
to OFF state.
(c) Disconnect the camshaft position sensor harness
EG08 Phase sensor harness connector
connector EG08.
(e) Measure the voltage value between terminal 3 of the
camshaft position sensor harness connector EG08 and
reliable grounding.
Standard value: 5 V
(f) Connect the camshaft position sensor harness connector
EG08.
(g) Confirm whether the voltage meets standard value.
No Go to step 6.
Yes
Step 3 Measure the internal reference circuit of sensor EMS.
to OFF state.
(c) Disconnect the camshaft position sensor harness
connector EG08.
ignition switch to turn the power supply mode to ON state.
camshaft position sensor harness connector EG08 and
reliable grounding.
(f) Connect the camshaft position sensor harness connector
EG08.
(g) Confirm whether the resistance meets the standard value.
No Go to step 8.
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Yes
ES
Step 4 Check the signal output of sensor.
(a) Start the engine, and check whether the output signal
waveform at terminal 2 is normal with an oscilloscope.
(b) Confirm whether the output signal waveform at terminal 2
is normal.
Yes Go to step 7.
No
Step 5 Replace the phase sensor.
(a) Replace the phase sensor, refer to "Phase sensor".

(b) Confirm whether the system is normal.
No
Step 6 Check sensor 5V reference voltage circuit.
to OFF state.
(c) Disconnect the phase sensor harness connector EG08,
phase sensor harness connector EG08 and terminal 34 of
EMS harness connector EG24; and check for open circuit.
supply.
Standard value:
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EG08(3)-EG24(34) resistance ES
EG24 Engine management system harness Less than 1 Ω
connector 2
value
10 kΩ or higher
0V
value.
Yes
Step 7 Check sensor signal circuit.
to OFF state.
EG08 Phase sensor harness connector (c) Disconnect the phase sensor harness connector EG08,
EG24 Engine management system harness supply.
connector 2
Standard value:
Less than 1 Ω
value
10 kΩ or higher
0V
value.
No
Yes
Step 8 Check the conductivity between sensor EMS internal reference circuit and the camshaft sensor.
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ES to OFF state.
(c) Disconnect the phase sensor harness connector EG08,
supply.
connector 2
Standard value:
Less than 1 Ω
value
0V
value.
Yes
Step 9 Check whether the camshaft signal disc is normal.
Yes

Yes
Next step
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interface.
ES
to ON state.
(c) Clear DTCs.
Yes
DTC P042000
1. DTC description:
P042000 The oxygen storing ability of three-way catalytic converter is reduced
EMS uses two oxygen sensors (front oxygen sensor, rear oxygen sensor) in the front and rear of the three-way catalytic
converter to detect the conversion efficiency of the three-way catalytic converter (TWC).
EMS uses the front oxygen sensor to realize the closed-loop control of the air-fuel ratio and meanwhile detects oxygen content
in the exhaust gas without TWC purification. Rear oxygen sensor transfer gas oxygen content after TWC purification to EMS
via voltage signal. EMS calculates whether the present TWC is in the normal working state via comparing front and rear
oxygen sensor signals. If it is detected that TWC conversion efficiency is too low, the fault lamp will light on and the DTC will be
set.
strategy strategy)
- 1. Front oxygen sensor
- 1. The catalytic converter aging factor
- 2. Rear oxygen sensor
- Beyond the calculated utilizing OSC ＜ 0.2
P042000 - 3. Three-way catalytic
maximum limit value - 2. Catalytic converter diagnosis
converter
detection activation time ＞ 3
- 4. Exhaust Leakage
3. Circuit diagram:
Please refer to “Diagram of system”.
Step 1 Confirm that there is no fault code other than DTC P042000.
interface.
to ON state.
scanner.
(e) Read DTCs, and confirm whether there are other DTCs
except DTC P042000.
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ES
Yes
Step 2 Start engine and turn on the fault diagnostic scanner.
Next step
Step 3 Keep the engine speed at around 2,500 rpm for more than 2 minutes to warm up the engine, until the
engine water temperature reaches 80 ℃ (176 °
F).
Next Step
Step 4 Select on the fault diagnostic scanner: Engine/Read data stream/Voltage 1 of oxygen sensor set 1 (front
oxygen sensor), Voltage 2 of oxygen sensor set 1 (rear oxygen sensor).
Normal TWC Degraded TWC
Front oxygen sensor
Rear oxygen sensor
Next Step
Step 5 Observe the output voltage of front and rear oxygen sensor.
(a) Whether the signal voltages in the front and rear oxygen
sensors conform to the "normal TWC" in the diagram?
Yes
No
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Step 6 Conduct oxygen sensor signal test.
ES
• Proper amount of propane gas will be injected in the inlet.
• Observe whether there is significant change on the sensor
data stream voltage, in which case the signal voltage will
increase rapidly.
Front oxygen sensor Rear oxygen sensor Go to step
signal voltage signal voltage
Obvious change Unchanged A
Unchanged Obvious change B
Obvious change Unchanged C
Unchanged Unchanged D
Replace the front oxygen sensor, refer to

B "Front oxygen sensor".
Replace the rear oxygen sensor, refer to
C "Rear oxygen sensor".
Refer to “Table of fault symptoms” to
D
check reasons for engine air-fuel ratio
too thin/rich.
Step 7 Check whether there is exhaust leakage.
Yes Repair fault position.
No
Step 8 Replace the three-way catalytic converter, refer to "Muffler".
Next Step
Step 9 Observe again whether output voltage of front and rear oxygen seniors is normal.
Yes Go to step 11.
No
Step 10 Replace the rear oxygen sensor, refer to "Rear oxygen sensor".
Next Step
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ES interface.
to ON state.
(c) Clear DTCs.
No
Yes
DTC P044413 P045811 P045912

1. DTC description:
P044413 Canister control valve control circuit open
P045811 Canister control valve control circuit voltage is too low
P045912 Canister control valve control circuit voltage is too high
Canister (EVAP) control valve’s function is to suck the fuel vapor into the intake manifold from the evaporation emission
canister. Carbon canister control valve uses the pulse width modulation (PWM) control mode. The circuit composition is:
– Working voltage: the battery arrives at terminal 1 of the canister control valve harness connector EG16 via terminal 87 of
EMS controlled main relay.
– EMS control circuit: canister control valve harness connector EG16 terminal 2 is connected to terminal 30 of EMS harness
connector EG24. EMS interior is equipped with a drive circuit to control the solenoid valve grounding. The drive circuit is
equipped with a feedback circuit to EMS; EMS determines whether the control circuit is open, short to ground or power supply
via feedback voltage monitor.
strategy strategy)
P044413 - The circuit is open - 1. Sensor circuit
P045811 - Circuit short to ground - 2. Sensor
hardware
P045912 - Circuit short to power supply - 3. EMS
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3. Circuit diagram:
ES
Carbon canister
Main relay solenoid valve
ER05
Step 1 Check whether the control system has other DTCs except P044413 P045811 P045912.
interface.
to ON state.
scanner.
(e) Read the fault diagnostic code, and confirm whether there
is no DTC other than DTCs P044413, P045811 and P045912.
Yes
Step 2 Test the canister control valve with a fault diagnostic scanner actively.

interface.
(b) Disconnect the vacuum pipe between the canister control
valve and the canister vacuum pipe.
(c) Start engine and open the fault diagnostic scanner.
NL-3 01/2016
(d) Enter the following menu: “Engine”/“Action test”/“Canister

control valve”.
ES (e) Use the fault diagnostic scanner to open "Canister control
valve", and press the control valve vacuum interface with
finger and check whether there is suction force.
Yes
Step 3 Check the canister solenoid valve fuse EF10.
Engine compartment fuse ,relay box
to OFF state.
(c) Remove the EF10 fuse, and check whether the fuse has
blown out.
Check and repair the short circuit, and
Yes
replace the EF10 fuse.
No
Step 4 Measure the working power supply of canister control valve.
to OFF state.
EG16 Canister control valve harness (c) Disconnect carbon canister control valve harness
connector connector EG16.
(d) Operate the power switch to turn the power supply mode
to ON state.
(e) Measure the voltage value between terminal 1 of carbon
canister control valve harness connector EG16 and reliable
grounding.
(f) Connect canister control valve harness connector EG16.
(g) Confirm whether the voltage value meets standard value.
Yes Go to step 7.
No
Step 5 Check control circuit of canister control valve.
to OFF state.
(c) Disconnect carbon canister control valve harness
connector EG16.
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(e) Measure the resistance between terminal 2 of the carbon ES
canister control valve harness connector EG16 and terminal
EG16 Carbon canister control valve harness
connector 30 of EMS harness connector EG24; check whether there is
open circuit.
(f) Measure the resistance between terminal 2 of the carbon
(g) Measure the voltage between terminal 2 of the carbon
grounding; check whether the circuit is short to power supply.
Standard value:
connector 2 Resistance between EG16(2)
Less than 1 Ω
and E24(30)
10 kΩ or higher
0V
(h)Confirm whether all measured values meet standard
value.
Repair or replace the harness connector,
No
and go to Step 8.
Yes
Step 6 Check the power circuit of solenoid valve of canister.
to OFF state.
EG16 Carbon canister control valve harness (c) Remove main relay ER05.
connector
(d) Disconnect canister control valve harness connector
EG16.
(e) Measure the resistance between the terminal 1 of carbon
canister solenoid valve harness connector EG16 and the
socket 87 of main relay ER05, and check whether the circuit
is broken.
(f) Check whether the resistance meets the standard.
Repair open circuit fault, and replace the
No
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ES Engine compartment fuse, relay box
Yes
Step 7 Replace the solenoid valve of canister. Please refer to the solenoid valve of carbon canister.
(a) Replace the carbon canister solenoid valve.
(b) Confirm whether the faults are eliminated
No

Check and repair the EMS power circuit,
No or replace the harness.
Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes
NL-3 01/2016

ES
DTC P048113 P048013
1. DTC description:
P048013 Cooling fan relay control circuit open (low speed)
P048113 Cooling fan relay control circuit open (high speed)
The working power supply of the cooling fan high/low speed relay coil is supplied by EMS controlled main relay; EMS controls
operation of the relay via terminal 31, 56 of the harness connector ca45. EMS interior is equipped with a drive circuit to control
the relay coil grounding. The drive circuit is equipped with a feedback circuit to EMS; EMS determines whether the control
circuit is open, short to ground or power supply via feedback voltage monitor.
strategy strategy)
P048113 - 1. Relay circuit
- The circuit is open - 2. Relay
P048013 hardware
- 3. EMS
3. Circuit diagram:
Main relay
ER05
Cooling Cooling fan

fan high Low speed
speed relay ER04
relay ER03
Cooling
fan
NL-3 01/2016
ES data accuracy for quick troubleshooting!
(a) Check whether the cooling fan relays ER03 and ER04 are
loosened or unreasonably installed.
(b) Check whether the circuit is not firmly connected.
No
Step 2 Check whether the control system has other DTCs except P048113 P048013.

interface.
to ON state.
scanner.
except DTC P048113 P048013.
Yes
Step 3 Use the “action test” of fault diagnostic scanner to drive the low-speed fan.
(a) Use the “action test” of fault diagnostic scanner to drive

the low-speed fan.
(b) Check whether the relay ER04 is working.
No Go to step 5.
Yes
Step 4 Use the “Action test” of fault diagnostic scanner to drive the high-speed fan.
(a) Use the “Action test” of fault diagnostic scanner to drive

the high-speed fan.
No Go to step 7.
Yes
Step 5 Check the power supply circuit between the cooling fan’s low-speed relay ER04 coil.
NL-3 01/2016
to OFF state. ES
(b) Remove cooling fan high-speed relay ER04.
to ON state.
(d) Measure the voltage between relay port 85 and effective
grounding point on vehicle body.
Circuit fault. If necessary, please replace
No
the harness
Yes
Step 6 Check the conductivity between terminal 56 of EMS harness connector CA45 and terminal 86 of relay
ER04.
to OFF state.
connector (b) Disconnect the EMS harness connector CA45.
(c) Remove the relay ER04.
(d) Measure the resistance between terminal 56 of EMS
harness connector CA45 and terminal 86 of relay ER04.
Standard resistance value: Less than 1Ω
(e) Confirm whether resistance meets the standard value.
No the harness
Yes
Step 7 Check the power supply circuit of the cooling fan high speed relay ER03 coil.
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ES Engine compartment fuse, relay box to OFF state.
to ON state.
No
the harness
Yes
Step 8 Check the conductivity between terminal 31 of EMS harness connector CA45 and terminal 86 of relay
ER03.
to OFF state.
connector (b) Disconnect the EMS harness connector CA45.
No
the harness
Yes
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Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes
DTC P069111 P069212

1. DTC description:
P069111 Cooling fan relay control circuit short to ground (low speed)
P069212 Cooling fan relay control circuit short to power supply (low speed)
strategy strategy)
P069111 – Circuit short to ground - Relay circuit
- Relay
P069212 hardware - Circuit short to power supply
- EMS
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3. Circuit diagram:
ES
Main relay
ER05
Cooling fan Cooling fan

high speed Low speed
relay ER03 relay ER04
Cooling
fan
(a) Check whether the cooling fan relay ER04 is loosened or
unreasonably installed.
No

interface.
to ON state.
scanner.
except P069111 P069212
NL-3 01/2016

ES
Yes

the low-speed fan.
No Go to step 5.
Yes
to ON state.
No
the harness
Yes
Step 5 Check the control circuit of low-speed fan relay ER04.
to OFF state.
CA45 Engine management system harness (b) Disconnect the EMS harness connector CA45.
connector
(d) Measure the resistance between the terminal 56 of EMS
harness connector CA45 and the socket 86 of relay ER03.
(e) Measure the resistance between the socket 86 of relay
ER04 and the reliable grounding point, and check whether
the control circuit of relay ER04 is short to the earth.
(f) Measure the voltage between the socket 86 of relay ER04
and the reliable grounding point, and check whether the
control circuit of relay ER04 is short to the power supply.
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ES Engine compartment fuse, relay box Resistance of socket 86 of
Less than 1 Ω
CA45(56)-ER04
Voltage between socket 86 of
10 kΩ or higher
ER04 and reliable grounding
0V
(g) Does the measured value conform to standard value?
No the harness
Yes
Step 6 Replace the ER04 relay.
to OFF state.
(c) Remove the low-speed cooling fan relay ER04, and
replace the relay of same model.
(d) Connect the negative battery cable.
(e) Operate the starter switch to turn the power supply mode
to ON state.
(f) Confirm whether the faults are eliminated
Yes Eliminate the fault, and go to the step 9
Yes

Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
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system has no DTC output. ES
No
Yes
DTC P069311 P069412

1. DTC description:
P069311 Cooling fan relay control circuit short to ground (high speed)
P069412 Cooling fan relay control circuit short to power supply (high speed)
strategy strategy)
P069311 - Circuit short to ground - 1. Relay circuit
hardware
- 2. Relay
P069412 - Circuit short to power supply - 3. EMS
hardware
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3. Circuit diagram:
ES
Main relay
ER05

Cooling
fan
(a) Check whether the cooling fan relay ER03 is loosened or
unreasonably installed.
No

interface.
to ON state.
scanner.
is no DTC other than DTCs P069311 P069412.
NL-3 01/2016

ES
No
Step 3 Use the “Action test” of fault diagnostic scanner to drive the high-speed fan.
(a) Use the “Action test” of fault diagnostic scanner to drive

the high-speed fan.
No Go to step 5.
Yes
to OFF state.
to ON state.
No
the harness
Yes
Step 5 Check the control circuit of high-speed fan relay ER03.
to OFF state.
connector
harness connector CA45 and the socket 86 of relay ER03.
(e) Measure the resistance between the socket 86 of relay
ER03 and the reliable grounding point, and check whether
the control circuit of relay ER03 is short to the earth.
(f) Measure the voltage between the socket 86 of relay ER03
and the reliable grounding point, and check whether the
control circuit of relay ER03 is short to the power supply.
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Engine compartment fuse, relay box Resistance value of socket 86
ES Less than 1 Ω
of CA45(31)-ER03
Resistance between socket
86 of ER03 and reliable 10 kΩ or higher
grounding
0V
(g) Does the measured value meet standard value?
No
the harness
Yes
to OFF state.
(c) Remove the low-speed cooling fan relay ER03, and
replace the relay of same model.
to ON state.
(f) Confirm whether the faults are eliminated
Yes Eliminate the fault, and go to the step 9
No

Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
NL-3 01/2016
system has no DTC output. ES
No
Yes
DTC P050129
1. DTC description:
P050129 Vehicle speed sensor signal fault
The vehicle speed signal is used to monitor the vehicle running speed, and is one of the reference signals for EMS to control
fuel cut-off during sudden deceleration. The vehicle speed signal is provided by the wheel speed sensor to ABS, which then
provides it to the engine control module EMS after calculation.
strategy strategy)
- Lower limit check
during fuel cut-off
- 1. Circuit fault
- Speed freezing fault - Speed <5 km/h
P050129 - 2.EMS
- Diagnosis on - Change in vehicle speed =0
- 3.ESP
reasonableness of
speed ratio
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3. Circuit diagram:
ES
Gateway
Step 1 Road test vehicle, and check whether the vehicle speed displayed on the instrument is normal.
(a) If the vehicle speed displayed in the instrument is normal,
the vehicle speed signal output and circuit are normal.
(b) If the vehicle speed displayed in the instrument is not
normal, there may be fault on vehicle speed signal output or
circuit.
(c) Confirm whether the instrument displayed vehicle speed is
normal.
Yes Go to step 3.
No
Step 2 Check whether the control system has DTCs except P050129.
NL-3 01/2016

interface. ES
to ON state.
scanner.
(d) Select the following menu: Engine/reading fault code.
(e) Read the fault diagnostic code, check whether the control
system has DTCs except P050129.
No

Yes
Next step

interface.
to ON state.
(c) Clear DTCs.
Yes
DTC P050600 P050700

1. DTC description:
P050600 Idle control speed is lower than target idle speed
P050700 Idle control speed is higher than target idle speed
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Throttle actuator control motor is controlled by the engine control module (EMS). Throttle valve body internal DC motor drives
throttle. In order to reduce idle speed and meanwhile change the ignition time and fuel supply, engine control module
ES commands the throttle to close. By reducing the air flow into the engine, idle speed is lowered. In order to increase idle speed,
the engine control module commands the throttle to open, so that more air flow passes through the throttle. Engine control
module (EMS) calculates and controls engine idle speed target based on coolant temperature, vehicle speed compensation,
deceleration adjustment, A/C compensation and voltage compensation.
(control strategy)
- Difference between static
-The idle speed actuator is stuck
P050600 target idle speed and actual
in smaller opening position - 1. Electronic throttle body
speed >100 U/min
- 2. Circuit fault
- Difference between static
-The idle speed actuator is stuck - 3. EMS
P050700 target idle speed and actual
in the larger opening position
speed < -200 U/min
interface.
to ON state.
scanner.
except P050600 and P050700.
No
Step 2 Check whether the alternator is working properly.
(a) Use a fault diagnostic scanner to observe whether the

system voltage parameters are normal.
(b) Confirm whether the generating capacity of the alternator
is normal.
No Check and repair the alternator fault.
Yes
Step 3 Check intake pressure parameter of intake temperature pressure sensor.
(a) Observe whether the intake pressure parameters of the

system intake temperature and pressure sensor are normal
with the fault diagnostic scanner.
(b) Confirm whether the parameters of the intake temperature
and pressure sensor are normal.
No Go to step 5.
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Yes
Step 4 Check the A/C working condition. ES
(a) Use a fault diagnostic scanner to observe whether the A/C

working status is consistent with the actual A/C working
condition.
(b) When the A/C is turned on and the A/C compressor pump
works, observe whether the engine idle speed is stable.
Yes Go to step 7.
No
Step 5 Check the intake system and exhaust system.
(a) Check intake system and exhaust system for blockage

and air leakage.
(b) Confirm whether there is too much carbon residue in
throttle.
No
Step 6 Check engine mechanical transmission and accessory transmission.
to OFF state.
(b) Check whether the drive belt of engine accessory is
loosened.
C. Remove engine accessory belt, neutral gear. Rotate the
engine crankshaft and inspect whether engine mechanical
moving components catching.
(d) Rotate engine accessory pulley and A/C pump. Check
whether there is engine and other accessory components
stagnation.
(e) Confirm whether the above faults are available
No

Yes
Next step
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ES
interface.
to ON state.
(c) Clear DTCs.
Yes
DTC 56000 P056200 P056300

1. DTC description:
P056000 System battery voltage signal is unreasonable
EMS power supply circuit consists of the following circuits:
– Battery power supply passes through EMS BAT 10A fuse to EMS harness connector CA45 terminal 20 directly.
– Operate the starter switch to turn the power supply mode to ON state. Battery power supply passes through IF17 10A fuse,
and finally reaches terminal 35 of EMS harness connector CA45.
– When EMS monitors there is battery voltage on terminal 5 of EMS harness connector CA45, EMS controls terminal 5 of
CA45 to realize the internal grounding. The main relay is engaged due to connection between terminal 5 of CA45 and terminal
85 of the main relay.
When the main relay engaged, the battery power supply will reach terminal 15, 16 of EMS harness connector CA45 via the
terminal 87 of the main relay.
(control strategy)
P056000 - Rationality check
- Lower than the lower limit - Circuit fault
P056200
- Voltage value of battery value - Alternator
- Higher than the upper limit - EMS
P056300
value
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3. Circuit diagram:
ES
Main relay
ER05
Step 1 Check whether the control system has other DTCs output.
interface.
to ON state.
scanner.
(d) Select the following menu: Engine/reading DTC.
except 56000, P056200 and P056300.
No
Step 2 Check the EMS fuses EF09, EF18 and IF17.
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ES to OFF state.
(c) Remove the fuses EF09 and EF18 from fuse & relay box
of engine compartment.
(d) Remove the fuse IF16 from indoor fuse relay box.
(e) Measure whether the two terminals of the fuse are
connected.
Rated capacity of fuse: EF09 30A\EF18 10A\IF17 10A
Check whether there is short circuit, and
No
replace the fuse.
Indoor fuse, relay box
Yes
Step 3 Check the supply voltage of EMS.
to OFF state.
CA45 Engine management system harness (b) Disconnect the negative battery cable.
connector
ignition switch to turn the power supply mode to ON state.
(e) Measure the voltage between the terminal 20/35/15/16 of
EMS harness connector CA45 and the reliable grounding.
No Go to step 5.
Yes
Step 4 Check the grounding circuit of EMS.
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to OFF state. ES
connector
(c) Disconnect the EMS harness connectors CA45 and
EG24.
(e) Measure the resistance between the terminals 63 and 64
of EMS harness connector CA45 and the reliable grounding.
(f) Measure the resistance between the terminals 47 and 48
of EMS harness connector EG24 and the reliable grounding.
EG24 Engine management system harness value.
connector 2
There is fault in grounding circuit of
No
EMS. Repair the relevant component,
and if necessary replace the harness.
Yes
Step 5 Check the charging system.
(a) Check the battery voltage.

(b) Check alternator charging voltage.
Yes
Step 6 Check the circuit from fuse EF09 and EMS.
to OFF state.
(c) Disconnect the EMS harness connector CA45, and
remove the fuse EF09 fuse from fuse & relay box of engine
compartment.
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(d) Measure the resistance between the terminal 15/16 of

ES EMS harness connector CA45 and the fuse EF09, and check
whether the circuit is broken.
connector (e) Measure the resistance between the terminal 15/16 of
EMS harness connector CA45 and the reliable grounding ,
and check whether the circuit is short to the earth.
(f) Confirm whether the above faults are available.
Standard value:
CA45(15)-EF09 resistance
value
Less than 1 Ω
value
Resistance value between
Engine compartment fuse, relay box CA45(15) and reliable

grounding
10kΩ or higher
CA45(16) and reliable
grounding
The circuit is faulty. Repair or replace the
No harness.
Yes
Step 7 Check the circuit from fuse EF18 and EMS.
to OFF state.
connector (c) Disconnect the EMS harness connector CA45, and
remove the fuse EF18 fuse from fuse & relay box of engine
compartment.
harness connector CA45 and the fuse EF18, and check
whether the circuit is open.
(e) Measure the resistance between the terminal 20 of EMS
harness connector CA45 and the reliable grounding, and
check whether the circuit is short to the ground.
Standard value:
Less than 1 Ω
value
Resistance between
CA45(20) and reliable 10kΩ or higher
grounding
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Engine compartment fuse ,relay box The circuit is faulty. Repair or replace the ES
No harness.
Yes
Step 8 Check the circuit from fuse IF17 and EMS.
to OFF state, and disconnect the negative battery cable.
connector (b) Remove the fuse IF17, and disconnect the EMS harness
connector CA45.
(c) Measure the resistance between the terminal 35 of EMS
harness connector CA45 and the fuse IF17, and check
whether the circuit is broken.
harness connector CA45 and the reliable grounding, and
check whether the circuit is short to the earth.
Standard value:
Indoor fuse, relay box Measured items Standard value
CA45(35)-IF17 resistance
Less than 1 Ω
value
Resistance between
grounding
(f) Does the measured value meet standard value?
No harness.
Yes
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Next Step
ES Step 10 Determine whether the DTC is saved again via the fault diagnostic scanner.

interface.
to ON state.
(c) Clear DTCs.
Yes
DTC P057129 P05711C

1. DTC description:
P05711C The brake lamp switch signal circuit fails
Brake switch is mainly used to control brake lamp working conditions and provide a brake signal to EMS, facilitating the control
of engine fuel cutting-off by EMS at high speed. Brake switch is connected to terminal 23 of engine control unit EMS harness
connector CA45 through terminal 2 of the harness connector CA09, providing a signal to the engine control unit EMS. Brake
switch is connected to terminal 25 of engine control unit EMS harness connector CA45 through terminal 1 of the harness
connector CA09, providing a signal to the engine control unit EMS and turning on the brake lamp.
(control strategy)
- Interaction between brake - Two brake signals not
P057129
switch and S_bls brake lamp synchronized during braking
- The ratio between voltage of - 1. Circuit fault
battery and voltage feedback - 2. Brake lamp switch
- Feedback voltage value of
P05711C from brake lamp switch is - 3. EMS
brake lamp switch
lower than 1.1328 or is higher
than 0.4688
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3. Circuit diagram:
ES
Main relay
ER05
Brake lamp
switch
(a) Depress the brake pedal, and check whether the brake
switch can normally popup.
(b) Check whether the contact between brake switch and
brake pedal is normal.
(c) Check whether the brake pedal return is normal.
No Adjust the brake pedal.
Yes
Step 2 Inspect the fuses IF17 and IF29.
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ES Indoor fuse, relay box to OFF state.
(C) Remove the fuse IF17, IF29 from indoor fuse relay box.
(d) Measure whether the two terminals of the fuse are
connected.
Rated capacity of fuse: IF29 10A\IF17 10A
Check whether there is short circuit, and
No
replace the fuse.
Yes
Step 3 Check the brake switch for conductivity.
to OFF state.
CA09 Brake pedal harness connector (c) Disconnect brake lamp switch harness connector CA09.
(d) Measure the resistance between the terminals 2 and 4 of
brake switch, and check the conductivity.
(e) Depress the brake switch, measure the resistance
between terminals 1 and 3 of brake switch, and check the
conductivity.
No Replace brake switch.
Yes
Step 4 Check the brake switch power supply circuit.
to OFF state.
CA09 Brake pedal harness connector
(c) Disconnect brake lamp switch harness connector CA09.
(e) Measure voltage value between brake switch harness
connector CA09 terminal 3 and reliable grounding.
Standard value: 11~14V
to ON state. Measure voltage value between terminal 4 of
brake switch harness connector CA09 and reliable grounding.
value.
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Check and repair circuits, and replace

No the harness if necessary. ES
Yes
Step 5 Check the connecting circuits between the brake switch and EMS.
to OFF state.
connector
(c) Disconnect the brake lamp switch harness connector
CA09, and disconnect the EMS harness connector CA45.
(e) Measure the resistance value between terminal 2 of brake
switch harness connector CA09 and terminal 23 of EMS
harness connector CA45.
(f) Measure the resistance value between terminal 2 of brake
switch harness connector CA19 and reliable grounding.
(g) Measure the resistance value between terminal 1 of brake
switch harness connector CA19 and terminal 25 of EMS
(h) Confirm whether the measured value is normal.
CA09(2)-CA45(23) resistance
CA09 Brake pedal harness connector
Less than 1 Ω
value
grounding
Less than 1 Ω
value
grounding
Check and repair circuits, and replace

No the harness if necessary.
Yes

Yes
Next Step
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ES
interface.
to ON state.
(c) Clear DTCs.
Yes
DTC P060100 P060611 P060612 P060443 P060543

1. DTC description:
P060100 Checksum calculation fault of EEPROM by logoff configuration
P060611 The voltage of ambient pressure sensor signal is too low
P060612 The voltage of ambient pressure sensor signal is too high
P060443 Electronic control unit RAM fault
P060543 Electronic control unit ROM fault
EMS internal program processing error.
(control strategy)
- Carry out diagnosis for - Judge whether the voltage
P060100
correctness of ECU Checksum is correct
- The voltage is lower than the
P060611 - Measure the voltage
lower limit value
- The voltage is higher than the - 1. EMS
upper limit value - 2. Circuit fault
- The voltage is higher than the
upper limit value
- The voltage is lower than the
lower limit value
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3. Circuit diagram:
ES
Main relay
ER05
Step 1 Check whether the control system has other DTCs except P060100, P060611, P060612, P060443 and
P060543.
interface.
to ON state.
scanner.
is no DTC other than DTCs P060100, P060611, P060612,
P060443 and P060543.
No

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Yes
ES Step 3 Replace the EMS, refer to "Engine ECU".
Next step

interface.
to ON state.
(c) Clear DTCs.
No
Yes
DTC P060694 P060692 P060664 P060661 P060667 P060696 P06061C P060655 P060600 P060662
P060663 P060648 P060647 P060675 P060649
1. DTC description:
P060694 Fault of electronic throttle security monitoring function (second layer torque monitoring fault)
P060692 The second-level safety monitoring fails (speed sensor)
P060664 Fault of electronic throttle security monitoring function (The second-level load signal monitoring fails)
Fault of electronic throttle security monitoring function (The second-level ignition angle signal
P060661
monitoring fails)
P060667 Fault of electronic throttle security monitoring function (ECU erroneous response monitoring fault)
P060696 Fault of electronic throttle security monitoring function (AD converter monitoring fault)
P06061C The safety monitoring function for electronic throttle fails (The second-level throttle body signal
monitoring fails)
P060655 Fault of electronic throttle security monitoring function (deformation code monitoring fault)
P060600 Fault of second-level safety monitoring (safety oil cutoff)
P060662 Fault of second-level safety monitoring (electronic accelerator pedal)
P060663 Fault of electronic throttle security monitoring function
P060648 Fault of electronic throttle security monitoring function (monitoring erroneous response fault)
P060647 Fault of electronic throttle security monitoring function (monitoring model feedback fault)
P060675 Fault of electronic throttle security monitoring function (path test off fault)
P060649 Fault of electronic throttle security monitoring function (monitoring model inquiry fault)
EMS internal program processing error.
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(control strategy) ES
P060694
P060692
P060664
P060661
P060667
P060696
P06061C
P060655 - Internal monitoring of EMS - Internal error of EMS - EMS
P060600
P060662
P060663
P060648
P060647
P060675
P060649
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3. Circuit diagram:
ES
Main relay
ER05
Step 1 Check whether the control system has other DTCs except P060694, P060692, P060664, P060661,
P060667, P060696, P06061C, P060655, P060600, P060662, P060663, P060648, P060647, P060675
and P060649.
interface.
to ON state.
scanner.
(e) Read DTC, and confirm whether there is DTC other than
DTCs P060694, P060692, P060664, P060661, P060667,
P060696, P06061C, P060655, P060600, P060662,
P060663, P060648, P060647, P060675 and P060649.
No

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ES
Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes
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DTC P062713 P062811 P062912

1. DTC description:
ES
P062713 The fuel pump relay control circuit open
P062811 Fuel pump relay control circuit short to ground or open
P062912 Fuel pump relay control circuit short to power supply
The coil working power supply of the fuel pump relay is supplied by EMS controlled main relay. EMS controls fuel pump relay
ER09 terminal 85 grounding via terminal 49 of EMS harness connector CA45; the fuel pump relay engages. EMS interior is
equipped with a drive circuit to control relay coil grounding; the drive circuit is equipped with a feedback circuit to EMS; EMS
determines whether the control circuit is open, short to ground or to power supply via feedback voltage monitor.
(control strategy)
P062713 - Open power circuit - 2.5 V> Voltage < 5.8 V - Relay circuit
P062811 – Circuit short to ground - Voltage < 2.5 V - Relay
P062912 - Circuit short to power supply - Current > 4 A - EMS
3. Circuit diagram:
Main relay
ER05
Fuel pump
relay ER09
Fuel Pump
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(a) Connect the fault diagnostic scanner to the diagnosis ES
interface.
to ON state.
scanner.
(e) Read DTC.
Displayed DTC Go to step
DTC other than P062713,
No
P062811 and P062912
P062713, P062811, P062912 Yes
Yes
Step 2 Check the fuel pump fuse EF20.
(a) Is the fuel pump fuse EF20 blown?

No Go to step 3.
Yes
Step 3 Repair fuel pump fuse EF20 circuit.
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(a) Check fuel pump fuse EF20 circuit.

ES (b) Repair fuel pump power supply circuit short to ground
fault.
(c) Replace the fuse EF20.
Rated capacity: 15A
(d) Is the fuel pump working properly?
No
Step 4 Check the voltage of fuel pump relay ER09 terminal 30.

to ON state.
(b) At the same time, use a multimeter to check the voltage
between the terminal 3 of fuel pump relay ER09 and the
reliable grounding point.
Standard voltage value: 11~14V
(c) Whether the voltage conforms to the standard value.
Yes Go to step 10.
No
Step 5 Overhaul open circuit fault between terminal 3 of fuel pump relay ER09 and fuel pump fuse EF20.
(a) Check open circuit fault between terminal 3 of fuel pump

relay ER09 and fuel pump fuse EF20.
(b) Is the fuel pump working properly?
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Engine compartment fuse, relay box System is normal.

Yes ES
No
(a) Use the multimeter to check the voltage between the

terminal 1 of fuel pump relay ER09 and the reliable grounding
point.
Yes Go to step 10.
No
Step 7 Repair the main relay circuit fault.
(a) Repair the main relay circuit fault.

No
Step 8 Check the conduction between terminal 49 of EMS harness connector CA45 and the grounding circuit.
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(a) Operate starter switch to ON mode.

ES (b) Connect a test lamp between EMS harness connector
CA45 Engine management system harness CA45 terminal 49 and the body grounding circuit.
connector
(c) Use a diagnostic scanner to carry out "Action test" on
pump relay.
(d) Does test lamp light up?
No Go to step 11.
Yes

No

(a) Operate starter switch to ON mode.
Engine compartment fuse, relay box (b)Inspect the pump relay ER09 terminal 5 voltage with a
multimeter.
(c) Whether the voltage meets the standard value.
Yes Go to step 12.
No
Step 11 Replace the fuel pump relay ER09.
(a) Replace the fuel pump relay ER09.

No
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Step 12 Check the voltage of fuel pump harness connector SO26 terminal 1.
(a) Use a multimeter to check the voltage between the
terminal 1 of fuel pump harness connector SO26 and the ES
S026 Fuel pump harness connector
(b) Does the voltage meet the standard value?
Yes Go to step 14.
No
Step 13 Overhaul the circuit between fuel pump harness connector SO26 terminal 1 and fuel pump relay ER09
terminal 5.
(a) Check circuit between fuel pump harness connector SO26
terminal 1 and the fuel pump relay ER09 terminals 5.
(b) Repair open circuit fault between fuel pump harness
connector SSO26 terminal 1 and the fuel pump relay ER09
terminal 5.
(c) Is the fuel pump working properly?
No
Step 14 Check the circuit between terminal 4 of fuel pump harness connector SO26 and body grounding.
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(a)Check resistance between fuel pump harness connector

ES SO26 terminal 4 and the body grounding with a multimeter to
confirm the grounding circuit continuity.
Standard resistance value: Less than 1Ω.
(b) Is fuel pump grounding circuit normal?
Yes Go to step 16.
No
Step 15 Repair the circuit between terminal 4 of fuel pump harness connector SO26 and body grounding.
(a) Repair circuit open fault between fuel pump harness

connector SO26 terminal 4 and the body ground.
S026 Fuel pump harness connector (b) Is the fuel pump working properly?
No
Step 16 Replace the fuel pump.
(a) Replace the fuel pump.

(b) Confirm the repair completed.
Next Step
Step 17 System is normal.
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DTC P064513 P064611 P064712

1. DTC description:
ES
P064513 A/C compressor replay control circuit fault
P064712 A/C compressor replay control circuit voltage is too high
The working power supply of A/C compressor relay is provided by main relay which is controlled by EMS. EMS controls A/C
compressor relay interior grounding via terminal 38 of EMS harness connector CA45; the relay engages. EMS interior is
DTC setting conditions (control
strategy)
- Voltage > 2.5 V and <5.8 V
P064513 - Open power circuit – System voltage: > 10.7 V and
<16.01 V
- Voltage > 2.5 V - Circuit
P064611 – Circuit short to ground – System voltage > 10.7 V and - EMS
<16.01 V - Relay
- Voltage > 4 V
- Circuit short to power
P064712 – System voltage > 10.7 V and
supply
<16.01 V
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3. Circuit diagram:
ES
Main relay
ER05
A/C control panel
A/C A/C relay

pressure ER02
switch
A/C
compressor
clutch
Step 1 Check DTC relevant to A/C system
(a) Read the fault code relating to A/C system.

(b) Repair DTC indicated faults.
(c) Clear DTC fault code.
(d) Whether the A/C clutch is working normally?
No
Step 2 Identify the fault of A/C system.
(a) Perform maintenance according to the following fault symptom table.

Symptoms Suspected fault position Maintenance plan
1. ECT sensor fault 1. Replace ECT
2. ECT sensor harness fault 2. Repair ECT harness
Engine coolant temperature is
3. In a major cycle, the engine 3. Replace the thermostat
too low
cooling system is working. 4. Overhaul EMS, if
4. EMS fault necessary, replace it
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1. The pressure switch shows

1. Replace the pressure
the signal of the A/C pressure
switch
not conforming to the
A/C pressure switch signal 2. Repair the pressure switch ES
standard value
abnormality harness
2. Pressure switch harness
3. Overhaul EMS, if
fault
necessary, replace it
3. EMS fault
1. Replace outdoor
1. The temperature sensor
temperature sensor
displays the outdoor
2. Repair outdoor temperature
Outdoor temperature sensor temperature is lower than 4 ℃
sensor harness
signal abnormality 2. Outdoor temperature
3. Overhaul and repair the
sensor harness fault
A/C control module, and
3. A/C control module fault
replace it if necessary.
1. Replace the evaporator
Evaporator temperature
temperature sensor
sensor displays temperature
2. Evaporator outdoor
Evaporator temperature below 2 ℃ (35.6
ºF).
temperature sensor harness
sensor signal abnormality 2. Evaporator temperature
3. Overhaul and repair the
A/C control module, and
1. Drain the excessive filled
refrigerant
2. Maintain poor cooling fault
1. The high pressure of A/C is
of the vehicle
higher than 3.14MPa
3. Maintain poor operation
Coolant pressure abnormality (455.4psi)
fault of the engine
2. A/C low pressure is lower
4. Overhaul interior blockage
than 0.196MPa (28.4 psi)
fault of the A/C system
5. Overhaul A/C system
leakage fault.
(b) Determine the fault repair is finished.
(c) Whether the A/C clutch is working normally.
No
Step 3 Check compressor fuse.
(a) Check compressor fuse EF06.

Rated value of the fuse: 10A
(b) Confirm whether fuse is blown out.
Yes Replace compressor fuse EF02.
No
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Step 4 Overhaul compressor clutch power supply circuit.

ES
(a) Check whether compressor clutch power supply circuit is
short to ground.
(b) Whether the A/C clutch is working normally.
Yes The system is normal.
No
Step 5 Detect compressor clutch power supply terminal voltage
(a) Start the engine, press down the A/C control switch (A/C
switch), and measure the voltage of terminal 1 of compressor
EG21 A/C compressor clutch harness connector
(b) Confirm whether the voltage meets standard value.
Yes Replace the compressor clutch.
No
Step 6 Overhaul compressor clutch power supply circuit
(b) Remove the compressor relay ER02.
(c) Disconnect compressor harness connector EG21.
(d) Measure the resistance between the terminal 5 of
compressor relay ER02 and the terminal 1 of compressor
Standard resistance value: Less than 1Ω.
No Maintain or replace the harness.
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ES
EG21 A/C compressor clutch harness connector
Yes
Step 7 Check the performance of compressor relay ER02.
to OFF state.
(b) Remove and replace the compressor relay ER02.
(c) Check whether the clutch works normally.
No Replace the compressor relay ER02.
Yes
Step 8 Check the supply voltage of compressor relay ER02.
(a) Measure the supply voltage of terminal 3 of compressor

relay ER02.
Yes
Step 9 Check the electromagnetic clutch of compressor.
(a) Connect the positive pole of battery with the binding post,
and connect the negative pole with the casing of compressor.
(b) Check the electromagnetic clutch which is powered on.
(c) Confirm whether the A/C clutch is working normally.
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Replace the electromagnetic clutch.

ES No
Yes
Step 10 Check the EMS control circuit fuse EF10.
(a) Check whether the fuse EF10 in fuse box of engine

compartment has blown out, and whether the connecting line
of fuse is normal.
When replacing the fuse, please check
No and repair the fuse harness if necessary.
Yes
Step 11 Check the conductivity of harness between EMS and compressor relay ER02.
to OFF state.
(b) Disconnect harness connector CA45 of EMS engine
management system.
EMS harness connector CA45 and the terminal 2 of relay
ER02.
(e) Confirm whether the resistance meets the standard value.
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ES
connector
Yes
Step 12 Check the conductivity of harness between compressor relay and fuse EF10.
to OFF state.
(b) Remove the fuse EF10.
(d) Measure the resistance value between the fuse EF10 and
the terminal1 of relay ER02.
Yes
Step 13 Check the conductivity of harness between EMS and compressor relay.
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ES to OFF state.
(b) Disconnect the EMS harness connector CA45.
(c) Remove the compressor relay ER02.
ER02.

connector
Yes
(a) Replace the EMS.

No
Step 15 Check the conductivity of harness between A/C pressure switch and EMS.
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to OFF state. ES
EG09 A/C pressure switch harness connector
(c) Disconnect A/C pressure switch harness connector EG09.
harness connector CA45 and the terminal 3 of A/C pressure
switch harness connector EG09.
(e) Measure the resistance between the terminal 24 of EMS
harness connector CA45 and the terminal 4 of A/C pressure
Check and repair the relevant harness
CA45 Engine management system harness No
connector
or terminal.
Yes
Step 16 Replace A/C pressure switch.
(a) Replace A/C pressure switch

No
Step 17 Check the grounding circuit of A/C pressure switch.
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(a) Remove the A/C pressure switch harness connector.

ES (b) Measure the resistance between terminal 2 of A/C
pressure switch harness connector EG09 and grounding.
(c) Confirm whether the resistance meets standard value.
Yes
Step 18 Check the harness between A/C pressure switch and A/C control panel.
to OFF state.
(b) Remove A/C pressure switch harness connector EG09.
(c) Remove the A/C control panel harness connector IP29.
(d) Measure the resistance between the air conditioning
pressure switch harness connector EG09 terminal 1 and air
conditioning control panel IP29 terminal 14.
IP29 A/C control module harness connector
Yes
Step 19 Replace the A/C control panel.
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(a) Replace the A/C control module.

(b) Confirm the repair is completed. ES
Next Step
DTC P068881
1. DTC description:
P068881 Main relay output voltage signal fault
Main relay is used to provide power supply to fuel injector nozzles and oxygen sensors and other vehicle components. Battery
provides power to main relay terminal 30, 86. EMS controls main relay grounding through EMS harness connector CA45
terminal 5. EMS interior is equipped with a detection circuit. By monitoring the feedback voltage, EMS determines whether the
control circuit is open, short to ground or short to power supply.
strategy)
- 1. The battery voltage (UBR) after
passing the main relay is less than
- 1. Main relay circuit
- 1. Signal check 3V.
P068881 - 2. Main relay
- 2. Rationality check - Battery voltage (UBR) after passing
- 3. EMS
the main relay is larger than or equal
to 3V
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3. Circuit diagram:
ES
Main
relay
ER05
Step 1 Appearance check.
(a) Check main relay for signs of damage.
Yes Replace main relay, and go to Step 8.
No
Step 2 Check whether the control system has any fault code other than DTC P068881.

interface.
to ON state.
scanner.
except DTC P068881.
NL-3 01/2016
No
Step 3 Check the voltage between terminals 30 and 85 of the engine main relay ER05 and reliable grounding. ES
(c) Remove main relay ER05.
(e) Measure the voltage between the socket 30/85 of main
relay ER05 of engine and the reliable grounding.
Check and repair the circuit between
No battery and socket 30/85 of ER05,
replace the harness if necessary, and
then go to the step 8.
Yes
Step 4 Check the circuit between the socket 86 of main relay ER05 of engine and the terminal 5 of CA45.
to OFF state.
connector
(d) Disconnect the EMS harness connector CA45.
(e) Measure the resistance between the socket 86 of main
relay ER05 of engine and the terminal 5 of EMS harness
connector
Check and repair the circuit between the
No
socket 86 of ER05 and the terminal 5 of
CA45, replace the harness if necessary,
Engine compartment fuse, relay box and then go to the step 8.
NL-3 01/2016
Yes
ES Step 5 Check the voltage of terminal 5 of EMS harness connector CA45.
to OFF state.
connector (c) Disconnect the EMS harness connector CA45.
(e) Measure voltage between CA45 terminal 5 and a reliable
ground.
Replace main relay ER05, and go to
No Step 8.
Yes

Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes
DTC P133600 P210612 P210619 P210692 P210613 P210629

1. DTC description:
NL-3 01/2016

P133600 Electronic throttle safety monitoring torque limit function ES
P210619 Power drive level fault of electronic throttle (overheat or overcurrent)
P210692 Power drive level fault of electronic throttle (SPI bus or signal)
P210629 Load monitoring fault
Electronic throttle valve body is a key component of the engine intake system in EGAS system, and its main function is to
adjust the intake passage area according to driver's driving intention, thereby controlling the intake quantity and meeting
intake demand under different engine working conditions. At the same time, it feeds back the position signal of the throttle
valve plate to the control unit to achieve precise control.
strategy)
-Difference between first level
-Monitoring diagnosis of
P133600 required torque and allowed
the first level torque
torque>0
- Monitor the short circuit
P210612 of power driven stage of - bit 0=TRUE
DVE
- Monitor the overheating - 1. Circuit fault
P210619 or overloading of power - bit 3 or bit 4=TRUE - 2. EMS
driven stage of DVE - 3. Engine speed sensor
-Monitor DVE power drive
P210692 level - SPI bus or signal - bit 0 and bit 3 and bit 4 =false
fault
- Monitor the broken
P210613 circuit of power driven - bit 1=TRUE
stage of DVE
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3. Circuit diagram:
ES
Main relay
ER05
Electronic throttle
Step 1 Check the battery voltage.
to OFF state.
(b) Measure the battery voltage with multimeter.
Voltage value: 11~14 V
Replace the battery or charge the
No battery.
Yes
Step 2 Check whether the system has other DTCs associated with ETC system.

interface.
to ON state.
scanner.
(e) Read DTCs, and confirm whether there is no other DTCs.
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ES
Yes
Step 3 Clean electronic throttle valve body.
(a) Remove the electronic throttle body, refer to "Electronic

throttle body".
(b) Clean electronic throttle body.
Next step
Step 4 Electronic throttle self-learning
Next step
Step 5 Check the drive control circuit of the electronic throttle.
to OFF state.
EG22 Electronic throttle harness connector (c) Disconnect the EMS harness connector EG24, and
disconnect the electronic throttle body harness connector
EG22.
(d) Measure the resistance value between terminal 1 of EG22
(e) Measure the voltage value between terminal 1 of EG22
(f) Measure the conductivity between terminal 1 of EG22 and
terminal 23 of EG24.
(e) Measure the resistance value between terminal 4 of EG22
(d) Measure the voltage value between terminal 4 of EG22
(i) Measure the conductivity between the terminal 4 of EG22
and the terminal 11 of EG24.
EG24 Engine management system harness Standard value:
connector 2
10 kΩ or higher
0V
Less than 1 Ω
value
10 kΩ or higher
0V
Less than 1 Ω
value
(j) Does the measured value meet standard value?
Check the circuit fault, and replace the
Yes
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ES interface.
to ON state.
(c) Clear DTCs.
Next step

Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
Yes
DTC P154500 P154522 P154521 P155900 P155929 P156400 P156500 P156800 P157900
1. DTC description:
P154500 The positional deviation fault of electronic throttle
P154522 The PID position control fault for electronic throttle
P155900 Electronic throttle limp position self-learning fault
P155929 The repeated self-learning fault for mechanical bottom dead center of electronic throttle
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P156400 System pressure cannot meet the condition for electronic throttle self-learning ES
P156500 The initial self-learning fault for bottom dead center of electronic throttle
P156800 The check fault on electronic throttle spring
P157900 Electronic throttle self-learning condition is not met
Electronic throttle valve body is a key component of the engine intake system in EGAS system, and its main function is to
adjust the intake passage area according to driver's driving intention, thereby controlling the intake quantity and meeting
intake demand under different engine working conditions. At the same time, it feeds back the position signal of the throttle
valve plate to the control unit to achieve precise control.
strategy)
- The systems exits from
- Check on self-learning of
P154500 self-learning since the supply
throttle
voltage is too low
P154522 – Monitor setting range of
- Duty ratio > 79.9988 %
P154521 PID
- Check on self-learning of - (Lameness position) Error in check
P155900
throttle on self-learning
- Check of voltage range of - TPS1 signal voltage TPS1<0.2124
P155929
mechanical BDC V or > 0.8655
- The systems exits from - 1. EMS
- Check on self-learning of
P156400 self-learning since the supply - 2. Throttle body
throttle
voltage is too low - 3. Circuit fault
- TPS1 signal voltage TPS1<0.2124
V or > 0.8655V
- Monitor learning position of
P156500 -Signal voltage TPS2 Signal
the mechanical BDC
voltage TPS2<4.1418 V or >
4.8413V
- Check spring closure - Opening time > 0.5600
P156800
reasonability - Test threshold value 3.003
- Check on self-learning of - Other conditions for exiting from
P157900
throttle self-learning
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3. Circuit diagram:
ES
Main relay
ER05
Electronic throttle
to OFF state.
Voltage value: 11~14 V
Replace the battery or charge the
No battery.
Yes
Step 2 Check whether the system has other DTCs associated with ETC system.

interface.
to ON state.
scanner.
NL-3 01/2016

ES
Yes
Step 3 Clean electronic throttle body.
(a) Remove the electronic throttle body, refer to "Electronic

throttle body".
(b) Clean electronic throttle body.
Next step
Step 4 Electronic throttle self-learning
Next step
to OFF state.
(c) Disconnect the EMS harness connector EG24, and
disconnect the electronic throttle body harness connector
EG22.
(d) Measure the resistance value between terminal 1 of EG22
(e) Measure the voltage value between terminal 1 of EG22
(f) Measure the conductivity between terminal 1 of EG22 and
terminal 23 of EG24.
(e) Measure the resistance value between terminal 4 of EG22
(d) Measure the voltage value between terminal 4 of EG22
(i) Measure the conductivity between the terminal 4 of EG22
and the terminal 11 of EG24.
Standard value:
10 kΩ or higher
0V
EG22(1)-EG24(23) resistance Less than 1 Ω
10 kΩ or higher
0V
EG22(4)-EG24(11) resistance Less than 1 Ω
(j) Does the measured value meet standard value?
Check the circuit fault, and replace the
No
Yes
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ES interface.
to ON state.
(c) Clear DTCs.
Next step

Yes
Next step

interface.
to ON state.
(c) Clear DTCs.
No
Yes
DTC P161000 P161100 P161200 P161300 P161400

1. DTC description:
P161200 The certification reply of PEPS is incorrect, and the anti-theft certification fails
Anti-theft system identifies whether the intelligent key is valid, and sends the signal to EMS, which starts the engine only when
receiving the valid signal.
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DTC No. DTC detection strategy DTC setting conditions (control Fault position ES
strategy)
P161000
- 1. Connecting circuit
P161100 - 1. Circuit open
- 2. EMS
P161200 - Check on hardware - 2. Circuit short to ground
- 3. PEPS
P161300 - 3. Circuit short to power supply
- 4. Intelligent Key
P161400
3. Circuit diagram:
Please refer to the diagram of system.
Step 1 Check whether the control system has other DTCs output.

interface.
to ON state.
scanner.
Yes
Step 2 Check the vehicle CAN bus integrity.
(a) Check the integrity of CAN bus, refer to "Check integrity of

CAN" (fault codes U003788, U005588, U002888, U004688,
U003887, U002987 and U004787).
Yes The fault is eliminated.
No
Step 3 Perform anti-theft system programming learning with the diagnostic scanner.
(a) Carry out reprogramming learning of the intelligent key.
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Yes
ES Step 4 Determine whether the DTC is saved again via the fault diagnostic scanner.

interface.
to ON state.
(c) Clear DTCs.
Next step

Yes
Next Step

interface.
to ON state.
(c) Clear DTCs.
engine for5 min at least.
No
Yes
DTC P208811 P208912

1. DTC description:
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Engine EMS controls the VVT intake control valve according to engine working conditions, in order to change the angle of
intake camshaft relative to the crankshaft position (CKP). The intake VVT solenoid valve is supplied with power by the main
replay. EMS controls grounding via pulse width modulation signal. It thus controls the engine oil flow to the camshaft position ES
actuator. The engine oil pressure makes the safety slide valve inside the camshaft position actuator fixed to the front of the
camshaft move. When the safety slide valve moves, the engine oil is guided into the camshaft position actuator to make the
camshaft rotate. Thus, provide the most suitable valve timing for the engine state, which improves the torques in the speed
range and the fuel economy, and decreases exhaust amount, thus controlling the angle of advance opening of the valve.
strategy)
P208811 - 1. Circuit open - 1.VVT intake control valve
- 2. Circuit short to ground circuit
P208912 hardware
- 3. Circuit short to power supply - 2. EMS
3. Circuit diagram:
Main relay
ER05
Variable valve
timing valve
(intake )
NL-3 01/2016

ES interface.
to ON state.
scanner.
(e) Read DTC.
DTC except P208811
No
P208912
DTC P208811 P208912 Yes
Yes
Step 2 Check the OVC solenoid valve fuse EF10.
(b) Pull out the OVC solenoid valve fuse EF10, and check
Replace the fuse and the fault is
No
eliminated.
Yes
Step 3 Measure the resistance value of the OCV solenoid valve assembly.
NL-3 01/2016
(a) Operate the starter switch to turn the power supply mode to
OFF state.
(c) Disconnect the OCV solenoid valve harness connector EG15. ES
(d) Connect two conductors to terminals 1 and 2 of OCV solenoid
valve.
(e) Measure the resistance value between terminals 1 and 2 of
OCV solenoid valve.
Standard value: 7.5-8.5Ω at 20 ℃ (68℉ )
(f) Remove the OCV solenoid valve assembly, connect the
terminals 1 and 2 to positive and negative poles of battery
respectively, and check whether the OCV solenoid valve works
normally; if the OCV solenoid valve works abnormally, just clean
up the OCV solenoid valve, and please refer to the section about
OCV valve; reconnect the battery, and check whether the OCV
solenoid valve works normally.
(g) Install the solenoid valve, and connect the OCV solenoid
valve harness connector.
(h) Confirm whether the resistance meets the standard value,
and confirm whether the OCV solenoid valve works normally
after being cleaned up.
Replace the OCV solenoid valve assembly
No and go to Step 12.
Yes
Step 4 Measure OCV solenoid valve power supply.
OFF state.
(b) Disconnect the OCV solenoid valve harness connector EG15.
(c) Operate the starter switch to turn the power supply mode to
EG15 Variable valve timing valve (intake) ON state.
harness connector (d) Measure the voltage between terminal 1 of the harness
connector EG15 and reliable grounding.
(e) Re-connect the OCV solenoid valve harness connector
EG15.
Yes Go to step 7.
No
Step 5 Check the power circuit of OVC solenoid valve.
OFF state.
(b) Disconnect the OCV solenoid valve harness connector EG15.
(c) Measure the resistance value between solenoid valve fuse
EF10 and terminal 1 of OVC solenoid valve connector EG15.
No Go to step 7.
Yes
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Step 6 Check where there is voltage on pins 30 and 85 of main relay ER05.
ES
to OFF state.
battery cable
the state ON.
No
Yes
Step 7 Check the power circuit of main relay ER05.
to OFF state.
EG38 is connected to the electrical box of engine

compartment (c) Remove the main electrical ER05.
(d) Measure the resistance between B+ of battery and the
circuit between power terminal of main relay ER05 and
terminal 1 of EG38.
Standard resistance: Less than 1 Ω.
Maintain or replace the harness, and the
No fault is eliminated.
Yes
NL-3 01/2016
relay ER05.

connector
Yes
to OFF state.
(b) Disconnect the harness connector EG01 of intake variable
EG15 Variable valve timing valve (intake) valve timing valve.
harness connector
(c) Disconnect engine EMS harness connector EG24.
exhaust VVT valve harness connector EG01 and grounding
with a multimeter, the standard valve is shown in table below.
measure voltage between terminal 2 of harness connector
EG01 of exhaust variable valve timing valve to grounding with
multimeter. The standard value is shown in table below.
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Resistance between
Less than 1 Ω
ES EG01(2) and EG24(7)
EG01(2)- Grounding
10kΩ or higher
resistance
EG01(2)- Grounding
0V
voltage
Yes

Yes

(a) Replace the EMS, and carry out the learning for engine
speed sensor.
Next Step
interface.
to ON state.
(c) Clear DTCs.
(e) Vehicle road test for 10 min at least.
Yes
Step 13 The diagnosis is finished.
NL-3 01/2016
DTC P212216 P212317

ES
1. DTC description:
P212216 Electronic accelerator pedal position sensor 1 signal voltage is too low
P212317 Electronic accelerator pedal position sensor 1 signal voltage is too high
The throttle actuator control system uses 2 electronic accelerator pedal position sensors to monitor the position of electronic
accelerator pedal. The electronic accelerator pedal position sensors 1 and 2 are located in pedal assembly. Every sensor has
-. A 5V reference voltage circuit
-. A low level reference voltage circuit
-. A signal circuit
In addition, two processors are used to monitor the data of throttle actuator control system. The two processors are located in
engine management system (EMS). Every signal circuit provides the two processors with signal voltage in proportional to
displacement of pedal. The two processors monitor the data of each other, so as to confirm that the calculated value of
electronic accelerator pedal position is correct.
strategy)
- Signal voltage <0.605 V
– Deviation 1 between the pedal signals - Circuit
P212216 - Exceed the lower limit 1 and 2 - EMS
– Signal voltage of pedal position sensor – Electronic accelerator
2 >1.113V pedal position sensor
P212317 - Exceed the upper limit - Signal voltage >4.824 V
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3. Circuit diagram:
ES
Accelerator
pedal
Notice
Prior to executing this diagnostic procedure, observe the data list of the fault diagnostic scanner and analyze data
accuracy for quick troubleshooting!

interface.
to ON state.
scanner.
(e) Read DTC.
DTC other than P212216 and
No
P212317
P212216, P212317 Yes
Yes
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Step 2 Check voltage of harness connector CA10 terminal 2 of electronic accelerator pedal position sensor.
(a) Operate the starter switch to turn the power supply mode ES
to OFF state.
CA10 Accelerator pedal harness connector

(b) Disconnect electronic accelerator pedal position sensor
to ON state.
(d) Measure the voltage between terminal 2 of CA10 and
reliable grounding.
Standard voltage value: 4.7~5.3V
No Go to step 6.
Yes
Step 3 Check resistance of harness connector CA10 terminal 3 of electronic accelerator pedal position sensor
to ground.
to OFF state.
(b) Disconnect the electronic accelerator pedal harness
CA10 Accelerator pedal harness connector connector CA10.
to ON state.
accelerator pedal CA10 and the reliable grounding.
(e) Confirm whether the resistance value meets the standard
value.
No Go to step 6.
Yes
Step 4 Check terminal 4 of electronic accelerator pedal position sensor harness connector CA10.
NL-3 01/2016
ES to OFF state.
(b) Disconnect the accelerator pedal sensor harness
connector CA10.
CA10 Accelerator pedal harness connector (c) Disconnect the EMS harness connector CA45.
accelerator pedal harness connector CA10 and the terminal
45 of EMS harness connector CA45, and check whether
there is broken circuit. As for standard value, please refer to
the table below.
accelerator pedal harness connector CA10 and the reliable
grounding, and check whether the circuit is short to the
ground. As for standard value, please refer to the table below.
grounding, and check whether the circuit is short to power
supply. As for standard value, please refer to the table below.
CA45 Engine management system harness (g) Confirm whether the measured value is normal.
connector Measured items Standard value
Less than 1 Ω
value
grounding
Voltage value between
CA10(4) and reliable 0 V
grounding
No Circuit is faulty; repair the fault position.
Yes
Step 5 Check output voltage of terminal 4 of harness connector CA10 of electronic accelerator pedal position
sensor.
(a) Check the voltage between the terminal 4 of electronic

accelerator pedal position sensor and the grounding on
vehicle body.
CA10 Accelerator pedal harness connector Standard voltage: 0V
(b) Confirm whether the output voltage meets standard value.
Replace the electronic accelerator pedal
No position sensor.
Yes
Step 6 Check terminal 2, 3 of electronic accelerator pedal position sensor harness connector CA10.
NL-3 01/2016
to OFF state.
(b) Disconnect electronic accelerator pedal position sensor ES
CA10 Accelerator pedal harness connector

the state ON.
(e) Measure the resistance between terminal 2 of CA10 and
reliable grounding.
(f) Measure the resistance between the terminal 2 of CA10
and the terminal 37 of CA45.
(g) Measure the voltage between terminal 3 of CA10 and
reliable grounding.
(h) Measure the conductivity between CA10 terminal 3 and
CA45 terminal 7.
(i) Confirm whether the values meet standard values.
connector Measured items Standard value
grounding
Less than 1 Ω
value
CA10(3) and reliable 0V
grounding
Less than 1 Ω
value
Yes
Step 7 Check EMS power supply circuit and ground circuit.
(a) Check the power circuit and grounding circuit of EMS.

(b) Confirm whether the power and grounding circuits of EMS
are normal.
Yes
Next Step
Step 9 Carry out the learning for engine speed sensor.
Next Step
NL-3 01/2016

ES interface.
to ON state.
(c) Clear DTCs.
(e) Vehicle road test for10min at least .
(f) Read control system DTCs again. Confirm system has no
fault code output.
Yes
DTC P212716 P212817

1. DTC description:
P212716 Electronic accelerator pedal position sensor 2 signal voltage is too low
P212817 Electronic accelerator pedal position sensor 2 signal voltage is too high
-. A signal circuit
strategy)
- Deviation 1 between the pedal signals - Circuit
P212716 - Exceed the lower limit 1 and 2 - EMS
- Signal voltage of pedal position sensor - Electronic accelerator
2>1.113V Pedal Position Sensor
P212817 - Exceed the upper limit - Signal voltage >4.824 V
NL-3 01/2016
3. Circuit diagram:
ES
Accelerator
pedal
Notice
Prior to executing this diagnostic procedure, observe the data list of the fault diagnostic scanner and analyze data

interface.
to ON state.
scanner.
(e) Read DTC.
DTC except P212716 and
No
P212817
DTC P212716 P212817 Yes
Yes
NL-3 01/2016
Step 2 Check voltage of harness connector CA10 terminal 1 of electronic accelerator pedal position sensor.
ES
to OFF state.
CA10 Accelerator pedal harness connector harness connector CA10.
to ON state.
(d) Measure the voltage value between terminal 1 of CA10
No Go to step 6.
Yes
Step 3 Check resistance of harness connector CA10 terminal 5 of electronic accelerator pedal position sensor
to ground.
to OFF state.
CA10 Accelerator pedal harness connector connector CA10.
to ON state.
accelerator pedal CA10 and the reliable grounding.
No Go to step 6.
Yes
NL-3 01/2016
to OFF state.
(b) Disconnect the accelerator pedal sensor harness ES
connector connector CA10.
accelerator pedal harness connector CA10 and the terminal
there is broken circuit. As for standard value, please refer to
the table below.
ground. As for standard value, please refer to the table below.
grounding, and check whether the circuit is short to power
supply. As for standard value, please refer to the table below.
(g) Confirm whether the measured value is normal.
CA10 Accelerator pedal harness connector Measured items Standard value
Less than 1 Ω
value
grounding
grounding
Yes
Step 5 Check output voltage of terminal 6 of harness connector CA10 of electronic accelerator pedal position
sensor.
(a) Check the voltage between the terminal 4 of electronic

accelerator pedal position sensor and the grounding on
vehicle body.
CA10 Accelerator pedal harness connector Standard voltage: 0V

(b) Confirm whether the output voltage meets standard value.
Replace the electronic accelerator pedal
No
position sensor.
Yes
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ES to OFF state.
CA10 Accelerator pedal harness connector (c) Disconnect the EMS harness connector CA45.
the state ON.
(e) Measure the resistance value between terminal 1 of CA10
(f) Measure the conductivity between CA10 terminal 1 and
CA45 terminal 36.
(g) Measure the voltage value between terminal 5 of CA10
(h) Measure the conductivity between CA10 terminal 5 and
CA45 terminal 59.
CA45 Engine management system harness CA10(1) and reliable 10kΩ or higher
connector grounding
Less than 1 Ω
value
grounding
Less than 1 Ω
value
Yes

are normal.
Yes
Next Step
Next Step
NL-3 01/2016

interface. ES
(b) Operate the starter switch to turn the power supply mode to
ON state.
(c) Clear DTCs.
(d) Start and run the engine at idle speed to warm up the engine
for at least 5min.
(e) Vehicle road test at least 10min.

fault code output.
No Intermittent fault. Please refer to the section

about check on intermittent fault.
Yes
Step 11 Troubleshooting.
DTC P213800 P213829

1. DTC descriptions:
DTC Fault descriptions
The signal of electronic accelerator pedal position sensor is unreasonable (Check on displacement
P213800
of pedal when the engine speed is near idle speed)
P213829 Electronic accelerator pedal position sensor signal unreasonable
-. A signal circuit
2. DTC set and faulty position:
DTC No. DTC detection strategy DTC setting condition (control strategy) Fault component
- Movement direction of signal 1 and

- The result of check on signal 2
P213800 movement of electronic
accelerator pedal is wrong - When the signal 1 goes beyond idle - 1. Electronic
speed position accelerator pedal
- 2.EMS
- Signal voltage comparison of pedal - 3. Line
P213829 - Check on reasonableness
position sensors 1 and 2
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3. Circuit diagram:
ES
Accelerator pedal
Notice
Prior to executing this diagnostic procedure, observe the data table of the fault diagnostic scanner and analyze data accuracy
for quick troubleshooting.
Step 1 Check no other fault code output of the control system

interface.
to ON state.
scanner.
(e) Read DTC.

DTC except P213800
No
P213829
DTC P213800 P213829 Yes
Please refer to the table of diagnostic

No fault codes.
Yes
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Check the output voltage signals of the electronic accelerator pedal position sensor 1 and electronic
Step 2
accelerator pedal position sensor 2. ES
(a) Confirm whether the output signals of electronic
accelerator pedal position sensor 1 and electronic
accelerator pedal position sensor 2 meet the specified
value.
No Replace the electronic accelerator

pedal assembly.
Yes

(b) Confirm whether the power and grounding circuits of
EMS are normal.
No Repair faulty position
Yes
Step 4 Replace the EMS. Please refer to “Engine ECU”.
Next step
Next step
Step 6 Use fault diagnostic scanner to confirm whether DTC is stored again.
interface.
(b) Operate the starter switch to turn the power supply
mode to ON state.
(c) Clear DTCs.
engine for at least 5min.
(f) Read control system DTC again. Confirm system has
no fault code output.
No
Intermittent fault. Please refer to the
section about check on intermittent fault.
Yes
DTC P217700 P217800 P218700 P218800

P217700 The air-fuel ratio closed-loop control self-learning vale exceeds the upper limit
P217800 The air-fuel ratio closed-loop control self-learning value exceeds the lower limit
P218700 The air fuel ratio close loop control self-learning value is beyond the upper limit (low load area)
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ES
P218800 The air fuel ratio close loop control self-learning value is beyond the lower limit (low load area)
The engine control module (EMS) controls the close loop air fuel ratio measure coefficient to realize optimum match of the
maneuverability, fuel economy and emission control. In the closed-loop mode, the engine control module detects the front
oxygen sensor (HO2S) signal voltage and adjusts the fuel supply according to it. The fuel supply variation will change
long-term and short-term fuel adjustment value. The short-term fuel adjustment value will rapidly vary with the front oxygen
sensor signal voltage. Such changes will fine tune the engine fuel supply. The long-term fuel adjustment value varies with the
approximately 0%. The positive fuel adjustment value indicates that the engine control module is increasing the fuel amount to
DTC detection
DTC No. DTC setting conditions (control strategy) Faulty position
strategy
P217700 - 1. Fuel injector

- Fuel correction - 1. Excessive air coefficient higher than
- 2. Carbon canister
P217800 exceeding the lower the standard value 1.23
limit - 3. Intake
- 2. Self-learning of air-fuel ratio starts
temperature and
P218700 pressure sensor
(MAP)
- 1. Excessive air coefficient lower than the
- Fuel correction standard value 0.77 - 4. Electronic throttle
P218800 exceeding the lower position sensor (TPS)
limit - 2. Speed and load are higher than the
self-learning area - 5. HO2S (upstream)
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Notice
for quick troubleshooting. ES

interface.
to ON state.
scanner.
(e) Read DTC.
(f) Confirm whether there are DTCs except for P217700,
P217800, P218700 and P218800.
No Please refer to the table of diagnostic

fault codes.
No
Step 2 View intake pressure sensor data stream.
to OFF state.
(b) Connect fault diagnostic scanner.
(c) Start the vehicle.
(d) View intake pressure sensor data stream.
(e) Confirm whether the reading of the atmospheric pressure
in the fault diagnostic scanner is normal.
No Repair the intake pressure sensor
Yes

(b) Engine warming vehicle, normal idle speed, throttle
opening less than 10%.
(c) Use the fault diagnostic scanner to view throttle position
sensor data stream.
(d) Confirm whether the throttle position sensor data is
normal.

No
P012317 and DTC P022129 P022216
P022317。
Yes
Step 4 View front oxygen sensor data stream.

(c) Use the fault diagnostic scanner to view the front oxygen
sensor data stream.
(d) Confirm whether the front oxygen sensor data is normal.
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ES No Replace the front oxygen sensor
Yes
Step 5 Observe long-term fuel correction parameter.

(c) Use the fault diagnostic scanner to view the long-term fuel
correction parameter
(d) Confirm whether the long-term fuel correction parameter is
normal.
No
to OFF state.
(b) Check vacuum hose rupture, twisting or connection
(c) Check intake manifold, throttle and fuel injector nozzle
vacuum leakage state.
(d) Check crankshaft ventilation system leakage state.
(f) Check too thin state of the injection fuel of fuel injection
nozzle.
(g) Check too thin state of the fuel system.
(h) Check too rich state of the fuel system.
(i) Check too rich state of the injection fuel of fuel injection
nozzle .
(j) Check intake pipe for collapse or blockage.
(k) Check excessive fuel in the crankcase.
(l) Check the working state of the evaporation emission
control system.
(m) Check the working state of other fault lamps in the
instrument.
(n) Confirm whether the engine system is normal.
No
Next step
Step 8 System is normal.
NL-3 01/2016
DTC U007300 U010182 U010183 U010387 U012282 U012283 U012287 U013187 U014087
U014187 U015182 U015183 U015187 P168386
ES
U007300 CAN communication related diagnosis
U010182 The counter of TCU message 0x118 is wrong
U010183 The check digit of TCU message 0x118 is wrong
U010387 Lose communication with PEPS or the signal is abnormal.
U012282 The counter of ESP message 0x025 is wrong
U012283 The check digit of ESP message 0x025 is wrong
U012287 The communication with ESP controller fails
U013187 Lose communication with EPS or signal abnormal
U015187 Communication with ACU is interrupt.
On NL-3 vehicle, there are 5 CAN buses, which are connected by gateways, namely: B-CAN, which is connected with rear
camera module (RCM), A/C controller (HVAC), body control module (BCM), emergency telecommunication box (T-BOX),
information host unit (IHU), tire pressure monitoring system (TPMS), and passive entry passive start (PEPS) . The terminal
resistor of B-CAN bus is located in BCM (body control module), of which the resistance is 120 ohm.
The dynamic control (or active safety) CAN is connected with electronic stability program (ESP), steering column combination
switch (TCM), airbag control unit (ACU), front camera system (FCS), front radar system (FRS), and 4-wheel drive system
(4WD). The terminal resistor of D-CAN bus is located in ACU (airbag control unit), of which the resistance is 120 ohm.
The power drive CAN is connected with engine management system (EMS), transmission controller (TCU), and electronic
power steering system (EPS). The terminal resistor of P-CAN bus is located in EMS (engine management system), of which
the resistor is 120 ohm.
The instrument CAN is connected with combination instrument. The terminal resistor of I-CAN bus is located in combination
instrument, of which the resistance is 120 ohm.
The OBD diagnostic CAN is connected with the OBD diagnostic interface.
1. The oscilloscope double-channel input can be used for signals monitoring which transits on CAN bus. The signals shall
have the following features:
(a) The voltage signal on CAN H line is 2.5~3.5V, and the voltage signal on the CAN L line is 1.5~2.5V.
(b) Two signals are mirror image of each other.
(c) The signal transmission starts while the starter switch is turned on, but stops 2s after the starter switch is switched off.
DTC U300385 U300384

U300385 The battery voltage is too high
NL-3 01/2016

ES
U300384 The battery voltage is too low

Battery power passes through EMS BAT 10A fuse to EMS harness connector CA45 terminal 20 directly.
Operate the starter switch to turn the power supply mode to ON state. Battery power supply passes through IF17 10A fuse,
and finally reaches terminal 35 of EMS harness connector CA45.
When EMS monitors there is battery voltage on terminal 5 of EMS harness connector CA45, EMS controls terminal 5 of CA45
to realize the internal grounding. The main relay is engaged due to connection between terminal 5 of CA45 and terminal 85 of
the main relay.
When the main relay is engaged, the battery power supply will reach terminal 15, 16 of EMS harness connector CA45 via the
terminal 87 of the main relay.

DTC No. DTC detection strategy Circuit fault.
(control strategy)
- The voltage of battery is

U300385 - 1 Battery
too high
- Measure the voltage - 2 EMS
- The voltage of battery is
U300384 - 3 Circuit fault
too low
3. Circuit diagram:
Main
relay
ER05
Notice: Prior to executing this diagnostic procedure, observe the data table of the fault diagnostic scanner and analyze data
accuracy for quick troubleshooting.
NL-3 01/2016
Step 1 Check whether there is other DTC output of control system.

ES
interface.
(b) Operate the starter switch to turn the power supply mode to
ON state.

scanner.
(e) Read the fault diagnosis code, and confirm that there is no
DTC other than DTC U300385 and U300384.
Please refer to the table of diagnostic fault

No codes.
Yes
Step 2 Check charging system.
(b) Start the engine, and check the charging voltage of

alternator.
(c) Confirm whether it is normal.
No Eliminate the fault in charging system, and

then go to the step 11.
Yes
Step 3 Check the EMS fuses EF09, EF18 and IF17.
Engine compartment fuse, relay box.
OFF state.
(b) Disconnect battery negative cable.
(c) Remove the fuses EF09 and EF18 from fuse & relay box of
engine compartment.
(b) Remove the fuse IF16 from indoor fuse relay box.
(d) Measure whether the two terminals of the fuse are

connected.
Rated capacity of fuse: EF09 30A\EF18 10A\IF17 10A
No Check whether there is short circuit, and

replace the fuse.
NL-3 01/2016
ES
Yes
to OFF state.
CA45 engine management system harness
connector (b) Disconnect battery negative cable.
(d) Connect the negative cable of battery, and operate the

(e) Measure the voltage between the terminal 20/35/15/16

of EMS harness connector CA45 and the reliable grounding.
Go to step 6.
No
Yes
(a) Operate the starter switch to turn the power supply

mode to OFF state.
CA45 engine management system harness connector
(c) Disconnect the EMS harness connectors CA45 and

EG24.
(d) Connect battery negative cable.
(e) Measure the resistance between the terminals 63

and 64 of EMS harness connector CA45 and the reliable
grounding. Standard value: Less than 1 Ω
(f) Measure the resistance between the terminal 47/48 of

EMS harness connector EG24 and the reliable
grounding. Standard value: Less than 1 Ω
(g) Confirm whether the resistance meets the standard

value.
NL-3 01/2016
There is fault in EMS grounding circuit.

No Eliminate the fault, and if necessary ES
EG24 engine management system harness connector 2 replace the harness.
Yes
No Repair the faulty position.
Yes
Step 7 Check the circuit from EF09 fuse to EMS.

mode to OFF state.

remove the fuse EF09 from fuse & relay box of engine
compartment.
(d) Measure the resistance between the terminal 15/16 of

EMS harness connector CA45 and the fuse EF09, and
check whether the circuit is broken.
(e) Measure the resistance between the terminal 15/16 of

EMS harness connector CA45 and the reliable grounding
point, and check whether the circuit is short to the ground.

Standard value:
NL-3 01/2016
Engine compartment fuse, relay box. Measure items Standard value

ES
Resistance between
CA45(15)-EF09
Less than 1 Ω
Resistance between
CA45(16)-EF09
Resistance between CA45(15)
10kΩ or higher

No
harness.
Yes
Step 8 Check the circuit from EF18 fuse to EMS.

mode to OFF state.
remove the fuse EF18 from fuse & relay box of engine
compartment.
EMS harness connector CA45 and the fuse EF18, and
check whether the circuit is open.
(e) Measure the resistance between the terminal 20 of
point, and check whether the circuit is short to the ground.
Standard value:
Measure items Standard value
Resistance between Less than 1 Ω

CA45(20)-EF18
Resistance between CA45(20) 10kΩ or higher



No harness.
NL-3 01/2016
Yes
ES
Step 9 Check the circuit from fuse IF17 and EMS.
(a) Operate the ignition switch so as to set the power mode
in the state OFF, and disconnect the negative cable of
CA45 engine management system harness battery.
connector
(b) Remove the fuse IF17, and disconnect the EMS
(c) Measure the resistance between the terminal 35 of
EMS harness connector CA45 and the fuse IF17, and
check whether the circuit is broken.
point, and check whether the circuit is short to the earth.
Standard value:
Measure items Standard value
Resistance between
Less than 1 Ω
Indoor fuse, relay box CA45(35)-IF17
Resistance between
grounding
(f) Does the measured value conform to standard value?
No The circuit is faulty. Repair or replace

the harness.
Yes
Next step
interface.
mode to ON state.
(c) Clear DTCs.
engine for at least 5 min.
(e) Read the DTC of the control system again and
determine the system doesn’t output DTC.
Intermittent fault. Please refer to check on
No intermittent fault.
Yes
NL-3 01/2016
ES
DTC P070400
P070400 The signal of clutch position sensor is unreasonable (MT model)
2. Circuit diagram:
Clutch
switch
Gateway MT model

interface.
to ON state.

scanner.
(d) Read DTC.
(e) Confirm there is no other DTC.
NL-3 01/2016
DTC other than P070400 No

ES
P070400 Yes
Please refer to the table of diagnostic fault

No codes.
Yes
Step 2 Check the CAN bus for open circuit.
to OFF state.
(b) Disconnect the EMS module harness connector CA45.
(c) Measure the resistance between the terminal 1 and

terminal 17 of EMS module harness connector CA45.
Standard resistance: 110 ~ 125 Ω
(d) Confirm whether the resistance meets the standard value.

Yes
Step 3 Check the power circuit and grounding circuit of EMS module.
(a) Check the power circuit and grounding circuit of EMS

module.

module are normal.
Yes
Step 4 Check the harness between clutch switch and PEPS.
NL-3 01/2016
to OFF state.
ES IP54 PEPS harness connector 1
(b) Disconnect the PEPS harness connector IP54.
(c) Disconnect clutch switch harness connector CA47.
(d) Use a multimeter to measure the resistance between the

terminal 14 of PEPS harness connector IP54 and the terminal
2 of clutch switch harness connector CA47.
Standard resistance: less than 1 Ω
No
Repair or replace harness.
CA47 Clutch switch harness connector（MT

model）
Yes
Step 5 Check the grounding circuit of clutch switch.
to OFF state.
CA47 Clutch switch harness connector（MT model）
(b) Disconnect the clutch switch harness connector CA47.
(c) Use a multimeter to measure the resistance between the

terminal 1 of clutch switch harness connector CA47 and the
reliable grounding of vehicle body.
Yes
Replace the clutch switch.
No
Step 6 Replace the EMS module. Please refer to “Engine ECU”.
Next step
NL-3 01/2016
ES
interface.
to ON state.
(c) Clear DTCs.
(f) Read control system DTC again. Confirm system has no
fault code output.
No Intermittent fault. Please refer to the section

about check on intermittent faults.
Yes
Engine Fault Indicator Lamp (MIL)/immediate repair indicator lamp of vehicle is not working
properly.
1. Fault description:
The vehicle adopts CAN network, and engine malfunction indicator lamp is controlled by the instrument. When EMS has set
DTC and need to light engine malfunction indicator lamp at the same time, EMS sends a “light the malfunction indicator lamp”
instruction to instrument via CAN network. The instrument lights the engine malfunction indicator lamp via internal circuit after
receiving the instruction.
2. Circuit diagram:
Combination instrument
Gateway
NL-3 01/2016
Step 1 Check the working of other malfunction indicator lamps in the instrument.
ES
to ON state.
(b) Check whether the working of other malfunction indicator

lamps in the instrument is normal.
Yes
Go to step 6.
No
Step 2 Check fuses IF17 and IF23 in indoor fuse relay box.
Indoor fuse, relay box to OFF state.
(b) Remove the fuse IF17, IF23 from indoor fuse relay box
(c) Measure whether the two terminals of the fuse are

connected.
(d) Confirm whether it is conductive.
No
Check whether there are short circuits.
Replace the fuses.
Yes
Step 3 Check the combination instrument power supply voltage.
to OFF state.
(b) Disconnect the combination instrument harness connector
IP17.
IP17 Combination instrument harness
connector (c) Operate the starter switch to turn the power supply mode
to ON state.
(d) Measure the voltage between the combination instrument
harness connector IP17 terminal 1 and reliable grounding.
(e) Measure the voltage between the combination instrument
harness connector IP17 terminal 2 and reliable grounding.
Standard value of the voltage: 11~14 V
No
Repair or replace the harness.
Yes
Step 4 Check the combination instrument grounding circuit.
NL-3 01/2016

mode to OFF state. ES
(b) Disconnect the combination instrument harness
IP17 Combination instrument harness connector IP17.
connector
(c) Operate the starter switch to turn the power supply
mode to ON state.
(d) Measure the resistance between combination
instrument harness connector IP17 terminal 3 and reliable
grounding.
(e) Measure the resistance between the combination
grounding.
Standard resistance: less than 1Ω
(f) Confirm whether the resistance meets the standard
value.
No
Combination instrument grounding
circuit is faulty and handle the faulty
position.
Yes

Standard value of the voltage: 11~14 V
Standard value of the voltage: 11.5~14.5 V
(c) Confirm whether they are normal.
No
Repair the faulty position.
Yes
Step 6 Check the instrument DTC.
(a) Connect fault diagnostic scanner.

mode to ON state.
(c) Read instrument DTC.
(d) Confirm whether there are CAN related DTC.
Yes
Go to step 8
No
Step 7 Malfunction indicator lamp test.

mode to ON state.
(c) Select on the fault diagnostic scanner “Malfunction
indicator lamp test” within the “Function test” menu.
(d) Confirm whether the malfunction indicator lamp is
normally light up.
Yes
Go to step 9
NL-3 01/2016
No
ES Step 8 Replace the combination instrument assembly.
(a) Replace combination instrument assembly.

(b) Confirm whether the faults are eliminated.
Yes
System is normal
No
Step 9 Check and repair the network communication between the instrument and the EMS.
(a) Check and repair the fault in network communication

between instrument and EMS.
Yes
System is normal
No
Step 10 Check the power circuit and grounding circuit of EMS module.
(a) Check the power circuit and grounding circuit of EMS

module.
module are normal.
No
Repair faulty position.
Yes
Next step

interface.
to ON state.
(c) Clear DTCs.

fault code output.
No Intermittent fault. Please refer to “Check on

intermittent fault.
Yes
NL-3 01/2016
Crankshaft rotation is normal, but the engine cannot start

Note
ES
Before carrying out this step, make sure the engine oil complies with the manufacturer requirements, the fuel tank has
sufficient fuel and battery has enough power for starting engine. Observe the fault diagnostic scanner data list, analyze the
accuracy of the data, as these will facilitate to eliminate fault quickly.
Diagnostic steps:
Step 1 Check the fuel pump fuse.
(a) Check whether the fuel pump fuse EF20 is faulty.

Engine compartment fuse, relay box. (b) Overhaul fuel pump fuse power supply circuit.
(c) If necessary, replace the faulty fuel pump fuse.
(d) Check whether the fault is eliminated.
Yes System is normal
No
Step 2 Read the engine DTC with the fault diagnostic scanner.

to ON state.
scanner.
(e) Read DTC.
(f) Carry out repair for any fault code relating to fuel system.
(g) Clear EMS DTC.
(h) Start the engine and confirm whether the fault has been
eliminated.
No
Step 3 Check the fuel pump relay.

to ON state.
(c) Select “Fuel pump relay” of the fault diagnostic scanner
“Action test” to drive the fuel pump relay forcefully.
(d) Confirm whether the fuel pump relay is working properly.
Yes Go to step 6
NL-3 01/2016
No
ES Step 4 Repair the fuel pump relay.
(a) Replace fuel pump relay.

(b) Overhaul fuel pump relay circuits and repair the circuit
fault.
(c) Start the engine and confirm whether the fault has been
eliminated.
Yes
System is normal
No
Step 5 Check the fuel pump circuit.
to OFF state.
(b) Disconnect fuel pump harness connector SO26.
(c) Connect fault diagnostic scanner.
the state ON.
(e) Select “Fuel pump relay” of the fault diagnostic scanner
“Action test” to drive the fuel pump relay forcefully.
(f) Use a test lamp to connect SO26 terminals no. 1 and 4.
(g) Confirm whether test lamp normally lights up.
Yes Go to step 8
No
Step 6 Repair the fuel pump circuit.
NL-3 01/2016
to ON state. ES
(b) Check fuel pump working circuit, repair the pump SO26
terminals 1 and fuel pump relay terminal 87 for open circuit
S026 Fuel pump harness connector fault.
eliminated.
No
(d) Operate the starter switch to turn the power supply

mode to OFF state.
(e) Install fuel pressure gauge, and connect fault diagnostic
scanner.
to ON state.
(g) Connect the fault diagnostic scanner, select "Fuel Pump
Relay" in the "Action Test" to drive the fuel pump relay
forcefully.
Standard fuel pressure value: 350 kPa
(h) Confirm whether the fuel pressure conforms to the
standard value.
Yes Go to step 9.
No
Step 8 Replace the fuel pump assembly.
to OFF state.
(b) Replace the fuel pump assembly.
eliminated.
NL-3 01/2016

ES
No
Step 9 Check (repair) fuel injectors.
(a) Check (repair) the fuel injector, and if necessary replace

the fuel injector in fault.
(b) Start the engine and confirm whether the fault has been
eliminated.
No
Step 10 Check the ignition coil.
to OFF state.
(b) Remove ignition wires of cylinder No.1, and connect the
intact spark plug at the ignition wires, so that the spark plug is
reliably grounding.
(c) Remove the fuel pump fuse.
(d) Start the engine.
(e) Confirm whether the ignition of the spark plug is normal.
Yes Go to step 13
No
Step 11 Replace the ignition coil.
to OFF state.
(b) Replace the ignition coil.
eliminated.
Yes
System is normal
No
Step 12 Check speed sensor and circuit.
(a) Measure speed sensor resistance.

(b) Check the sensor circuit, repair the parts in fault, and if
necessary replace speed sensor ,
eliminated.
Yes
System is normal
No
NL-3 01/2016
Step 13 Test cylinder pressure.

ES
(a) Carry out the cylinder compression pressure test.
Standard cylinder pressure: 1,000 kPa
(b) Confirm whether all cylinders compression pressure is
equal to or higher than the standard value.
Yes
Go to step 16
No
Step 14 Check the alignment of timing chain.
(c) Operate the power switch so as to set the power mode in

the state OFF.
(d) Check the positioning of timing chain. Please refer to
“Timing chain”.
(c) Confirm whether the alignment of timing chain is normal.
Yes
Go to step 16
No
Step 15 Install the timing chain.
to OFF state.
(b) Re-install the timing chain. Please refer to “Timing chain”.
eliminated.
Yes
System is normal
No
Step 16 Check the mechanical parts inside the engine.
(a) Remove the engine.
(b) Check engine interior mechanical parts. If necessary,

repair the damaged interior components.
(c) Confirm the engine interior damaged components repair

has been completed.
Next step
NL-3 01/2016
Electronic Throttle Control (ETC) Self-adaptive Learn Program

ES
Note
After cleaning and serving for the throttle body, carry out ETC self-adaptive learn. Otherwise there will be idle instable, jitter
and so on.
Before the gear learning, the following conditions must be met:
1. The accelerator pedal is released.
2. There is no fault relating to throttle body.
3. Battery voltage greater than threshold value (8 V)
4. The intake temperature is higher than 5.25°C.
5. The temperature of engine coolant is 5.25 - 100°C.
When the above conditions are met, carry out the following steps.
Step 1 Connect the diagnostic scanner to OBD diagnostic interface.
Next step
Step 2 Operate starter switch to turn power supply mode to “ON” state.
Next step
Step 3 Turn on the diagnosis instrument and enter into the engine management system.
Next step
Step 4 Enter special function.
Next step
Step 5 Carry out the learning of mechanical and electrical position for electronic throttle.
Next step
Step 6 Confirm the execution conditions.
(a) The command is in resetting state.
(b) The system exits after the resetting is completed.
Next step
Step 7 The learning for mechanical and electrical position of electronic throttle is completed.
NL-3 01/2016
Learning of speed sensor (CKP)

Notice
ES
After replacing the speed sensor, replacing the EMS or dismantling/installing the engine, please carry out the self-adaptive
learning for speed sensor; otherwise the fault lamp will always be lit.
1. Make sure the engine coolant temperature is above 60 ℃(140 ºF).
2. A/C switch is not turned on.
3. 10 s after starting the engine.
Next step
Next step
Step 3 Enter into the learning page on diagnosis instrument, and click “Start”
Next step
Step 4 Depress the accelerator pedal to 80% and hold.
Next step
Step 5 After the engine speed jumps from 1300rpm to 4500rpm back and forth for 3~5 cycles, the speed is
stabilized at 4000rpm or more.
Next step
Step 6 Release the accelerator pedal, and operate the ignition switch to set the power mode in the state OFF.
Next step
Step 7 Complete the learning, and clear fault codes.
NL-3 01/2016
ES - 254 JLD-4G20/24 Engine Control System - OCV Valve
OCV Valve
ES Component
Engine trim cover
Engine assembly 4G20 / 24
NL-3 01/2016
JLD-4G20/24 Engine Control System - OCV Valve ES - 255
ES
OCV valve component
NL-3 01/2016
Removal
ES
Warning!
Before repairing any electrical component, the power mode shall
be set in the state OFF, and all electrical loads shall be turned off,
unless otherwise specified in the operating procedure.
Disconnect the battery negative cable if a tool or any equipment
easily comes in contact with an exposed electrical terminal.
Failure to follow these precautions may result in personal injury
and/or damage to the vehicle or its components.
1. Open engine hood.
2. Remove the upper trim panel of front bumper. Please refer to

“Decorative & covering parts of engine compartment”.
3. Remove the connecting plate of upper trim panel of fender.

Please refer to “Decorative & covering parts of engine
compartment”.
4. Remove the upper trim panel of right fender. Please refer

to ”Decorative & covering parts of engine compartment”
5. Disconnect battery negative cable
6. Remove the trim cover of engine. Please refer to “Trim cover of

engine”
7. Remove the OCV valve
1) Disconnect the OCV valve harness connector.
2) Remove OCV solenoid valve fixing bolts.
NL-3 01/2016
3) Remove the OCV solenoid valve.

ES
Check
1. Check the resistance of OCV valve
1) Use an ohm gauge to measure the resistance

between the two terminals.
Standard resistance: （8±0.5）Ω
2. Check the operation of OCV valve.
1) Connect the positive and negative poles of battery

with 2 terminals of OCV valve respectively, and check
the operation of OCV valve.
Valve
NL-3 01/2016
Clean
ES
1. Clean up the OCV solenoid valve
1) Clean the filter screen on the OCV solenoid valve

with cleaning agent.
Notice
During cleaning, ensure OCV solenoid valve harness
connection end is upward and OCV solenoid valve is
in vertical state, or else, the detergent may easily enter
into OCV solenoid valve interior and cause damage of
OCV solenoid valve.
2) Clean OCV valve's oil holes and filter screens via

air gun and remove the remained detergent.
3) Constantly power on/off the OCV solenoid valve to

make it work under open/close state; then clean it with
air gun and repeat the procedure 2~3 times.
Notice
Each power on time shall not exceed 2s, or else, it
may possibly damage OCV solenoid valve.
NL-3 01/2016
Installation
ES
1. Install OCV valve.
1) Confirm the intactness of the new OCV solenoid

valve seal ring; apply a little engine lubricant to the
seal ring.
2) Install OCV solenoid valve and tighten the fixing

bolt.
Torque: 6±1N·m (metric) 3.7-5.1lb-ft (English)
3) Connect the OCV valve harness connector.
2. Install the trim cover of engine
3. Connect battery negative cable
4. Install the upper trim panel of right fender.
5. Install the upper trim panel connecting plate of fender
6. Install the front bumper upper trim panel
7. Close the engine hood
NL-3 01/2016
ES - 260 JLD-4G20/24 Engine Control System - Electronic Throttle Body
Electronic Throttle Body

ES Component
Engine trim cover
NL-3 01/2016
JLD-4G20/24 Engine Control System - Electronic Throttle Body ES - 261
ES
Air filter assembly
Clamp
Electronic throttle
Intake manifold
Throttle body gasket
NL-3 01/2016
Removal
ES
Warning!
Before repairing any electrical component, the power mode

shall be set in the state OFF, and all electrical loads shall be
turned off, unless otherwise specified in operating
procedure. Disconnect the battery negative cable if a tool or
any equipment easily comes in contact with an exposed
electrical terminal. Failure to follow these precautions may
result in personal injury and/or damage to the vehicle or its
components.
2. Remove the upper trim panel of front bumper. Please

refer to “Decorative & covering parts of engine
compartment”.
3. Disconnect the negative battery cable
4. Remove the trim cover of engine. Please refer to ”Trim

cover of engine”
5. Remove the electronic throttle valve body.
1) Loosen the type-B worm-driven hose hoop, and

separate the intake hose of engine from electronic throttle
body.
2) Disconnect the electronic throttle valve body harness

connector.
NL-3 01/2016
JLD-4G20/24 Engine Control System - Electronic Throttle Body ES - 263
3) Remove the fixing bolt and nut of electronic throttle

body, and remove the electronic throttle body from ES
intake manifold.
Check
1. Check the mechanical parts
1) While there is no power supply, the valve plate is

supposed to at the "NLP" mode. Then move it with
hand, the valve plate should be able to rotate smoothly.
Yet, if any jam occurs, there might be damages on the
inner parts.
2. Measure the resistance
1) Use an ohm gauge to measure the resistance of

copper winding on both ends of DC motor between pin 1
and pin 4
Standard resistance value: 2.0~2.5Ω
NL-3 01/2016
Installation
ES
1. Install the electronic throttle valve body.
1) Install a new gasket onto electronic throttle body.
2) Install and tighten up the fixing bolt and fixing nut of

throttle body.
Tightening torque for bolt: 9N·m (metric) or 6.6lb-ft

(English)
Tightening torque for nut: 9N·m (metric) or 6.6lb-ft

(English)
3) Connect the harness clap.
4) Connect the electronic throttle valve body harness

connector.
5) Connect the intake hose of engine with the electronic

throttle body, and fix the clamp.
4. Connect the negative battery cable
NL-3 01/2016
JLD-4G20/24 Engine Control System - Intake Pressure/temperature Sensor ES - 265
Intake Pressure/Temperature Sensor

Component
ES
Engine trim cover
NL-3 01/2016
ES - 266 JLD-4G20/24 Engine Control System - Intake Pressure/temperature Sensor
ES
Air filter seembly
Clamp
Electronic throttle
Intake manifold
Throttle body gasket
NL-3 01/2016
ES
Intake manifold
Intake pressure temperature

sensor
NL-3 01/2016
ES - 268 JLD-4G20/24 Engine Control System - Intake Pressure/temperature Sensor
On-board dismantlement
ES Warning!
Before repairing any electrical component, the power mode
shall be set in the state OFF, and all electrical loads shall be
turned off, unless otherwise specified in operating
procedure. Disconnect the battery negative cable if a tool or
any equipment easily comes in contact with an exposed
components.
compartment”.
4. Remove the connecting plate of upper trim panel of
fender. Please refer to “Decorative & covering parts of
engine compartment”.
5. Remove the upper trim panel of left fender. Please refer
to “Decorative & covering parts of engine compartment”
6. Remove the trim cover of engine. Please refer to “Trim
cover of engine”
7. Remove the electronic throttle body assembly. Please
refer to “Electronic throttle body”
8. Remove the intake manifold component. Please refer to
“Intake manifold component”
9. Remove the intake pressure and temperature sensor.
1) Remove the fixing bolts of intake pressure and
temperature sensor.
2) Plug out intake pressure and temperature sensor.
NL-3 01/2016
Check
1. Check the resistance. ES

between the pin 1 (grounding) and the pin 2
(temperature signal) of intake pressure/temperature
sensor
Standard resistance: 2.5kΩ±5% (20 ℃)
On-board installation
1. Install the intake pressure temperature sensor
1) Install the new intake pressure/temperature sensor

onto intake manifold, and tighten up the fixing bolt.
Torque: 9N·m (metric) or 6.6lb-ft (English)
2) Connect intake pressure and temperature sensor

harness connector.
2. Install intake manifold component
3. Install the electronic throttle valve body assembly.
4. Install the upper trim panel of left fender.
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ES - 270 JLD-4G20/24 Engine Control System - Water Temperature Sensor
Water Temperature Sensor

ES Component
Engine trim cover
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JLD-4G20/24 Engine Control System - Water Temperature Sensor ES - 271
ES
Water temperature
sensor
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Removal
ES
Warning!
Before repairing any electrical component, the power
mode shall be set in the state OFF, and all electrical loads
shall be turned off, unless otherwise specified in operating
procedure. Disconnect the battery negative cable if a tool
or any equipment easily comes in contact with an exposed
components.
Warning!
When there is pressure in the cooling system, even if the
solution in radiator does not boil,
the temperature of solution may be much higher than the
boiling temperature. If the fluid reservoir cap is removed
while the engine is still hot and under high pressure during
maintenance, the engine coolant will boil immediately and
spray into the operator's body, causing serious burns.
2. Release cooling system pressure
Notice
You must slowly loosen the expansion tank when
releasing the cooling system pressure, so as to
prevent coolant spraying.

compartment.

engine compartment.

to “Decorative & covering parts of engine compartment

cover of engine”
8. Remove water temperature sensor
1) Disconnect the water temperature sensor harness

connector.
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JLD-4G20/24 Engine Control System - Water Temperature Sensor ES - 273
2) Remove water temperature sensor

ES
Check
1. Check on resistance

water temperature sensor.
Rated resistance of terminals 1 and 2:

1.825KΩ-2.155KΩ
Notice
If the measured resistance is not within the specified

range, please replace the water temperature sensor
with a new one.
2. Check whether the sealing ring of water temperature

sensor is damaged,
1. Install water temperature sensor
1) Under the circumstance that the sealing ring of

water temperature sensor is in good conditions,
please apply a small amount of sealant onto thread
and sealing gasket of water temperature sensor, and
then install and tighten up the water temperature
sensor.
Torque: 15N·m (metric) 8.8lb-ft (English)
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2) Connect the water temperature sensor harness

ES connector.
3. Check and fill the coolant until the appropriate level is

reached.
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JLD-4G20/24 Engine Control System - Phase Sensor ES - 275
Phase Sensor
Component
ES
Engine trim cover
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ES - 276 JLD-4G20/24 Engine Control System - Phase Sensor
ES
Phase sensor
4G24 engine +AT
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JLD-4G20/24 Engine Control System - Phase Sensor ES - 277
ES
Warning!
shall be turned off, unless otherwise specified in
operating procedure. Disconnect the battery negative
cable if a tool or any equipment easily comes in contact
with an exposed electrical terminal. Failure to follow these
precautions may result in personal injury and/or damage
to the vehicle or its components.
compartment.
fender. Please refer to Decorative & covering parts of
engine compartment.
to Decorative & covering parts of engine compartment
6. Remove the trim cover of engine. Please refer to Trim
cover of engine
7. Remove phase sensor
1) Disconnect phase sensor harness connector.
2) Remove 1 fixing bolt of sensor.
3) Remove phase sensor.
Check
1. Check the resistance.
1) Turn the LCR to ohm position (serial mode, testing
frequency 10kHz), and connect the two pins with pins
1 and 3 of sensor respectively, so as to measure the
resistance
Standard parameter: 100Ω±20%
Notice
range, please replace the phase sensor
Sensor
Installation
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ES - 278 JLD-4G20/24 Engine Control System - Phase Sensor
1. Install phase sensor

ES
1) Install the phase sensor onto engine.
2) Tighten up the fixing bolt.
3) Connect the phase sensor harness connector.
3. Install the upper trim panel of left fender
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JLD-4G20/24 Engine Control System - Crankshaft Position Sensor ES - 279
Crankshaft Position Sensor

ES
Component
Trim cover of engine
Engine assembly 4G20/24
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ES - 280 JLD-4G20/24 Engine Control System - Crankshaft Position Sensor
ES
Cylinder block
Crankshaft
component
Compression
disc of
flywheel
Driving disc
assembly
Crankshaft belt pulley

component
Crankcase body
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Removal
ES
Warning!
refer to the section about decorative & covering parts of
engine compartment.
fender. Please refer to the section about decorative &
covering parts of engine compartment.
to the section about decorative & covering parts of engine
compartment
6. Remove the trim cover of engine. Please refer to trim
cover of engine
7. Remove air filter intake pipe
8. Remove the air vent flange of upper housing
9. Remove air filter assembly
10. Remove the crankshaft position sensor
1) Disconnect the crankshaft position sensor harness
connector.
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ES - 282 JLD-4G20/24 Engine Control System - Crankshaft Position Sensor
2) Remove the crankshaft position sensor fixing bolt.

ES
3) Remove the crankshaft position sensor.

Notice
After removing the sensor, plug the sensor mounting
hole to prevent debris falling into it.
Check
frequency 10kHz),
and connect the two pins with pins 1 and 3 of sensor
respectively, so as to measure the resistance
Notice
range, please replace the crankshaft position sensor
with a new one.
Installation
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1. Install the crankshaft position sensor

ES
1) Mount the crankshaft position sensor into the
installation hole, and tighten up the fixing bolt of
crankshaft position sensor
Torque: 9±1N·m (metric) 6.64±0.74lb-ft (English)
2) Connect the crankshaft position sensor harness

connector.
2. Install air filter assembly
3. Install the intake pipe of air filter
4. Install the air vent flange of upper housing
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ES - 284 ES JLD-4G20/24 Engine Control System - Knock Sensor
Knock Sensor
ES Component
Engine bottom guard plate

assembly
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ES JLD-4G20/24 Engine Control System - Knock Sensor ES - 285
ES
Upper cover of intake
manifold
Intake manifold
Intake manifold
gasket
Intake pressure and

temperature sensor
Isolating pad of intake

manifold
Lower cover of
intake manifold
Engine assembly
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ES
Knock sensor
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ES JLD-4G20/24 Engine Control System - Knock Sensor ES - 287
ES
Warning!
3. Remove the intake manifold component and intake
pressure temperature sensor. Please refer to Intake
manifold component
4. Lift up the vehicle
5. Remove the guard plate on bottom of engine. Please
refer to Left and right guard plate on bottom of engine.
6. Remove the knock sensor
1) Disconnect knock sensor harness connector.
2) Remove knock sensor fixing bolt and take out the

knock sensor.
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Check
ES
1) At the normal temperature, connect the pins of ohm
gauge with pins 1 and 2 of sensor respectively,
and then measure the resistance
Standard parameters: (4.9±20%) MΩ
Notice
If the resistance is not within the specified range,
please replace knock sensor.
1. Install knock sensor

1) Mount the knock sensor onto engine cylinder block.
2) Tighten up the fixing bolt of knock sensor fixing
bolt.
3) Connect knock sensor cable connector.

2. Install the engine bottom guard plate.
3. Lower down the vehicle
4. Install the intake manifold component and intake
pressure temperature sensor
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ES JLD-4G20/24 Engine Control System - Engine ECU ES - 289
Engine ECU
ES
Component
Engine ECU(4G24_6AT)
Engine ECU(4T18)
Engine ECU bracket assembly

(4G24)

(4G18TD)
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ES - 290 ES JLD-4G20/24 Engine control system - Engine ECU
On-board check
ES 1. Use the diagnosis instrument to check whether the
engine ECU works normally.
Removal
Warning!
refer to Decorative & covering parts of engine
compartment.
3. Remove the connecting plate of trim panel of fender.
Please refer to Decorative & covering parts of engine
compartment
4. Remove the trim panel of right fender. Please refer to
Decorative & covering parts of engine compartment
6. Remove the engine ECU

1) Disconnect the engine ECU harness connector.
2) Remove the 4 fixing bolts of engine ECU, and then

remove the engine ECU.
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ES JLD-4G20/24 Engine Control System - Engine ECU ES - 291
Installation
ES
1. Install the engine ECU
1） Install the engine ECU to mounting bracket, and tighten 4
fixing bolts of engine ECU.
Torque: 9±1N·m (Metric) 5.84-7.3lb-ft (English)
2） Connect the engine ECU harness connector.

3. Install the trim panel of right fender
4. Install the upper trim panel of front bumper
5. Install the trim panel connecting plate of fender
6. Close the engine hood.
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ES - 292 ES JLD-4G20/24 Engine Control System - Accelerator Pedal
Accelerator Pedal
ES Component
AT(MT) accelerator pedal
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ES JLD-4G20/24 Engine Control System - Accelerator Pedal ES - 293
On-board check
1. Check accelerator pedal. ES
1) Connect fault diagnostic scanner.
2) Read the voltage indicated on accelerator pedal
potentiometer, and confirrm whether it is normal. The
rated voltage is 5V
Removal
Warning!
3. Remove the accelerator pedal

1) Disconnect the accelerator pedal harness
connector.
2) Remove the 3 fixing nuts of accelerator pedal, and

take out the accelerator pedal assembly.
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ES - 294 ES JLD-4G20/24 Engine Control System - Accelerator Pedal
ES Check
between pins 1 and 5 or between pins 2 and 3 of
accelerator pedal sensor
Standard parameter: (1.7±0.8)KΩ
Installation
1. Install the accelerator pedal

1) Install the accelerator pedal onto bracket, and
tighten up the 3 fixing nuts of accelerator pedal.
Torque: 9N·m (Metric) or 6.6lb-ft (English)
2) Connect the accelerator pedal harness connector.

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JLE-4G18TDB Engine Control System - Contents ES-1
ES JLE-4G18TDB engine control system
Electronic fuel injection system ..................................................................................... ES- 5

ES
Precautions .............................................................................................................................ES- 5
Component position ................................................................................................................ES- 6
System diagram ......................................................................................................................ES- 8
System description ................................................................................................................ES- 10
How to carry out the analysis for elimination of fault ..............................................................ES- 12
Intermittent fault check ..........................................................................................................ES- 14
Fault symptoms table ............................................................................................................ES- 17
EMS terminal ........................................................................................................................ES- 24
CA01 engine management system (plug-in part K) harness connector 2 ..............................ES- 27
Diagnostic system .................................................................................................................ES- 31
Check/troubleshooting for DTC of components .....................................................................ES- 31
Data sheet/active test ............................................................................................................ES- 32
Table of DTCs .......................................................................................................................ES- 38
DTC P000A64 P000A77 P001013 P208811 P208912 ..........................................................ES- 47
DTC P000B64 P000B77 P001313 P209011 P209112 ...........................................................ES- 53
DTC P001676 P001678 P034100 P034200 P034300 P001200 ............................................ES- 59
DTC P001776 P001778 P001500 P036600 P036700 P036800 ............................................ES- 64
DTC P003013 P003111 P003212 P00531E P01351E ...........................................................ES- 68
DTC P003313 P003411 P003512 P226100 ..........................................................................ES- 73
DTC P003613 P003711 P003812 P00541E ..........................................................................ES- 79
DTC P222816 P222917 P22302F P22308F..........................................................................ES- 84
DTC P008700 P008784 P008800 P008885 P304B00 P304C00 ...........................................ES- 88
DTC P009716 P009817 ........................................................................................................ES- 94
DTC P013600 P013700 P013800 P014000 P227000 P227100 P042000 .............................ES- 99
DTC P016929 P016961 P016964 P016992 P016993 P016994 ..........................................ES- 106
DTC P020113 P026111 P026300 P214600 P214611 .......................................................... ES- 112
DTC P020213 P026411 P026600 P215500 P020213 ......................................................... ES- 117
DTC P020313 P026711 P026900 P214900 ........................................................................ES- 122
DTC P020413 P027011 P027200 P215200 P215211 .........................................................ES- 127
DTC DTC P021900 .............................................................................................................ES- 133
DTC P022317 P210612 P210613 P210619 P210692 .........................................................ES- 136
DTC P023400 P024313 P024511 P024612 ........................................................................ES- 142
DTC P023621 P023622 P023623 P023624 P023716 P023817 ..........................................ES- 147
DTC P025111 P025113 P025212 P025311 P025412 ..........................................................ES- 154
DTC P030000 P030100 P030200 P030300 P030400 P130B00 .........................................ES- 160
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ES-2 JLE-4G18TDB Engine Control System - Contents
DTC DTC P032100 P032200 ..............................................................................................ES- 167

DTC P032516 P032517 P032700 P032714 P032800 P032815 P138600 ...........................ES- 174
DTC P044413 P045811 P045912 .......................................................................................ES- 180
DTC P048013 P06344B P069111 P069212 ........................................................................ES- 185
ES DTC P048113 P063449 P069311 P069412.........................................................................ES- 192
DTC P050022 P050029 P050123 P05012F ........................................................................ES- 200
DTC P050600 P050700 ......................................................................................................ES- 203
DTC P010184 P010185 P010216 P010317 ........................................................................ES- 207
DTC P010500 P010621 P010622 P010684 P010685 P010716 P010817 ...........................ES- 215
DTC P011216 P011317 P011100 ........................................................................................ES- 222
DTC P011600 P011716 P011817 ........................................................................................ES- 228
DTC P012129 P012216 P012317 .......................................................................................ES- 233
DTC P013029 P013116 P013217 P013300 P219500 P219600 P223100 P224300 P225100
P309691 P309692 P309694 P309696 P241400 P262600 ..................................................ES- 239
DTC P056000 P056200 P056300 U300384 U300385.........................................................ES- 247
DTC P057129 .....................................................................................................................ES- 251
DTC P060616 P060617 P060644 P060645 P060143 P060149 P060100 ...........................ES- 256
DTC P060629 P060647 P060648 P060649 P060661 P060662 P060663 P060691 P060692
P060693 P060694 P060696 P060697 P133600 .................................................................ES- 259
DTC P062713 P062811 P062912 .......................................................................................ES- 267
DTC P062B08 P062B29 P062B86 ......................................................................................ES- 274
DTC P063491 P064513 P064611 P064712 ........................................................................ES- 276
DTC P064100 P065100 P069700 P069000 ........................................................................ES- 286
DTC P154500 P154521 P154522 P155800 P155900 P155929 P157900 P156400 P156500
P156800 P156821 P156822 P157900 ................................................................................ES- 290
DTC P212216 P212317 ......................................................................................................ES- 294
DTC P212716 P212817 ......................................................................................................ES- 300
DTC P213829 .....................................................................................................................ES- 306
DTC P217700 P218700 ......................................................................................................ES- 309
DTC P217800 P218800 ......................................................................................................ES- 313
DTC P161000 P161100 P161200 P161300 P161400 .........................................................ES- 317
DTC P168300 P168386 ......................................................................................................ES- 320
DTC U007300 .....................................................................................................................ES- 323
DTC U007300 U010187 U012287 U014087 U015187 U010387 U014187 U010182 U010183
U012282 U012283 U015182 U015183 U010182 U010183 .................................................ES- 325
DTC P070400 .....................................................................................................................ES- 326
properly. ..............................................................................................................................ES- 330
Crankshaft rotation is normal, but the engine can not start ..................................................ES- 334
Electronic Throttle Control (ETC) Self-adaptive Learning Program ......................................ES- 339
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JLE-4G18TDB Engine Control System - Contents ES-3
Learning of speed sensor (CKP) .........................................................................................ES- 340
Engine oil control valve (OCV) ........................................................................................ ES- 341
Component .........................................................................................................................ES- 341

Removal ..............................................................................................................................ES- 342 ES
Check ..................................................................................................................................ES- 343
Clean ..................................................................................................................................ES- 344
Installation ...........................................................................................................................ES- 344
Electronic throttle body .................................................................................................. ES- 347
Component .........................................................................................................................ES- 347

Removal ..............................................................................................................................ES- 348
Check ..................................................................................................................................ES- 349
Installation ...........................................................................................................................ES- 350
Intake air temperature sensor ......................................................................................... ES- 351
Component .........................................................................................................................ES- 351

On-board Check ..................................................................................................................ES- 352
On-board dismantlement .....................................................................................................ES- 352
Check ..................................................................................................................................ES- 354
On-board installation ...........................................................................................................ES- 354
Water temperature sensor .............................................................................................. ES- 356
Component .........................................................................................................................ES- 356

Removal ..............................................................................................................................ES- 358
Check ..................................................................................................................................ES- 359
Camshaft phase sensor .................................................................................................. ES- 361
Component .........................................................................................................................ES- 361

Check ..................................................................................................................................ES- 363
Crankshaft position sensor ............................................................................................ ES- 366
Component .........................................................................................................................ES- 366

Check ..................................................................................................................................ES- 368
Knock sensor ................................................................................................................. ES- 369
Component .........................................................................................................................ES- 369
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ES-4 JLE-4G18TDB Engine Control System - Contents

Check ..................................................................................................................................ES- 373
Engine ECU .................................................................................................................... ES- 375

ES
Component .........................................................................................................................ES- 375
Removal ..............................................................................................................................ES- 376
Installation ...........................................................................................................................ES- 377
Engine ECU bracket ....................................................................................................... ES- 377
Removal ..............................................................................................................................ES- 377

Installation ...........................................................................................................................ES- 378
Electronic accelerator pedal ........................................................................................... ES- 379
Component .........................................................................................................................ES- 379

On-board Check ..................................................................................................................ES- 380
Removal ..............................................................................................................................ES- 380
Check ..................................................................................................................................ES- 381
Installation ...........................................................................................................................ES- 381
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JLE-4G18TDB Engine Control System - Electronic Fuel Injection System ES-5
Electronic Fuel Injection System

Precautions
1. Notices for operation of airbag system
a. When replacing the EMS controller, TCU controller or BCM controller, please implement the initialization operation. ES
b. This vehicle is equipped with airbags. If the repair is not carried out in correct sequence, the airbag may be deployed
unexpectedly in the course of repair. This may cause serious accident. Before repair (including check, replacement,
removal or installation of part), be sure to read the notices about airbag system.
2. Notices for CAN Communication System
a. When sending out the DTC of CAN communication system, please eliminate the fault of communication line. Be sure to
eliminate the fault of EMS only after it is confirmed that the CAN communication system is normal.
b. Since the CAN communication line has its own length and route, it is impossible to carry out repair temporarily by using
bypass harness.
3. Cooling fan system
a. When the power mode is in the state OFF and the engine temperature is too high, the cooling fan may run continuously
for about 3 minute. After operating the power switch so as to set the power mode in the state OFF, be sure to keep your
hands and other articles away from the running fan.
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ES-6 JLE-4G18TDB Engine Control System - Electronic Fuel Injection System
Component Position
Position diagram of components of engine control system
ES Ignition coil Exhaust camshaft position sensor (exhaust

Rear oxygen
sensor
Camshaft position sensor (intake side)
Control valve
(exhaust side)
Engine oil control

valve (intake side) Intake pressure and
temperature sensor
High pressure fuel rail
Electronic throttle body
Spark plug
Fuel pressure sensor
Fuel injector
Water temperature
Knock sensor sensor
Engine oil pressure

alarm
Front oxygen Crankshaft position

sensor sensor
EMS controller
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Position Diagram of Components of Engine Control System (continued)
ES
OBD diagnostic Electronic accelerator

interface pedal
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System Diagram
EMS control system
Intake pressure and temperature sensor

ES Cylinder No.1 fuel injector
Cylinder No.2 fuel injector

Engine coolant temperature sensor
Throttle position sensor
Rotary speed sensor

Ignition coil Spark plug of
cylinder No.1
Intake camshaft phase sensor cylinder No.2
cylinder No.3
Spark plug of
Ignition coil
Exhaust camshaft phase sensor cylinder No.4
Engine EMS
Upstream oxygen sensor

Intake variable valve timing
valve
Downstream oxygen sensor Exhaust variable valve

timing valve
Accelerator pedal sensor
Knock sensor Throttle control motor
Fuel control valve

Fuel evaporation emission control
Carbon canister control valve

Mass air flow meter
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Supercharging pressure sensor
Fuel pressure sensor

Starter switch
ES
Power signal
Brake lamp switch
A/C pressure switch
A/C compressor relay
Exhaust control valve
Engine EMS
Fuel pump control
Fuel pump relay

Gateway
Cooling fan control
Low-speed cooling fan relay
High-speed cooling fan relay
Main relay
Electronic water pump for cooling of

turbocharger
Intake relief valve
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System description
1. Overview
1. JLE-4G18TDB engine is the latest direct injection, inline 4-cylinder, 1.8L Turbocharged engine with DOHC 16-valve of
Geely, which uses double DVVT (Dual variable valve timing) system, DIS (Direct ignition system), and electronic throttle
control system. The control system is mainly composed of engine management system (EMS), EMS working circuit, and
ES system input/output components. EMS is the control center of engine control system that constantly monitors signals from
all sensors and controls every system with effect on vehicle performances. The engine control system can also perform
system diagnostics.It can identify operation fault and remind the driver via malfunction indicator lamp (MIL) and save the
DTC to indicate faulty position so as to facilitate repair by the repair personnel. These control functions can improve
engine performance, increase fuel economy, improve engine power, and reduce harmful exhaust emissions. In case of
damage of EMS, it has to be replaced as a whole as no single part in the module can be repaired alone.
2. Information input components: crankshaft position sensor, camshaft position sensor, air mass flow meter sensor, knock
sensor, throttle position sensor, accelerator pedal position sensor, evaporator surface temperature sensor, water
temperature sensor, oxygen sensor (before catalytic converter), oxygen sensor ((after catalytic converter)), A/C pressure
switch, steering wheel angle sensor, defrost heating enable input, CAN information input, serial data line input.
3. Output components: throttle valve body, fuel injector assembly, ignition coils, variable valve timing solenoid valve, carbon
canister solenoid valve, main relay, fuel pump relay and pumps, cooling fan low speed and high speed relay, A/C
compressor relay, electric power steering gear, CAN information output, and serial data line output.
2. System working principle
1. System Working Principle
EMS functions to calculate the basic injection duration according to the engine intake and speed signal to make the engine
work at the almost ideal air fuel ratio and control the corresponding operation. For example, in cold start, according to related
signals, EMS increases the fuel-injection quantity to achieve a smooth start and control the engine idle speed. Besides, EMS
has automatic fault diagnosis and protection function. In case of the engine fault, the control unit will automatically diagnose
fault, save fault code and generate alarm via the fault indicator lamp. The saved code may be output under a certain triggering
condition. Once the sensor or actuator fails, EMS automatically start the backup system, to ensure the safety of the vehicle,
maintain the vehicle driving ability. The control unit may also communication with the maintenance diagnosis instrument. The
diagnosis instrument can be used to view the fault diagnosis code saved in the control unit and scan the present control unit's
system parameter, i.e. data stream. The diagnosis instrument can be also used for forced drive test the actuator of the control
system and provides utmost convenience during maintenance and diagnosis over the control system.
2. Correction of fuel-injecting amount
During startup, EMS comprehensively calculates injection duration according to the engine speed, engine coolant temperature,
etc. After startup, it determines basic fuel-injection quantity according to the intake manifold absolute pressure sensor. After
determining the basic fuel volume, conduct the following corrections according to different operation conditions of the engine:
– Start condensation increase: the start condition represents the engine's speed lower than the specified value; the ignition
switch is at the start level. Especially during low temperature, in order to improve ignition performance, properly increase
fuel injection time and increase condensation of the combustible mixture.
– Post-start condensation increase: just after engine startup, in order to sustain its steady operation, EMS properly
increases the fuel volume according to the engine coolant temperature.
– Warm engine condensation increase: when the engine temperature is low, the engine evaporation performance is poor,
supply denser mixture. EMS can increase the concentration of gas mixture according to the engine coolant temperature
sensor, engine speed sensor and throttle position sensor signals.
– Large load condensation increase: when the engine is at the maximum power, in order to ensure its good operation, EMS
will increase injection duration according to throttle position, engine speed, air flow, engine coolant temperature, etc. The
increased condensation can be 8%~30% of the normal fuel volume.
– Intake temperature correction: since the air condensation varies with temperature, in order to ensure accurate air-fuel
ratio, EMS takes the air condensation at 20 ℃（68 ℉）as the standard. It corrects fuel volume according to the actually
measured intake temperature signal. Increase fuel volume when the temperature is low and reduce fuel volume when the
temperature is high. The maximum amplitude is approximately 10%.
– Idling stability correction: in the engine control system, when the intake manifold pressure rises, the idling will drop; EMS
increases the fuel injection quantity and the idling based on throttle position, engine speed, intake manifold absolute
pressure sensor signals. Or else, reduce the fuel volume so as to reduce the speed.
– Air-fuel ratio feedback correction: EMS corrects the fuel-injection quantity according to the oxygen sensor signal. EMS will
not conduct close loop control during engine start, post-start condensation increase, large load, engine coolant
temperature lower than the specified temperature and fuel interruption.
– Fuel cut-off control: To enable the engine with good fuel economy, reduce emissions pollution, the EMS temporarily cuts
off the fuel according to throttle valve position, engine speed and engine coolant temperature sensor signals when the
engine is in forced idling state. Fuel is cut off even during sudden engine deceleration, engine acceleration and vehicle
over speed.
– Voltage correction: the power supply voltage has influence on the fuel injection amount. When the voltage is low, the
actual injection duration is shorter than normal, the mixture becomes thinner, correction shall be made. EMS automatically
corrects fuel volume according to the voltage level. Power voltage signal mainly comes from the battery.
3. Automatic fault diagnosis and protection function
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When the system enters into the working condition and the engine runs, EMS controls all parts of the system and monitors the
parts directly connected with it in real time; and when one or more parts of the system work abnormally, the system will
automatically give an alarm. Each fault condition has a corresponding unique fault code. Once a fault occurs, the system will
output the code through the diagnostic interface and turns on the engine fault indicator lamp at the same time to remind the
driver of timely repairing, and the fault code indicates the part that the fault may be incurred.
When a fault occurred, the system can also take temporary emergency scheme to control the engine, in order to make sure
the user can drive the vehicle to the maintenance station for maintenance.
ES
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Control system check
Diagnostic steps:
Step 1 Client mentioned fault analysis.

ES
Next step
Step 2 Connect fault diagnostic scanner.

(a) Install the fault diagnostic scanner.
(b) Connect the power supply of the fault diagnostic

scanner.
(c) Whether the fault diagnostic scanner is power on?
Yes Go to step 11
Yes
Step 3 Make the fault diagnostic scanner communicate with engine management system.
mode to ON state.
(b) Try to build up the communication with engine

management system (EMS).
(c) Confirm whether the fault diagnostic scanner

communicates with the engine control module.
No Go to step 14
Yes
Step 4 Whether the engine can start?
(a) Whether the engine can start?
No Please refer to “Check on intermittent

faults.
Yes
Select the fault code reading function for engine management system, and confirm whether there is
Step 5
fault code for the system.
(a) Whether the engine can start?
No Please refer to “Check on intermittent

faults.
Yes
Step 6 After recording the DTC, clear it.
Next step
Step 7 Confirm whether the fault can occur.
(a) Confirm whether the fault can occur.
NL-3 01/2016
No
Go to step 9
Yes
Step 8 Fault symptom simulation. ES
Next step
Step 9 Check whether the control system has any DTC.
(a) Check whether the control system has any DTC.

No
Please refer to “Check on intermittent
faults.
Yes
Carry out repair on the basis of fault diagnosis code. Please refer to the table of diagnosis fault
Step 10
codes.
Next step
Step 11 Use a normal vehicle, and connect the fault diagnostic scanner to check whether it can start.
(a) Use a normal vehicle, connect the fault diagnostic

scanner to check whether it can start.
For fault diagnostic scanner fault,
No please replace the fault diagnostic
scanner with a new one.
Yes
Step 12 Check fault diagnostic interface power supply circuit.
Next step
Step 13 Carry out the integrity diagnosis for CAN bus.
(a) Carry out the diagnosis on integrity of CAN bus.

Please refer to the table of diagnosis fault codes.
Next step
Step 14 Conduct confirmation test.
Next step
Step 15 End.
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Intermittent Fault Check

Notice
— Clear the DTC.
— Carry out the simulation test.

ES
— Check and shake the harness and terminal of connection box.
Carry out preliminary check firstly before carrying out fault diagnosis according to engine fault symptoms:
1. Check whether engine fault indicator lamp works normally;
2. Use diagnostic tool for check and check whether there is fault information record;
3. Check whether the fault symptom complained by car owner exists and determine the conditions if the fault occurs.
When the fault can't be determined via DTC check, the fault only occurs occasionally during operation. At this time, determine
all faults and components possibly leading to fault. Under most conditions, rapidly locate the faulty element via executing the
basic check in the following flow chart. Especially for poor contact and other faults of harness connector.
Fault definition: the fault is not available at present; the DTC log shows this fault in history. Or the client reports this fault,
however, the fault is not related to the fault diagnosis code and the fault symptoms can't be recreated.
Diagnostic steps:
Step 1 Check whether the battery voltage is normal.

mode to OFF state.
(b) Measure the voltage of battery.
(c) Implement the corresponding step on the basis of
measured value.
Result Go to step
11~14V Yes
Less than 11V No
No Check the battery.
Yes
Step 2 Check visually and physically.
If the following phenomenon exists, please firstly carry out

repair for such fault; otherwise the subsequent fault
diagnosis will be affected.
(a) Check whether the harness is broken, worn, peeling
off, etc.
(b) Check where there is leakage on fuel pipeline.
(c) Check whether the layout of harness is incorrect. It
is prohibited to make harness close to the following
high-voltage or high-current devices: ignition coil,
ignition conductor, starter motor and alternator. The
operation of these components will generate bigger
electromagnetic interference, thus influencing
correct signal transmission and leading to system
operation anomaly.
(d) Check whether the high-voltage line system is aged,
broken, flattened or damaged.
(e) Check whether the vacuum hose ruptures, damages
or twisted. Confirm line connection and arrangement
correctness.
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(f) Check whether the grounding point of engine

management system (EMS) and the grounding point
of vehicle body are oxidized, loosened or displaced.
The position of the bonding point of the control
system shall not be altered without authorization, or
else, the control system's normal operation will be
affected.
(g) Check whether the positive and negative cable of ES
the battery are reliably connected, whether there is
looseness, oxidation, erosion, etc. (b) Check where
there is leakage on fuel pipeline.
Yes
Step 3 Check the harness, connectors.

(a) Many intermittent faults are caused by the
movement of harness and connectors due to
vibration, distortion, uneven road or component
operation.
(b) Too huge circuit resistance may cause component
operation anomaly Use the fault diagnostic scanner
to forcibly drive the actuator. If it can’t work normally,
check whether the relevant circuit has the fault such
as too high resistance.
Next step
Step 4 Make the fault appear again and use the instrument to record data of the engine control unit.
(a) Connect vehicle fault diagnostic scanner and use its
data record function to record the data of the
intermittent fault during road test. After pressing the
button for the vehicle data recorder, record engine
control module data during intermittent fault. The
data is used to clarify fault component.
(b) Another diagnostic method is when the vehicle is
running, connect a digital multimeter to the
suspicious circuit. The abnormal reading of the
digital multimeter may indicate the faulty position.
Next step
Step 5 Malfunction indicator lamp lights intermittently, however, the system doesn't set the DTC.
(a) The following conditions may cause intermittent
lighting of the fault indicator lamp. However, the
system will not set fault diagnosis code:
(b) The electromagnetic interference is caused by
solenoid valve or switch which is controlled by
abnormally-working relay or engine management
system.
(c) Non original or installed accessories after sale, such
as on-board telephone, alarm, lamp, wireless
equipment mounting not correct
(d) Intermittent short circuit to ground of the fault
indicator lamp control circuit.
(e) The grounding point of engine management system
is loosened.
Next step
Step 6 Other check.
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(a) Test whether the circuit between the diodes on both
ends of the A/C compressor clutch and other diodes
is open.
(b) Check whether the charging system has the
following conditions:
 Alternator rectifier bridge fault may possibly lead to
ES AC signal interference in the electric system.
(c) Whether the alternator output voltage is correct If
the engine output voltage is less than 9V or higher
than 18 V, repair the charging system.
Next step
Step 7 Enter into the table of fault symptoms.
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Tips:
 The table below can help identify the cause of fault. The descending sequence is used to indicate the possibility of
causes of fault. Check every suspected location in accordance with the sequence. If necessary, repair, replace or adjust
the part which has failed.
ES
 Before checking the following suspected locations, please check the fuses and relays relating to the system.
Symptoms Suspected Parts Measures/Reference

P069700 P069000
2. Intake pressure (MAP) sensor P010622 P010684 P010685 P010716
The action is slow, the speed P010817
reduces, or the speed 3. Fuel pressure anomaly
is unstable Please refer to “Fuel system”.
Fault definition: depress the
acceleration pedal, there is no Refer to DTC P022317 P210612
instant response. Such fault P210613 P210619 P210692
may occur under any vehicle
speed. During initial start of the 6. Ignition system: spark plug or ignition
vehicle (e.g. start after conductor anomaly
parking), the fault is usually 7. Longer delay of the ignition of the knock
more obvious Under serious sensor (KS) system
condition, such fault may
possibly lead to engine speed 8. Wheel speed sensor Refer to DTC P057129
loss.
9. Accelerator pedal position sensor 1 Refer to DTC P212216 P212317
10. Accelerator pedal position sensor 2 Refer to DTC P212716 P212817
11. Supercharger
P023623 P023624 P023716 P023817
Only when the A/C is working, 1. A/C signal circuit Please refer to “A/C system”
the idle speed of engine Refer to DTC P060629 P060647
Stall P060648 P060649 P060661 P060662
2. Electronic throttle body
Fault Definition: when A/C is P060663 P060691 P060692 P060693
working, engine speed is not P060694 P060696 P060697 P133600
stable or engine stalls. 3. EMS Refer to “Engine ECU”
P069700 P069000
High fuel consumption, poor 2. Air flow meter
P010216 P010317
fuel economy
Fault definition: the oil 3. Air filter element blockage Please refer to “Air filter”
consumption via the actual 4. Poor fuel quality, fuel contamination
road test obviously exceeds
the expected value. In addition, 5. Fuel pressure anomaly Please refer to “Fuel system”.
the fuel consumption is also
significantly higher than the 6. Nozzle operation anomaly
previous road test. Refer to DTC P060629 P060647
P060648 P060649 P060661 P060662
P060663 P060691 P060692 P060693
P060694 P060696 P0697 P133600
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8. The use has any of the following driving

habits: The A/C or defroster mode is always
activated, the tire pressure is incorrect, the
vehicle is overloaded, or the acceleration is
carried out too quickly or too frequently
ES
9. Air leakage in intake system and crankcase
system
10. Positive crankcase ventilation valve
stagnation
11. Knock sensor (KS) system ignition delay is
too large
ablation, too much carbon deposit, Please refer to “Ignition system”
High fuel consumption, poor 14. Ignition coil broken
fuel economy
15. Engine coolant level too low, thermostat
Fault definition: the oil Please refer to “Cooling system”
fault
consumption via the actual
road test obviously exceeds 16. Too much oil inside the combustion
the expected value. In addition, chamber or valve seal leakage
the fuel consumption is also
significantly higher than the 17. Incorrect cylinder compression pressure
previous road test.
broken, valve timing incorrect Please refer to “Engine”
19. Too much carbon deposit in the combustion
chamber
20. Vacuum hose rupture or twisting, unreliable
connection
21. Drainage is not smooth: three-way catalytic
converter blocked, silencer interior damaged
22. Brake system delay or operation anomaly Please refer to “Brake system”
23. Electromagnetic interference (EMI) in the
misfire fault. The fault diagnostic scanner may
be used to monitor the engine speed
parameter. If the engine speed parameter
increases suddenly but the actual engine speed
remains unchanged, this means that there is
electromagnetic interference.
Fuel interruption, misfire P069700 P069000
Fault definition: when the 2. Air filter element blockage Please refer to “Air filter”
engine speed increases,
constantly pulsate or jitter. It 3. Fuel pressure anomaly
Please refer to “Fuel system”.
becomes more obvious when 4. Nozzle operation anomaly
the engine load increases.
When the engine speed is Refer to DTC P012129 P012216
higher than 1500 rpm, the fault P012317
is usually invisible. Refer to DTC P022317 P210612
P210613 P210619 P210692
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sensor (KS) system
ablation, too much carbon deposit, Please refer to “Ignition system” ES
Fuel interruption, misfire 11. Wheel speed sensor Refer to DTC P057129
Fault definition: when the 12. Too much oil inside the combustion
engine speed increases, chamber or valve seal leakage
constantly pulsate or jitter. It
becomes more obvious when 13. Incorrect cylinder compression pressure
the engine load increases.
When the engine speed is 14. Valve stagnant or leakage
above 1,500 rpm, the fault 15. Camshaft convex corner wear
does not appear.
16. Valve timing incorrect Please refer to “Engine”
17. Valve spring broken

chamber
19. Camshaft, cylinder lid, piston, link rod and
bearing anomaly
P069700 P069000
Please refer to the section about
Poor idling, unstable, incorrect 2. Air filter element blockage
replacement
or stalled
Fault definition: unsteady
engine operation during idle Please refer to the section about fuel
4. Fuel contamination
speed In case of serious system.
scenario, the engine or the 5. Injector operation anomaly
vehicle will vibrate. With a
P060648 P060649 P060661 P060662
engine idle speed may 6. Electronic throttle body
P060663 P060691 P060692 P060693
fluctuate. Any of these
P060694 P060696 P060697 P133600
circumstances is likely to be
serious enough to make the 7. Electronic accelerator pedal position sensor Refer to DTC P213829
engine stall.
8. Positive crankcase ventilation
9. Evaporation drain (EVAP) carbon canister system”
solenoid valve
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sensor (KS) system
ES ablation, too much carbon deposit, Please refer to “Ignition system”
Poor idling, unstable, incorrect
or stalled 15. Too much oil inside the combustion
Fault definition: unsteady chamber or valve seal leakage
engine operation during idle
speed In case of serious
scenario, the engine or the 17. Valve blockage or leakage, valve spring
vehicle will vibrate. With a broken, valve timing incorrect
engine idle speed may 18. Too much carbon deposit in the combustion
fluctuate. Any of these chamber
circumstances is likely to be 19. Check engine bracket
serious enough to make the
engine stall. 20. Electromagnetic interference (EMI) in the Please refer to “Engine”
misfire fault. Usually, the fault diagnostic
scanner can be used to detect electromagnetic
interference via monitoring engine speed
parameter. When the engine speed parameter
suddenly increases and the actual engine
speed almost remains unchanged, it means the
electromagnetic interference is available. If
there is a fault, check whether there is a high
voltage component near the ignition control
circuit.
P069700 P069000
2. Incorrect fuel number
Combustion and ignition knock 3. Fuel pressure anomaly
Fault definition: the explosion Please refer to “Fuel system”.
and vibration sound
aggravates during accelerate 5. Mixture too thin
With variation of the throttle
opening, the engine will 6. Longer delay of the ignition of the knock
generate sharp metal strike sensor (KS) system Please refer to “Ignition system”
sound.
7. Spark plug's calorific value not correct
8. Cooling system: level too low, engine coolant
not correct, engine coolant leakage, cooling fan Please refer to “Cooling system”
not operating
9. There is too much engine oil in combustion
Combustion and ignition knock chamber and the sealing part of valve leaks.
Fault definition: the explosion Please refer to the section about engine
and vibration sound
10. Cylinder compression pressure too high
aggravates during accelerate Please refer to “Engine”
With variation of the throttle 11. Too much carbon deposit in the combustion
opening, the engine will chamber
generate sharp metal strike
sound. 12. Camshaft, cylinder lid, piston, link rod and
bearing anomaly
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1. Too much oil inside the combustion chamber

or valve seal leakage
chamber Please refer to “Engine”
ES
3. Timing assembly not correct
Engine is difficult to start 5. Fuel pump relay, fuel pump, injector, fuel
Fault definition: normal contamination
operation of the engine
crankshaft, no start for a long 6. Ignition system: ignition leads, spark plug,
time. The engine may finally ignition coil
start and may immediately Refer to DTC P064100 P065100
flameout 7. EMS power circuit
P069700 P069000
8. Engine coolant temperature sensor Please refer to “Cooling system”
P060648 P060649 P060661 P060662
P060663 P060691 P060692 P060693
P060694 P060696 P060697 P133600
10. Electronic accelerator pedal position sensor Refer to DTC P213829
P069700 P069000
3. Fuel contamination Please refer to “Fuel system”.
4. Injector operation anomaly
Backfire, blast 5. Air leakage in the intake system and
Fault definition: the not fully crankcase Please refer to “Auxiliary emission
combusted gas in the system”
combustion chamber enters 6. Positive crankcase ventilation
the intake manifold or drain 7. Longer delay of the ignition of the knock
system for ignition, it generates sensor (KS) system
very big blast sound.
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P069700 P069000
2. A/C compressor Please refer to “A/C system”
ES 3. Heating type oxygen sensor anomaly

5. Fuel pressure anomaly Please refer to “Fuel system”.
Surge 6. Nozzle operation anomaly

Fault definition: engine power Refer to DTC P060629 P060647
varies when the throttle P060648 P060649 P060661 P060662
stabilizes. It seems that the 7. Electronic throttle body
P060663 P060691 P060692 P060693
vehicle speed will increase or P060694 P060696 P060697 P133600
decrease when the position of
the acceleration pedal remains 8. Intelligent variable valve timing system
unchanged. Please refer to “Engine”
9. Vacuum hose rupture or twisting, unreliable
connection
contamination by fuel Please refer to “Ignition system”
P069700 P069000
2. Air filter element blockage Please refer to “Replacement”
4. Fuel pressure anomaly Please refer to “Fuel system”.
Insufficient power, viscosity or Refer to DTC P060629 P060647
weakness P060648 P060649 P060661 P060662
Fault definition: the engine P060663 P060691 P060692 P060693
power output is lower than P060694 P060696 P060697 P133600
expected. When half tramping
the acceleration pedal, little or
sensor (KS) system
no speed increase at all.
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12. Too much oil inside the combustion

Insufficient power, viscosity or 13. Incorrect cylinder compression pressure

weakness 14. Valve blockage or leakage, valve spring
Please refer to “Engine” ES
Fault definition: the engine broken, valve timing incorrect
power output is lower than
expected. When half tramping 15. Too much carbon deposit in the combustion
the acceleration pedal, little or chamber
no speed increase at all. 16. Intelligent variable valve timing system
1. Battery
2. Starter Please refer to “Start system and
3. Start relay charging system”
No operation of the engine
Definition of fault: When the 4. Starter switch
power switch is in the state ST,
the engine crankshaft does not Please refer to “Central controller
rotate. 5. BCM assembly (anti-pinch function of four
doors)”
Please refer to “Intelligent entry &
6. Engine Anti-theft System
start system”
P069700 P069000
Engine does not start with no Refer to DTC P001676 P001678
sign of the vehicle starting. P034100 P034200 P034300 P001200
Fault Definition: When start DTC P001776 P001778 P001500
switch in the ST position, the P036600 P036700 P036800
engine crankshaft rotates, but 4 Ignition system Please refer to “Ignition system”
no sign of the vehicle starting.
5. Fuel pump control circuit
6. Fuel injector operation circuit
7. EMS Refer to “Engine ECU”
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EMS Terminal
EN35 engine management system (plug-in part A) harness connector 1
ES
Notice:
- UB is the battery voltage.
- If there is no description, GND is 0 V or close to 0 V.
When the engine is
1 IGN4 Control line of ignition coil 4
running
When the engine is
running
3 FPCV- Fuel control valve - -
When the engine is
4 FPCV+ Fuel control valve +
running
When the engine is
5 O.T.CVVTE Exhaust variable valve timing valve
running
6 - - -
When the engine is
7 SV SNR Air flow meter power supply line
running
When the engine is
8 ENG GND Camshaft position sensor grounding
running
9 - - -
10 KNOCK SNR- Knock sensor - -
11 - - -
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12 5V SNR Constant power supply All
Sensor grounding wire (5V power The power mode is in
13 SNR GND ENG2
supply negative) the state ON
Earthing wire of water temperature
14 s NR GND TEMT All
sensor
ES
15 - - -
When the engine is
running
When the engine is
running
18 WGCV Exhaust control valve control line When engine is running
When the engine is
19 ECT+ Throttle actuator motor +
running
When the engine is
20 ECT- Throttle actuator motor-
running
G.R.CLUTCH
21 Clutch pump (GND) -
（MT model）
22 SNR GND Speed sensor grounding wire -
23 ENG SNR Speed sensor signal line -
24 TPSNR1 Throttle position sensor 1 signal line -
The power mode is in
25 KNOCK SNR+ Knock sensor+
the state ON
26 - - -
Intake/exhaust camshaft position When the engine is
27 ENG SNR1
sensor power supply running
28 - - -
Positive pole of 5V power supply of
29 SNR ENG2 sensor (including fuel rail pressure In the course of heating
sensor)
30 - - -
31 INJECTOR1+ Fuel injector 1+
the state ON
the state ON
When the engine is
33 INJECTOR1- Fuel injector 1-
running
When the engine is
running
35 CPV Canister control valve control line -
Supercharge pressure sensor
36 B.A.T SNR -
temperature signal line
37 - - -
Intake pressure sensor temperature The power mode is in
38 IAT SNR
signal line the state ON
Supercharge pressure sensor
39 BAP SNR -
pressure signal line
40 ERP SNR Fuel rail pressure sensor signal line
the state ON
41 TP SNR2 Throttle position sensor 2 signal line
the state ON
I.T.CLUTCH （MT
42 Clutch pump EPB -
model）
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43 - - -
Internal grounding of electronic The power mode is in
44 SNR GND
throttle sensor the state ON
ES
45 - - -
the state ON
the state ON
When the engine is
running
When the engine is
running
Intake variable valve timing valve
50 VCTC(INTAKE) -
control line
51 - - -
52 - - -
Intake camshaft position sensor
53 CPI SNR -
signal line
Exhaust camshaft position sensor The power mode is in
54 CPE SNR
signal line the state ON
When the engine is
55 AIR FLOW SNR Air flow signal line
running
Temperature signal of air flow
56 TEMP SER -
meter
TEMP SNR Water temperature sensor signal
57 -
WATER line
58 - - -
59 SNR GND Air flow meter grounding -
60 - - -
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CA01 engine management system (plug-in part K) harness connector 2
ES
CA01 engine management system (plug-in part K) harness connector 2
Notice:
- UB is the battery voltage.
- If there is no description, GND is 0 V or close to 0 V.
When the engine is
1 EMS G1 Grounding line
running
When the engine is
running
3 MAIN RLY1 Power supply 1 of main relay -
When the engine is
running
When the engine is
5 MAIN RLY2 Power supply 2 of main relay
running
When the engine is
6 MAIN RLY3 Power supply 3 of main relay
running
7 - - -
8 DUMP VALVE Intake drain valve control line -
9 - - -
10 - - -
Electronic accelerator position
11 SNR GND -
sensor signal grounding
12 - - -
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13 BV SNR Vacuum temperature signal line
the state ON
Intake pressure sensor grounding
14 SNR GND All
line
ES 15 - - -
16 - - -
17 - - -
18 - - -
When engine is
19 BRAKE LIGHT SW Brake lamp switch signal
running
When the engine is
20 A/C REQUEST A/C request signal line
running
21 AC MID PRE SW A/C pressure switch -
22 - - -
23 - - -
24 BREAK SW Brake switch
the state ON
25 - - -
Cooling fan low speed relay
26 COOL FAN RLY HO -
control line
Cooling fan high speed relay When the engine is
27 COOL FAN RLY HI
control line running
28 LPFP RLY Fuel pump relay control line -
DOWN SNR Downstream oxygen sensor
29 -
HEATING heating control line
30 - - -
31 - - -
32 - - -
Downstream oxygen sensor The power mode is in
33 O2 SNR GND
grounding the state ON
34 - - -
When the engine is
35 SNR GND Sensor 5V power line
running
36 - - -
37 - - -
38 - - -
39 - - -
40 - - -
41 - - -
42 AC RLY A/C compressor relay control line -
43 - - -
44 PCAN-L CAN low
the state ON
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45 PCAN-H CAN high
the state ON
46 LOAD SIGNAL Alternator monitoring line
the state ON
When the engine is ES
47 ELECTRIC LOAD2 Power supply of left high beam
running
I.S.CS10% (MT
48 Top switch of clutch pump -
model)
49 - - -
50 - - -
51 - - -
52 - - -
53 - - -
54 - - -
55 - - -
56 - - -
57 - - -
Intake pressure sensor power
58 ANALOG SNR -
supply line
When the engine is
59 SNR DIGITAL Speed sensor power supply line
running
60 - - -
Electronic accelerator pedal sensor When the engine is
61 APP
2 running
Downstream oxygen sensor signal When the engine is
62 DOWN O2 SNR
line running
When the engine is
63 MP SNR Intake pressure sensor signal line
running
64 - - -
65 - - -
66 - - -
67 - - -
68 - - -
69 MAIN RLY Main relay control line -
70 - - -
71 - - -
72 - - -
Upstream oxygen sensor heating The power mode is in
73 UPO2 SNR
line the state ON
Turbine cooling electronic water
74 TURBO PUMP All
pump
75 - - -
Upstream oxygen sensor The power mode is in
76 O2 SNR VM
grounding line the state ON
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Upstream oxygen sensor voltage
77 O2 SNR UN -
signal line
Upstream oxygen sensor current When the engine is
78 O2 SNR IA
signal line running
ES Upstream oxygen sensor heating When the engine is
79 O2 SNR IP
control line running
80 - - -
Electronic accelerator pedal When the engine is
81 5V SNR
sensor 2 power supply 5V running
Electronic accelerator pedal -
82 5V SNR Voltage 5V
sensor 1
Electronic accelerator pedal When the engine is
83 APP1
sensor running
84 - - -
85 - - -
86 - - -
87 IGN KEY SW Power supply line
the state ON
88 - - -
89 - - -
90 - - -
91 - - -
92 - - -
93 - - -
94 - - -
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Diagnostic System
1. Instructions
When eliminating a fault on the vehicle equipped with
IP12 OBD diagnostic interface multi-channel on-board diagnostic system, the vehicle
shall be connected to the intelligent tester. And then
ES
various data from EMS can be read.
The OBD specifications require that, the on-board
computer shall light the MIL on instrument panel when a
fault is found in any of the following components:
1) Emission control system/component
2) control components of drive train (which affect
the emission of vehicle)
3) In addition, the corresponding DTC will be
recorded in EMS memory. If the fault does not
recur within 3 consecutive cycles, then the MIL
will go out automatically, but the DTC will still
be recorded in EMS memory.
Notice:
Before measuring the resistance, don’t operate the
vehicle for at least 1 minute, and don’t operate the power
switch, any other switch or door. If the result does not
meet the specified value, maybe the diagnostic interface
fails. Repair or replace the harness connector.
4) Connect the fault diagnostic scanner to the
diagnostic interface, and operate the power
switch so as to set the power mode in the state
ON. If the display screen indicates that there is
communication error, then the problem is not in
the vehicle, but in the diagnosis instrument.
Notice:
If the communication is normal when the diagnosis
instrument is connected with another vehicle, please
check the diagnostic interface on original vehicle.
If the communication still can’t be built up when the
diagnosis instrument is connected with another vehicle,
maybe the problem exists in diagnosis instrument. Refer
to the user’s manual for the scanner or contact the
manufacturer.
1. Check the DTC

Check/troubleshooting for DTC of
1) Connect the fault diagnostic scanner to the
components diagnostic interface.
2) Operate the power switch so as to set the power

mode in the state ON.
3) In accordance with the instructions given on

display of diagnosis instrument, read the value of
DTC.
2. Clear DTC


3) In accordance with the instructions given on

display of diagnosis instrument, delete the DTC.
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Data sheet/active test
Read the data stream

Notice:
ES On the basis of the date sheet displayed on fault
diagnostic scanner, under the circumstance that no part is
removed, you can read the value of switch, sensor,
actuator and other components. When eliminating a fault,
please firstly read the data sheet, which can shorten the
working hours.
2) Operate starter switch to put power supply mode
in ON state.
3) On the basis of the indication on display screen of
diagnosis instrument, select “EMS”/“Real-time
Display”, and then read the “data sheet”.
Data Flow Table.
Data stream name Power mode in state ON Idling
Actual air-fuel ratio 1 1
Battery voltage 12.22 13.39
Opening angle of throttle relative to
6.84 5.42
mechanical BDC
Fuel rail pressure 7.20 7.55
Intake temperature 60.00 56.25
Environmental temperature 25.50 25.50
Upstream intake pressure of throttle valve
1009.30 1023.13
body
Accelerator pedal opening 0 0
Fuel flow (L/s) 0 0
Actual downstream exhaust back pressure of
1009.30 1018.13
exhaust valve
Model value of exhaust temperature in
331.72 504.32
exhaust manifold
Relative opening of exhaust control valve 0.04 0.04
Maximum indication torque of engine 400 400
Maximum set fuel rail pressure 19 19
Flow of air flow meter corrected 1.30 19.9
Relative air inflow 0 41.41
Intake flow 0 20
Catalytic converter downstream oxygen
0.27 0.50
sensor output voltage
Relative inflation volume 54.75 39.75
SKA Freeze frame information 0 0
Environmental conditions for monitoring and
0 0
diagnosis of ETS route
Diagnosis and monitoring conditions for
0 0
torque route
Actual torque for comparison of torque of
0 0
monitoring function
NL-3 01/2016

Substitute value of engine temperature at
102.75 99.75
fault
Target throttle opening relative to mechanical
1.57 5.10
BDC
Model value of downstream exhaust ES
300 365
temperature of catalytic converter
Engine coolant temperature 102.00 104.25
Engine coolant temperature model substitute
50.25 50.25
value
Calculation of actual torque by the monitoring
0 0
function
Current gear 0 0
Relative fuel flow 0 39
Actual ignition angle 0 -2.25
Flow correction factor as a substitute of load
1 1
signal
Set value of fuel rail pressure 7.20 7.71
Position signal of throttle potentiometer 1 6.84 5.37
Position signal of throttle potentiometer 2 6.69 5.20
Duty ratio of throttle valve body control signal 100 18.33
Throttle position in limp mode 0 0 0 0
Voltage of throttle potentiometer 2 under limp
4.22 4.22
mode
Voltage of throttle potentiometer 1 under limp
0.78 0.78
mode
Voltage signal of throttle potentiometer 1 at
0.51 0.51
mechanical BDC
Acceleration in heading direction of the
0 0
vehicle
Ambient pressure sensor signal voltage 3.98 3.98
Ambient pressure 1009.30 1009.30
Intake manifold absolute pressure 1009.30 746.09
Number of clutches 0 0 0 0
Intake temperature 63.00 54.75
Vehicle speed output 00 0 0
Battery voltage (ADC scanning value) 12.22 13.39
Signal voltage of upstream wide-range
oxygen sensor of catalytic converter (ADC 1.50 1.49
scanning value)
Actual air-fuel ratio 1.00 1
LRSHK integral factor 00 0 0
Wide-range oxygen sensor dynamic value 0.71 0.71
Relative angle of intake VVT 37 33.30
Target angle of intake VVT 37 37
NL-3 01/2016

Oil temperature 100.58 96.65
Control output of air-fuel ratio 1.00 0.99
Correction factor for mixer self-learning
1.03 1.03
multiplication
ES
Signal voltage of throttle opening
0.78 0.72
potentiometer 1
Signal voltage of throttle opening
4.22 4.27
potentiometer 2
Control duty ratio of intake VVT 0 5.0
Wide-range oxygen sensor ceramic body
1914.69 298.91
temperature
Correction factor for mixer self-learning
0 0.28
addition
Voltage of PWG potentiometer 0.75 0.75
Voltage of PWG potentiometer 2 0.37 0.37
Doubled voltage of PWG potentiometer 2 0.74 0.74
Downstream oxygen sensor ceramic body
0 102
temperature
Model value of upstream exhaust
282.08 449.97
temperature of front catalytic converter
Flow of air flow meter not corrected 1.30 19
Transmission ratio 0 0
Signal voltage of throttle upstream pressure
2.01 2.03
sensor
Throttle upstream intake pressure 1007.27 1021.09
Fuel injection pulse width 0 1.98
Target idle speed 750 750
Delay of dynamic ignition angle of cylinder
0 0
No.1
0 0
No.2
0 0
No.3
0 0
No.4
Reference level of knock signal of cylinder
1.05 0.09
No.1
1.05 0.11
No.2
1.05 0.10
No.3
1.05 0.13
No.4
Engine start water temperature 102.00 97.50
Flow of carbon canister valve 0 2.45
Basic ignition angle 0 14.25
Misfire rate 0 0
Times of misfire of cylinder No.1 5 5
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Air-fuel ratio modulation period 0 0
Times of misfire of cylinder No.4 18 18 ES
Correction of idle control torque 0 0
Maximum speed of misfire diagnosis 0 0
Minimum speed of misfire diagnosis 16383.75 16383.75
Minimum load of misfire diagnosis 0.78 0.78
Maximum load for misfiring diagnosis 00 0 0
Maximum achievable indication torque 44.73 44.86
Actual indication torque 0 15.27
Engine temperature 102.00 103.50
Signal voltage of intake manifold pressure
2.01 1.53
sensor
Self-learning of engine resistance torque 0 2.82
Relative angle of exhaust VVT -33 -35.45
Target exhaust VVT angle -33 -33
Duty ratio of exhaust VVT 0 5.00
The carbon canister valve controls the duty
0 47.68
ratio
State of oil pump relay OFF ON
Status of low-speed fan relay OFF ON
State of high-speed fan relay OFF OFF
Status of A/C clutch OFF ON
Engine speed 0 751.50
Time after starting 0 45.7
Oil level 0 0
Oil temperature 101.99 102.74
Vehicle speed 0 0
Ambient pressure 1009.3 1009.3
Active test
Notice:
It’s able to run the relay, actuator and other components
under the circumstance of removing no parts during
automatic test of the diagnostic scanner. When
eliminating the fault, firstly carry out the active test, so as
to shorten the working time.
NL-3 01/2016
1) Connect the intelligent tester to diagnostic interface.

3) Carry out “Active test” according to the diagnostic
scanner screen.
ES Table of active test
Items displayed by the fault
diagnosis instrument
Solenoid valve would
Control duty ratio of Enable solenoid valve of
0%, 50%, 100% open/close within 3~5s when
canister valve charcoal canister
command is ON.
Notice: only when the vehicle
speed is zero and the speed
sensor has no faults, execute
this function test.
State of oil pump relay Enable fuel pump ON/OFF
The function may control fuel
pump relay. The fuel pump
relay will connect/disconnect
within 3~5s.
Notice: Only in the condition
of the engine coolant
temperature is lower than
100 ℃ （ 212 ºF) and A/C
switch is off, can this function
Enable low-speed cooling test execute.
State of low-speed fan relay ON/OFF
fan This function can control low
speed cooling fan relay.
Cooling fan would be
enabled for 5s at slow speed
when it receives the
command of switch-on.
Notice: Only in the condition
of the engine coolant
temperature is lower than
100 ℃ （ 212 ºF) and A/C
switch is off, can this function
State of high-speed fan Enable high-speed cooling test execute.
ON/OFF
relay fan This function can control high
speed cooling fan relay.
When receiving the
connection instruction, the
cooling fan will start 5s at
high speed.
When the command is for the
Throttle opening Open throttle 0%, 50%, 100% state ON, the throttle will be
opened/closed within 3-5s.
When the command is the
state ON, the intake
Control of intake camshaft Opening of intake camshaft 0%, 50%, 100%
camshaft will be
When the command is the
Control of exhaust state ON, the intake
Opening of exhaust camshaft 0%, 50%, 100%
camshaft camshaft will be
When the command is for
Enable air pressure solenoid state ON, the air pressure
Air pressure solenoid valve 0%, 50%, 100%
valve solenoid valve will be
NL-3 01/2016
Items displayed by the fault

diagnosis instrument
This function can control the
relief valve of turbocharger.
Turbine supercharger relief Enable the turbocharger Turbine supercharger relief
ON/OFF
valve relief valve valve would open when it
receives the command of ES
switch-on.
coolant pump. The coolant
Coolant pump Enable coolant pump ON/OFF pump would be enabled
flowrate control valve. The
Flow control valve Enable flow control valve ON/OFF flow control valve would open
idle control function. The idle
Idle control Enable idle control ON/OFF control would be enabled
NL-3 01/2016
Table of DTCs
DTC Description Diagnosis procedures

ES Refer to DTC P000A64
P001013 The intake VVT circuit is broken P000A77 P001013 P208811
P208912
P000B64 Operating fault of exhaust VVT (delay)
P000B77 Operating fault of exhaust VVT (jamming)
Refer to DTC P000B64
P001313 VVT exhaust control valve circuit fault（Bank 1) P000B77 P001313 P209011
P209112
P209011 Exhaust VVT valve circuit is short to ground
P209112 Exhaust VVT valve circuit is short to power supply
The relative position between intake-side camshaft and
P001676
crankshaft unreasonable (Bank 1, EOL diagnosis)
Intake side camshaft and crankshaft relative mounting
P001678
position unreasonable（Bank 1)
P034100 Intake side phase sensor signal unreasonable (Bank 1) Refer to DTC P001676 P001678
P034100 P034200 P034300
Intake side phase sensor signal circuit voltage is too low P001200
P034200
(Bank 1)
Intake side phase sensor signal circuit voltage is too high
P034300
(Bank 1)
P001200 The locked position of intake camshaft unreasonable
The relative position between exhaust-side camshaft and
P001776
crankshaft unreasonable (Bank 1, EOL diagnosis )
Exhaust camshaft and crankshaft relative mounting
P001778
position unreasonable（Bank 1)
The locking position of exhaust camshaft unreasonable
P001500 Refer to DTC P001776 P001778
fault
P001500 P036600 P036700
P036600 Exhaust side phase sensor signal unreasonable（Bank 1） P036800
Exhaust phase sensor signal circuit voltage is too low
P036700
（Bank 1）
Exhaust phase sensor signal circuit voltage is too high
P036800
（Bank 1）
Upstream oxygen sensor heating control circuit short to
P003111
ground
Upstream oxygen sensor heating control circuit short to
P003212 Refer to DTC P003013 P003111
power supply
P003212 P00531E P01351E
Upstream oxygen sensor heating internal resistance
P00531E
unreasonable (Bank1)
Upstream oxygen sensor heating circuit signal fault (ECU
P01351E
internal adjustable resistance is out of range)
NL-3 01/2016

P003313 Supercharge relief control valve drive circuit is open
P003411 Supercharge relief control valve drive circuit is short to
ground Refer to DTC P003313 P003411
P003512 Supercharge relief control valve drive circuit is short to P003512 P226100
power supply ES
P226100 Supercharge relief control valve failure
P003711 Downstream oxygen sensor heating control circuit short to
ground
P003812 Downstream oxygen sensor heating control circuit short to P003812 P00541E
power supply
P00541E Downstream oxygen sensor heating internal resistance
unreasonable (bank1)
P222816 Ambient pressure sensor voltage is too high
P222917 Ambient pressure sensor voltage is too low Refer to DTC P222816 P222917
P22302F The signal of ambient pressure sensor signal is incorrect P22302F P22308F
P22308F Ambient pressure sensor signal unreasonable

P008700 Fuel rail pressure is too low
P008784 Fuel rail pressure is too low (exceeding the lower limit of
the allowable reasonable range)
P008800 Fuel rail pressure is too high
P008885 Fuel rail pressure is too high (exceeding the lower limit of Refer to DTC P008700 P008784
the allowable reasonable range) P008800 P008885 P304B00
P304C00
P019216 Fuel rail pressure sensor signal circuit voltage is too low
P019317 Fuel rail pressure sensor signal circuit voltage is too high
P304B00 High pressure fuel rail pressure is too high
P304C00 High pressure fuel rail pressure is too low
P009716 Intake pressure sensor signal circuit voltage is too low (in
front of throttle)
P009817 Intake pressure sensor signal circuit voltage is too high (in
front of throttle)
P013600 Downstream oxygen sensor signal unreasonable
P013700 Downstream oxygen sensor signal circuit voltage is too
low
P013800 Downstream oxygen sensor signal circuit voltage is too
high Refer to DTC P013600 P013700
P013800 P014000 P227000
P227100 P042000
P042000 Three-way catalytic converter oxygen storage capacity
aging (emission over limit) (Bank 1)
NL-3 01/2016

P016929 Oilpipe monitoring fault (working mode monitoring fault)
P016961 Oilpipe monitoring fault (load comparison monitoring fault)
P016964 Oilpipe monitoring fault (gas mixture monitoring fault)
P016992 Oilpipe monitoring fault (oilpipe comparison fault in the oil P016964 P016992 P016993
ES supply mode) P016994
P016993 Oilpipe monitoring fault (oilpipe comparison fault in the oil
supply mode)
P016994 Oilpipe monitoring fault (load forecasting monitoring fault)
P026300 Cylinder No.1 fuel injector control circuit voltage
unreasonable Refer to DTC P020113 P026111
P026300 P214600 P214611
P214600 Short circuit of high-pressure fuel injector on high and low
sides of cylinder No.1
P214611 Short circuit to ground on high-pressure side of
high-pressure fuel injector of cylinder No.1
P026600 Cylinder No. 2 fuel injector control circuit voltage Refer to DTC P020213 P026411
unreasonable P026600 P215500 P020213
P026900 Cylinder No. 3 fuel injector control circuit voltage Refer to DTC P020313 P026711
unreasonable P026900 P214900
P027200 Cylinder No.4 fuel injector control circuit voltage
unreasonable Refer to DTC P020413 P027011
P027200 P215200 P215211
P215211 Short circuit to ground on high-pressure side of
high-pressure fuel injector of cylinder No.4
P021900 The engine speed is too high Refer to DTC P021900
P022129 Signal of electronic throttle position sensor 2
unreasonable
P022216 Electronic throttle position sensor 2 signal circuit voltage Refer to DTC P022317 P210612
is too low P210613 P210619 P210692
P022317 Electronic throttle position sensor 2 signal circuit voltage
is too high
P023400 Pipe of exhaust gas control valve to the relief valve
pressure chamber leaks or falls off
P024313 The driving circuit fault of exhaust control valve
P024511 The voltage of driving circuit of exhaust control valve is P024511 P024612
too low
P024612 The voltage of driving circuit of exhaust control valve is
too high
NL-3 01/2016

P023621 Turbocharge pressure sensor signal is less than the
minimum limit
P023622 Turbocharge pressure sensor signal is greater than the
maximum limit
Refer to DTC P023621 P023622 ES
P023623 Turbocharge pressure sensor signal fault P023623 P023624 P023716
P023817
P023624 Turbocharge pressure sensor signal unreasonable fault
P023716 Supercharge pressure sensor signal voltage is too low
P023817 Supercharge pressure sensor signal voltage is too high
P025111 Flow control valve drive circuit is short to ground (high
pressure side)
P025113 Flow control valve drive circuit is open
P025212 Flow control valve drive circuit is short to power supply
(high pressure side)
P025212 P025311 P025412
P025311 Flow control valve drive circuit is short to ground (low
pressure side)
P025412 Flow control valve drive circuit is short to power supply
(low pressure side)
P030200 Cylinder No. 2 misfire Refer to DTC P030000 P030100
P030300 Cylinder No. 3 misfire P030200 P030300 P030400
P130B00
P130B00 The misfiring fault caused by damage of catalytic
converter
P032100 Crankshaft TDC tooth missing signal unreasonable
P032517 Knock sensor signal circuit voltage is too high
P032700 Multiple circuit fault in signal end of knock sensor (too low
voltage)
P032714 Multiple circuit fault in signal end of knock sensor (too low Refer to DTC P032516 P032517
voltage) P032700 P032714 P032800
P032815 P138600
P032800 Multiple circuit fault in signal end of knock sensor (too high
voltage)
P032815 Multiple circuit fault in signal end of knock sensor (too high
voltage)
P138600 Knock signal control unreasonable
P044413 Carbon column control valve control circuit open
P045811 Canister control valve control circuit voltage is too low
P045912
P045912 Canister control valve control circuit voltage is too high
NL-3 01/2016

P048013 Cooling fan relay control circuit fault (low speed)
P06344B Low-speed fan internal chip temperature is too high
Refer to DTC P048013 P06344B
P069111 Cooling fan relay control circuit fault (low speed) P069111 P069212
ES P069212
Cooling fan relay control circuit voltage is too high (low
speed)
P048113 Cooling fan relay control circuit fault (high speed)
P063449 High-speed fan internal chip temperature is too high
P069311 Cooling fan relay control circuit fault (high speed) P069311 P069412
Cooling fan relay control circuit voltage is too high (high
P069412
speed)
The vehicle speed exceeds the maximum permissible
P050022
value
P050029 The vehicle speed signal from CAN is in fault Refer to DTC P050022 P050029
P050123 P05012F
P050123 Vehicle speed sensor signal delay
P05012F Vehicle speed sensor signal unreasonable fault
P050600 Idle control speed lower than target idle speed
P050700 Idle control speed higher than target idle speed
The flow through the air flow meter is too low (exceeding
P010184
the lower limit of the allowable reasonable range)
The flow through the air flow meter is too high (exceeding Refer to DTC P010184 P010185
P010185
the upper limit of the allowable reasonable range) P010216 P010317
P010216 Mass air flow meter circuit voltage is too low
P010317 Mass air flow meter circuit voltage is too high
P010500 Intake pressure sensor signal no fluctuations
Intake pressure sensor signal is less than the minimum
P010621
limit
Intake pressure sensor signal is greater than the
P010622
maximum limit
Intake pressure sensor signal is less than the model P010622 P010684 P010685
P010684
minimum pressure value P010716 P010817
Intake pressure sensor signal is more than the model
P010685
maximum pressure value
P010716 Intake pressure sensor signal circuit voltage is too low
P010817 Intake pressure sensor signal circuit voltage is too high
P011216 Intake temperature sensor signal circuit voltage is too low
P011317 Intake temperature sensor signal circuit voltage is too high
P011100
P011100 Intake temperature sensor signal unreasonable
P011600 Engine coolant temperature sensor signal unreasonable
Engine coolant temperature sensor circuit voltage is too
P011716 Refer to DTC P011600 P011716
low
P011817
Engine coolant temperature sensor circuit voltage is too
P011817
high
NL-3 01/2016
Signal of electronic throttle position sensor 1

P012129
unreasonable
Electronic throttle position sensor 1 signal circuit voltage Refer to DTC P012129 P012216
P012216
is too low P012317
ES
Electronic throttle position sensor 1 signal circuit voltage
P012317
is too high
P013029 Open IA circuit of upstream oxygen sensor
P013217 Upstream oxygen sensor signal circuit voltage is too high
P013300 Upstream oxygen sensor dynamic response slow
Upstream oxygen sensor signal unreasonable - signal

P219500
continuously too thin （Bank1）
Upstream oxygen sensor signal unreasonable - signal

P219600
continuously too rich (Bank1)
The upstream oxygen sensor signal line is coupled with P013217 P013300 P219500
P223100 P219600 P223100 P224300
the heater wire (Bank2)
P225100 P309691 P309692
P224300 Open UN circuit of upstream oxygen sensor P309694 P309696 P241400
P262600
P225100 Open VM circuit of upstream oxygen sensor
P309691 Maximum fault of upstream oxygen sensor CJ chip
P309692 Upstream oxygen sensor CJ chip signal fault
P309694 Minimum fault of upstream oxygen sensor CJ chip
P309696 Upstream oxygen sensor CJ chip unreasonable fault
P241400 Upstream oxygen sensor output voltage unreasonable
P262600 Open IP circuit of upstream oxygen sensor
P056000 System battery voltage signal unreasonable

P056300 U300384 U300385
U300384 The voltage of battery is lower than limit (CAN diagnosis)
U300385 The voltage of battery is higher than limit (CAN diagnosis)
P057129 The signal of two brake switches is not synchronous Refer to DTC P057129
P060616 ECU controller fault (5V undervoltage fault)
P060617 ECU controller fault (5V overvoltage fault)
P060644 ECU controller fault (software reset 0 fault)

P060644 P060645 P060143
P060143 Electronic control unit RAM fault (EEP reading fault) P060149 P060100
P060149 Electronic control unit RAM fault (EEP writing fault)
The calculation of checksum of EEPROM for wiring

P060100
configuration is in fault (unreasonable)
NL-3 01/2016
Electronic throttle safety monitoring function fault (first

P060629
layer safe fuel cutting-off monitoring fault)

P060647
(monitoring model feedback fault)
ES
P060648
(monitoring erroneous response fault)

P060649
(monitoring model inquiry fault)

P060661
(ignition angle signal, harness or ECU fault)
Electronic throttle safety monitoring function fault (second

P060662
layer accelerator pedal signal rationality fault)
Electronic throttle safety monitoring function fault P060648 P060649 P060661
P060691
(overvoltage causes DVE drive shutdown fault) P060662 P060663 P060691
Electronic throttle safety monitoring function fault (second P060692 P060693 P060694
P060692 P060696 P060697 P133600
layer engine speed monitoring fault)
Electronic throttle valve safety monitoring fault (second

P060693
layer safe oil cutting-off monitoring fault)
Electronic throttle safety monitoring function fault (second

P060694
layer torque monitoring fault)
The safety monitoring function fault for electronic throttle

P060663
(start/stop monitoring fault )
Fault of electronic throttle security monitoring function (AD

P060696
converter monitoring fault)
Electronic throttle valve safety monitoring fault (AD given

P060697
voltage test fault)
P133600 Electronic throttle safety monitoring torque limit function
P062713 Fuel pump relay control circuit fault

P062912
P062912 Fuel pump relay control circuit voltage is too high
P062B08 High pressure fuel injector drive level signal fault

Refer to DTC P062B08
P062B29 High pressure fuel injector drive level unreasonable fault
P062B29 P062B86
P062B86 High pressure fuel injector drive level minimum fault
P064100 System reference circuit A is open
P065100 System reference circuit B is open Refer to DTC P064100 P065100

P069700 System reference circuit C is open P069700 P069000
P069000 Main relay output voltage is too high
Please refer to “Engine

malfunction indicator lamp
P070000 The external request MIL fault (AT vehicle) (MIL)/vehicle immediate
overhaul indicator lamp is not
working properly”.
The signal of clutch pedal switch is incorrect (for MT

P070400
model)
NL-3 01/2016
The temperature of A/C compressor internal chip is too

P063491
high
P064513 A/C compressor replay control circuit fault Refer to DTC P063491 P064513
P064611 P064712
P064611 A/C compressor replay control circuit fault ES
P064712 A/C compressor replay control circuit voltage is too high
P154500 The position of electronic throttle is incorrect
P155800 Return spring check minimum fault
P155900 Self-learning fault for electronic throttle
The repeated self-learning fault for mechanical bottom

P155929
dead center of electronic throttle Refer to DTC P154500 P154521
P154522 P155800 P155900
P157900 Electronic throttle self-learning condition not meet
P155929 P157900 P156400
System voltage not meet the conditions for self-learning of P156500 P156800 P156821
P156400 P156822 P157900
electronic throttle
The initial self-learning fault for bottom dead center of

P156500
electronic throttle
P156821 Return resistance of the electronic throttle is too great
Power drive level fault of electronic throttle (overheat or Refer to DTC P022317 P210612
P210619 P210613 P210619 P210692
overcurrent)
Power drive level fault of electronic throttle (SPI bus or

P210692
signal)

P212216
voltage is too low
P212317
voltage is too low

P212716
voltage is too low
P212817
voltage is too low
Electronic accelerator pedal position sensor signal

unreasonable
Air-fuel ratio closed-loop control self-learning value

P217700
exceeds the upper limit (middle load area)（Bank1）
P217800
exceeds the lower limit (middle load area)（Bank1）
NL-3 01/2016

P218700
exceeds the upper limit (low load area) (Bank1)
P218800
exceeds the lower limit (low load area) (Bank1)
ES
P168300 The CAN receives any collision signal
The certification reply of PEPS is incorrect, and the Refer to DTC P161000 P161100
P161200
anti-theft certification fails P161200 P161300 P161400
U007300 Bus signal communication lost or signal abnormal
The communication with TCU is lost or the signal is

U010187
abnormal (AT vehicle)
The communication with ABS_ESP is lost or the signal is

U012287
abnormal
The communication with BCM is lost or the signal is

U014087
abnormal
The communication with ACU is lost or the signal is

U015187
abnormal
The communication with PEPS is lost or the signal is

U010387
abnormal
Refer to DTC U007300 U010187
The communication with EPS is lost or the signal is U012287 U014087 U015187
U013187 U010387 U014187 U010182
abnormal
U010183 U012282 U012283
The communication with HVAC is lost or the signal is U015182 U015183 U010182
U014187
abnormal U010183
U010182 The counter of message 0x118 is wrong
U010183 The check digit of message 0x118 is wrong
NL-3 01/2016
DTC P000A64 P000A77 P001013 P208811 P208912


ES
The camshaft position actuator is connected to intake/exhaust camshaft and acted hydraulically. Its hydraulic pressure is
provided by the engine oil pump that changes angle of the camshaft relative to the engine speed sensor. The intake variable
valve timing valve is supplied with power by the main replay. EMS controls grounding via pulse width modulation signal. It thus
controls the engine oil flow to the camshaft position actuator. The engine oil pressure makes the safety slide valve inside the
camshaft position actuator fixed to the front of the camshaft moves. When the safety slide valve acts, engine oil is fed into
camshaft position actuator to force the camshaft to rotate and thus to provide the valve timing most suitable for the engine
state. In this way, torque in the entire speed scope is improved.
DTC No. DTC detection strategy DTC setting condition Fault component
(control strategy)
- Speed<6480rpm
- Deviation between the
actual value and the target
value≥8KW - Valve timing
- Testing time: 2 s - Intake variable valve
timing valve
- Time scope: 3 s
- Slow response fault -
P000A64 intake VVT responds - Fault counter≥ 6
- Solenoid valve filter
slowly core
- Measured camshaft angle
change> 2KW - VVT actuator
assembly
- Coolant temperature:
[-10,120 ℃ ] - EMS
- Oil temperature:
[-10,120 ℃ ]
NL-3 01/2016

DTC No. DTC detection strategy Fault component
(control strategy)
ES - Speed<6480rpm
value≥8KW
- Testing time: 2 s
- Stuck fault - intake VVT - Time scope: 3 s
only adjusts a very small
P000A77 angle. - Fault counter≥ 6
A very small angle - Measured camshaft angle
change> 2KW
[-10,120 ℃ ]
- Oil temperature:
[-10,120 ℃ ]
- Valve timing
- Intake variable valve
timing valve
- Output voltage >2.5 V
- Solenoid valve filter
- Output voltage < 5.8 V core
- Work cycle controls the - VVT actuator
P001013 - The circuit is open power level - Intake
assembly
camshaft <= 90 %
- EMS
- Engine speed >= 0 rpm
- Exceed 0.5 s
- Output voltage >2.5 V

- Work cycle controls the
power level - Intake
P208811 - Circuit short to ground camshaft <= 6.25 %
- Exceed 0.5 s
- Output current > 6 A

P208912 - Circuit short to power - Engine speed >= 0 rpm
supply
- Exceed 0.5 s
NL-3 01/2016
3. Circuit diagram:
Variable Variable valve

Main
valve timing timing valve
relay
valve (intake )
ES
ER05
(exhaust
Notice: prior to executing this diagnosis procedure, observe the data table of the fault diagnostic scanner and analyze data
Check whether the control system has DTCs except P000A64, P000A77, P001013, P208811,
Step 1
P208912.
(a) Connect the fault diagnostic scanner to the

diagnosis interface.
mode to ON state.
scanner.
(d) Select the following menu: engine/reading fault
code.
(e) Read DTC.
DTC other than P000A64,

P000A77, P001013, P208811 No
and P208912
P000A64, P000A77 P001013,

Yes
P208811 P208912

No
fault codes
NL-3 01/2016
Yes
(a) Whether the engine viscosity and cleanness are

ES normal.
operation scope.
Replace the engine oil and the oil filter

No
element, if necessary, clean the
engine lubricating system
Yes
Step 3 Check the resistance of the intake variable valve timing valve
(a) Disconnect the harness connector EN15 of intake

variable valve timing valve.
Variable valve timing valve (b) Measure resistance between the two terminals of
intake variable valve timing valve.
Standard resistance value: 9.4~10.6Ω in
temperature of 20 ℃ （68 ℉）
(c) Confirm whether the resistance meets the standard
value.
No Replace the intake variable valve

timing valve
Yes
Step 4 Check action situations of the intake variable valve timing valve.
Notice
During testing, to directly connect two wires is strictly
Variable valve timing valve prohibited, or else, it may possibly cause explosion, fire
accident and some other dangers.
(a) Connect positive pole of battery to terminal 1 of the
intake variable valve timing valve and its negative
pole to terminal 2 of the intake variable valve timing
valve.
(b) Check the filter element action situations.
(c) Is valve core acting?
No Replace the intake variable valve

timing valve
Yes
Step 5 Check filter net of the intake variable valve timing valve.
NL-3 01/2016
(a) Remove the intake variable valve timing valve.

(b) Check whether the strainer is clogged.
(c) Check whether the strainer is damaged.
(d) Re-install filter net of the intake variable valve timing
valve.
ES
No Clean filter net of the intake variable
valve timing valve and replace if
necessary.
Yes
Step 6 Check fuse of the intake variable valve timing valve.

mode to OFF state.
(c) Remove the EF10 fuse, and check whether the fuse
has blown out.
Replace with a fuse with standard

Yes
capacity.
Standard capacity: 10A
No
Step 7 Measure the working power supply of intake variable valve timing valve.

mode to OFF state.
(b) Disconnect the harness connector EN15 of intake
EN15 variable valve timing valve (intake) harness connector
mode to ON state.
(d) Measure the voltage between the terminal 1 of
intake variable valve timing valve harness connector
EN15 and the reliable grounding point.
(e) Does the measured value meet the standard value?
No
Go to step 9
Yes
NL-3 01/2016

mode to OFF state.
(b) Disconnect the harness connector EN15 of intake
EN15 variable valve timing valve (intake) harness connector variable valve timing valve.
(c) Disconnect engine EMS harness connector EN35.
ES (d) Measure the resistance between the terminal 2 of
EN15 and the terminal 50 of EN35. As for standard
(e) Measure the resistance between terminal 2 of
exhaust VVT valve harness connector EN15 and
grounding with a multimeter, the standard valve is
shown in table below.
(f) Turn ignition switch to “ON” position (note:
connectors EN35, EN15 must be disconnected at
this moment), and measure voltage between
terminal 2 of harness connector EN15 of exhaust
variable valve timing valve to grounding with
EN35 engine management system (plug-in part A) harness
multimeter. The standard value is shown in table
connector 1 below.
Resistance between
Less than 1 Ω
EN15（2） and EN35（50）
Resistance between
10kΩ or higher
EN15(2) and grounding
Voltage between EN15(2)

0V
and grounding
(g) Measure whether the value meets the standard

value.
No Repair or replace the harness
Next step

No Repair the faulty position
Yes
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear fault code.
(d) Start and run the engine at idle speed to warm up ES
the engine for at least 5 min.
(f) Read the DTC of the control system again and
Yes Intermittent fault. Please refer to

check on intermittent fault.
Next step
DTC P000B64 P000B77 P001313 P209011 P209112

P000B64 Operating fault of exhaust VVT (delay)
P000B77 Operating fault of exhaust VVT (jamming)
P001313 VVT exhaust control valve circuit fault（Bank 1)
P209011 Exhaust VVT valve circuit is short to ground
P209112 Exhaust VVT valve circuit is short to power supply
The camshaft position actuator is connected to intake/exhaust camshaft and acted hydraulically. Its hydraulic pressure is
provided by the engine oil pump that changes angle of the camshaft relative to the engine speed sensor. The intake variable
valve timing valve is supplied with power by the main replay. EMS controls grounding via pulse width modulation signal. It thus
controls the engine oil flow to the camshaft position actuator. The engine oil pressure makes the safety slide valve inside the
camshaft position actuator fixed to the front of the camshaft moves. When the safety slide valve acts, engine oil is fed into
camshaft position actuator to force the camshaft to rotate and thus to provide the valve timing most suitable for the engine
state. In this way, torque in the entire speed scope is improved.
NL-3 01/2016

(control strategy)
- Speed<6480rpm
ES actual value and the target
value≥8KW
- Testing time: 2 s
- Time scope: 3 s
- Exhaust VVT operation
P000B64
fault (slow) - Fault counter≥ 6
- Measured camshaft angle
change＜2KW
[-10,120 ℃]
- Oil temperature:
[-10,120 ℃]
- Speed<6480rpm
value≥8KW
- Testing time: 2 s
- Valve timing
- Time scope: 3 s
- Exhaust VVT operation - Variable valve timing
P000B77
fault (seized) - Fault counter≥ 6 valve
- Measured camshaft angle - Solenoid valve filter
change＜ 2KW core
- Coolant temperature: - Camshaft position
[-10,120 ℃] actuator assembly
- Oil temperature: - EMS
[-10,120 ℃]
- Output voltage >2.5V

- Output voltage < 5.8V
- VVT exhaust control valve
P001313
circuit fault（Bank 1) - Work cycle controls the
power level - Intake
camshaft <= 90 %
- Output voltage >2.5V

- Output voltage < 5.8V
- Work cycle controls the
- Exhaust VVT circuit short
P209011 power level - Intake
to the ground
camshaft >= 6.25%
- Exceeding 0.5s
- Output current > 6 A

- Exhaust VVT circuit short
P209112 - Engine speed >= 0 rpm
to the power supply
- Exceeding 0.5s
NL-3 01/2016
3. Circuit diagram:
Main Variable Variable valve

relay valve timing timing valve ES
ER05 valve (intake )
(exhaust
Check whether the control system has DTCs except DTC P000B64 P000B77 P001313 P209011
Step 1
P209112.

mode to ON state.
scanner.
code.
(e) Read DTC.
DTC other than

P000B64, P000B77
No
P001313, P209011,
P209112
P000B64, P000B77
P001313, P209011, Yes
P209112

fault codes
NL-3 01/2016
Yes
(a) Whether the engine viscosity and cleanness are

normal.
ES
operation scope.
No Replace the engine oil and the oil filter

element, if necessary, clean the
engine lubricating system
Yes
Step 3 Check the resistance of the intake variable valve timing valve
(a) Disconnect the harness connector EN06 of exhaust

Variable valve timing valve (b) Measure the resistance between two terminals of
exhaust variable valve timing valve.
Standard resistance value: 9.4~10.6Ω in temperature of
20 ℃ （68 ℉）
value.
No Replace exhaust variable valve timing

valve
Yes
Step 4 Check action situations of the intake variable valve timing valve.
Notice
During testing, to directly connect two wires is strictly
Variable valve timing valve prohibited, or else, it may possibly cause explosion, fire
accident and some other dangers.
(a) Connect positive pole of battery to terminal 1 of the
intake variable valve timing valve and its negative pole to
terminal 2 of the intake variable valve timing valve.
(b) Check the filter element action situations.
(c) Is valve core acting?
No
Replace exhaust variable valve timing
valve
Yes
Step 5 Check filter net of the exhaust variable valve timing valve.
NL-3 01/2016
(a) Remove exhaust variable valve timing valve.

(b) Check whether the strainer is clogged.
(c) Check whether the strainer is damaged.
(d) Re-install filter net of the intake variable valve timing
valve.
ES
No Clean filter net of the exhaust variable
valve timing valve and replace it if
necessary.
Yes
Step 6 Check exhaust variable valve timing valve fuse.

mode to OFF state.
(c) Remove the EF10 fuse, and check whether the fuse
has blown out.
Replace with a fuse with standard

Yes
capacity.
Standard capacity: 10A
No
Step 7 Measure the working power supply of exhaust variable valve timing valve.

mode to OFF state.
EN06 variable valve timing valve (exhaust) harness connector (b) Disconnect the harness connector EN06 of exhaust
mode to ON state.
(d) Measure the voltage between the terminal 1 of
harness connector EN15 for the exhaust variable valve
timing valve and the reliable grounding point.
No Go to step 9
Yes
Step 8 Check the control circuit of exhaust variable valve timing valve.
NL-3 01/2016

mode to OFF state.
EN06 variable valve timing valve (exhaust) harness connector

(b) Disconnect the harness connector EN06 of exhaust
ES (d) Measure the resistance between the terminal 2 of
EN06 and the terminal 5 of EN35. As for standard value,
(e) Measure the resistance between terminal 2 of exhaust
VVT valve harness connector EN06 and grounding with a
multimeter, the standard valve is shown in table below.
EN35, EN06 must be disconnected at this moment), and
measure voltage between terminal 2 of harness
connector EN06 of exhaust variable valve timing valve to
grounding with multimeter. The standard value is shown
in table below.
Tseter connection Standard value

Resistance between
Less than 1 Ω
EN06(2) and EN35(5)
Resistance between
10kΩ or higher

0V
and grounding
Next step

Yes
Next step
NL-3 01/2016

interface.
mode to ON state.
(d) Start and run the engine at idle speed to warm up ES

Next step
DTC P001676 P001678 P034100 P034200 P034300 P001200

P001676 The relative position between intake-side camshaft and crankshaft is unreasonable (Bank 1, EOL
diagnosis)
P001678 Intake side camshaft and crankshaft relative mounting position is unreasonable（Bank 1)
P034100 Intake side phase sensor signal unreasonable (Bank 1)
P034200 Intake side phase sensor signal circuit voltage too low (Bank 1)
P034300 Intake side phase sensor signal circuit voltage too high (Bank 1)
Phase sensor is installed at the end of the camshaft, which is also known as the camshaft position sensor. It is used to detect
the position and speed of the camshaft, and cooperates with the speed sensor to determine the cylinder compression TDC
and the exhaust TDC. Phase sensor is a Hall sensor, and the camshaft drives the signal wheel mounted at the end to rotate.
Hall sensor adopts the Hall effect. The corresponding circuit output is low when the signal wheel is at the high teeth, and the
corresponding circuit output is high when the signal wheel is at missing teeth. Accordingly one revolution of the crankshaft has
signal, and the other does not have signal, which distinguishes the two different TDCs in the four strokes.

(control strategy)
- Timing chain tensioner

- Timing chain
- All aging torsional
deviation at the falling - Crankshaft sprocket
P001678 - Angle deviation diagnosis
edge of the camshaft - Exhaust sprocket
signal > 15KW or <-15KW
- VVT actuator
- EMS
NL-3 01/2016

(control strategy)
- Camshaft synchronization
ES - Camshaft synchronization state
P034100
status matching
- Signal fault counter > 20
- The signal voltage is

- Signal circuit short to always low
P034200
ground
- No signal counter > 8 - Timing chain tensioner
- Timing chain
- Crankshaft sprocket
- Exhaust sprocket
- VVT actuator
- The signal voltage is - EMS
- Signal circuit short to always high
P034300
power supply
- No signal counter > 8
- Whether the intake VVT - Difference between actual

locates at the locking angle of intake VVT and
P001200
position at the starting the default position (at the
stage. moment of start) >15KW
NL-3 01/2016
3. Circuit diagram:
Engine speed sensor
Main
relay ES
ER05
Exhaust phase sensor Intake phase sensor
Check whether the control system has DTC P001676 P001678 P034100 P034200 P034300
Step 1
P001200.

interface.
mode to ON state.
scanner.
(e) Read DTC.

P001678, P034100,
No
P034200, P034300,
P001200
P001676, P001678,
P034100, P034200, Yes
P034300, P001200
NL-3 01/2016

fault codes
Step 2 Check control circuit of the intake phase sensor
ES (a) Operate the starter switch to turn the power supply

mode to OFF state.
(b) Disconnect harness connector EN24 of the intake
EN24 intake phase sensor harness connector phase sensor.
connectors EN35 and EN24 must be disconnected at
this moment), and measure voltage between terminal
2 of harness connector EN24 of exhaust variable
valve timing valve to grounding with multimeter. The
standard value is shown in table below.
Resistance between
Less than 1 Ω
EN24（2） and EN35（53）
Resistance between
10kΩ or higher

0V
and grounding

value.

Yes
(a) Check whether the camshaft, crankshaft and timing

chain are correct.
(b) Check whether the positive chain tension is normal.
No Go to step 6
Yes

NL-3 01/2016
Yes
Next step
ES
Notices
It is not recommended to use lubrication system detergent. This type of detergent includes the powerful solvent, bearing side
effect for the seal and other engine components.
(a) Check EMS. View vehicle maintenance record and

check whether the recent maintenance involves
timing chain, camshaft, crankshaft and whether the
replacement interval of the engine oil is too long.
(b) If the engine oil is contaminated or contains
impurities, you should identify the cause, and
remove the timing chain, camshaft position
actuators and sprocket.
(c) If the engine oil pressure is too low, you should find
out the cause and repair if necessary.
Next step

interface.
mode to ON state.
(d) Start and run the engine at idle speed to warm up
Next step
NL-3 01/2016
DTC P001776 P001778 P001500 P036600 P036700 P036800

The relative position between exhaust-side camshaft and crankshaft is unreasonable (Bank 1,
ES P001776
EOL diagnosis )
P001778 Exhaust camshaft and crankshaft relative mounting position is unreasonable（Bank 1)
P001500 The locking position of exhaust camshaft is unreasonable fault
P036600 Exhaust side phase sensor signal unreasonable（Bank 1）
P036700 Exhaust phase sensor signal circuit voltage too low（Bank 1）
P036800 Exhaust phase sensor signal circuit voltage too high（Bank 1）
Phase sensor is installed at the end of the camshaft, which is also known as the camshaft position sensor. It is used to detect
the position and speed of the camshaft, and cooperates with the speed sensor to determine the cylinder compression TDC
and the exhaust TDC. Phase sensor is a Hall sensor, and the camshaft drives the signal wheel mounted at the end to rotate.
Hall sensor adopts the Hall effect. The corresponding circuit output is low when the signal wheel is at the high teeth, and the
corresponding circuit output is high when the signal wheel is at missing teeth. Accordingly one revolution of the crankshaft has
signal, and the other does not have signal, which distinguishes the two different TDCs in the four strokes.

(control strategy)
- All aging torsional

deviation at the falling
P001778 - Angle deviation diagnosis
edge of the camshaft
signal > 15KW or <-15KW
- The difference between

- Whether the exhaust VVT
actual angle of exhaust
locates at the locking
P001500 VVT and the default
position at the starting - Timing chain tensioner
position (at the moment of
stage.
start) >15KW - Timing chain
- Crankshaft sprocket
- Camshaft synchronization
- Camshaft synchronization state - Exhaust sprocket
P036600
status matching
- Signal fault counter > 20 - VVT actuator
- EMS
- Signal circuit short to always low
P036700
ground

- Signal circuit short to always high
P036800
power supply
NL-3 01/2016
3. Circuit diagram:
Engine speed sensor
Main
relay ES
ER05
Notice:
Prior to executing this diagnosis procedure, observe the data table of the fault diagnostic scanner and analyze data accuracy
for quick troubleshooting!
Step 1
P036800.

mode to ON state.
scanner.
code.
(e) Read DTC.

P001778 , P001500,
No
P036600, P036700,
P036800
P001776, P001778,
P001500, P036600, Yes
P036700, P036800
NL-3 01/2016
No
fault codes
Step 2 Check control circuit of exhaust phase sensor t.

ES
mode to OFF state.
(b) Disconnect harness connector EN14 of the exhaust
EN14 exhaust phase sensor harness connector phase sensor.
connectors EN35 and EN24 must be disconnected at
this moment), and measure voltage between terminal
2 of harness connector EN14 of exhaust variable
valve timing valve to grounding with multimeter. The
standard value is shown in table below.
Resistance between
Less than 1 Ω
EN14（2） and EN35（54）
Resistance between
10kΩ or higher

0V
and grounding

value.
Yes
(a) Check whether the camshaft, crankshaft and timing

chain are correct.
(b) Check whether the positive chain tension is normal.
No Go to step 6
Yes
NL-3 01/2016

ES
Yes
Next step
Notices
It is not recommended to use lubrication system detergent. This type of detergent includes the powerful solvent, bearing side
effect for the seal and other engine components
(a) Check EMS. View vehicle maintenance record and

check whether the recent maintenance involves
timing chain, camshaft, crankshaft and whether the
replacement interval of the engine oil is too long.
(b) If the engine oil is contaminated or contains
impurities, you should identify the cause, and remove
the timing chain, camshaft position actuators and
sprocket.
(c) If the engine oil pressure is too low, you should find
out the cause and repair if necessary.
Next step

interface.
mode to ON state.
Next step
NL-3 01/2016
DTC P003013 P003111 P003212 P00531E P01351E


ES
P003212 Upstream oxygen sensor heating control circuit short to power supply
P00531E Upstream oxygen sensor heating internal resistance unreasonable (Bank1)
P01351E Upstream oxygen sensor heating circuit signal fault (ECU internal adjustable resistance is out of
range)
The heating type oxygen sensor (HO2S) is used for fuel control and monitoring of rear catalyst. Every heating type oxygen
sensor compares oxygen content in ambient air with that in exhaust flow. The heating type oxygen sensor must arrive at the
working temperature in order to provide accurate voltage signals. Heating element inside the heating type oxygen sensor
makes the time necessary for the sensor to arrive at the working temperature the minimum. The ignition voltage circuit
provides voltage to the heater through a fuse. While the engine is operating, low level control circuit of the heating type oxygen
sensor heater provides grounding to the heater through the drive at low level side inside the engine management system
(EMS). The engine management system (EMS) uses pulse width modulation (PWM) to control working of the heating type
oxygen sensor heater and makes the heating type oxygen sensor always within the specified working temperature scope.
The working voltage of the heating coil of the front oxygen sensor is provided by EMS controlled main relay, i.e. when the
starter switch turns to “ON”, the sensor terminal 4 of the harness connector EN04 has battery voltage. EMS controls the heater
working duration via terminal 73 of harness connector CA01.

(control strategy)
- Voltage > 2.5 V

- Voltage < 5.8 V
P003111 - Circuit short to ground - Voltage < 2.5 V

P003212 - Current > 10 A
supply
- Harness
- Rationality check –
- Front oxygen sensor
compare the current - Output of heating target
P00531E temperature during full duty ratio of front oxygen - Electronic throttle
power heating and the set sensor >89.9994 % body
value
- EMS
- Dynamic monitoring:
assess output voltage of
rear oxygen sensor- the - Dynamic coefficient of
P01351E time constant measured HO2S front oxygen
exceeds the set threshold sensor < 0.2
value (oxygen clearing
status).
NL-3 01/2016
3. Circuit diagram:
ES
Rear oxygen sensor Front oxygen sensor
Main
relay
ER05
Notice
Check whether there are following conditions with effect

on sensor working
(b) Heated oxygen sensor connector incoming with
water.
(c) During the engine is working under over
temperature, check whether the exhaust pipe is too
red.
Next step
Step 2 Check front oxygen sensor heater resistance.
NL-3 01/2016

mode to OFF state.
(b) Disconnect front oxygen sensor harness connector
EN05 upstream oxygen sensor harness connector EN05.
(c) Measure resistance of the heater between terminal
1 and 2 of the front oxygen sensor.
ES
Standard resistance value: 3.2 ± 0.8Ω (room
temperature 25℃)
(d) Connect the front oxygen sensor harness connector
EN05.
(e) Confirm whether the resistance meets the standard
value.
No Replace the front oxygen sensor
Step 3 Check front oxygen sensor heater resistance.

mode to OFF state.
(c) Remove oxygen sensor fuse EF11 and check
Yes Replace the fuse
Rated capacity: 10A
Yes
Step 4 Check the voltage between the terminal 4 of EN05 and the reliable grounding.

mode to OFF state.
EN05 upstream oxygen sensor harness connector (b) Disconnect front oxygen sensor harness connector
EN05.
mode to ON state.
(d) Measure the voltage between terminal 4 of front
oxygen sensor harness connector EN05 and reliable
grounding.
Standard value of the voltage: 11~14V
(e) Connect the front oxygen sensor harness connector
EN05.
value.
No Go to step 6
Yes
NL-3 01/2016
Step 5 Check front oxygen sensor heater control terminal for continuity.

mode to OFF state.
EN05 upstream oxygen sensor harness connector (b) Disconnect front oxygen sensor harness connector
EN05.
(c) Disconnect the EMS harness connector CA01. ES
(d) Measure the conductivity between terminal 3 of the
front oxygen sensor harness connector EN05 and
terminal 73 of the EMS harness connector CA01.
Standard resistance: Less than 1Ω
EN05.
(f) Connect EMS harness connector CA01.
value.
Yes Go to step 7
CA01 engine management system (plug-in part K) harness
connector 2
No
Step 6 Check heating power circuit of the oxygen sensor

mode to OFF state.
EN05 upstream oxygen sensor harness (b) Disconnect the negative battery cable.
connector
(c) Disconnect the front oxygen sensor harness
connector EN05.
front oxygen sensor harness connector EN05 and
fuse of EF11. As for standard value, please refer to
the table below.
(e) Measure resistance between terminal 4 of front
grounding; the standard value is shown in the
following table.
Resistance between
Less than 1 Ω
EN05(4) and EF11
Resistance between
10kΩ or higher
NL-3 01/2016
(f) Does the measured value conform to standard

Engine compartment fuse relay box value?
No
Repair or replace harness
ES
Yes
Step 7 Check EMS working circuit.

Next step
Next step

mode to ON state.
(c) Clear DTC.
the engine for at least 5min.
(f) Read control system DTC again. Confirm system
has no fault code output.
No Intermittent fault. Please refer to

Yes
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DTC P003313 P003411 P003512 P226100

P003313 Supercharge relief control valve drive circuit is open

ES
P003411 Supercharge relief control valve drive circuit is short to ground
P003512 Supercharge relief control valve drive circuit is short to power supply
P226100 Supercharge relief control valve failure
When the engine is running at idle speed or shut down, and the throttle is about to be closed fully or closed fully, constantly
increasing pressure will be produced in intake pipe of the supercharger (the air hardly flows at the moment), and the
turbocharger will bear substantial brake resistance. To quickly release the pressure, the system is added with an intake bleed
valve. The intake bleed valve is a kind of electronic control element. After EMS sends control signal to open the intake bleed
valve, air at air outlet end of the compressor flows to the intake end through pipeline inside the valve.

(control strategy)

P003411 - Short to the ground
hardware
- Intake bleed valve
P003512 - Short to the power supply
- Harness
- Turbulence of airflow at - EMS
- Relief valve is stuck and the outlet of supercharger
P226100
cannot move impeller results in the
pulse counting > 10
NL-3 01/2016
3. Circuit diagram:
To positive pole
B+ of the
battery
ES
Main Intake relief

Relay Exhaust control valve
valve
NL-3 01/2016
Notice
Step 1 Check whether the control system has other DTC P003313 P003411 P003512 P226100.
ES
mode to ON state.
scanner.
code.
(e) Read DTC.
DTC other than

P003313, P003411, No
P003512, P226100
P003313, P003411,
Yes
P003512, P226100

fault codes
Step 2 Measure the intake bleed valve fuse.

Engine compartment fuse relay box mode to OFF state.
(c) Remove EF10 fuse and check whether the fuse has
blown out.
Yes Replace the fuse with the rated

capacity of 10A
Step 3 Measure the intake relief valve working power supply.
NL-3 01/2016

mode to OFF state.
EN02 Intake relief valve harness connector (b) Disconnect the intake relief valve harness connector
EN02.
mode to ON state.
ES
(d) Measure terminal 1 of intake bleed valve harness
connector EN02.
(e) Connect harness connector of the intake bleed
valve.
(f) Confirm whether the voltage meets the standard
value.
No Go to step 5
Yes
Step 4 Measure control circuit of the intake VVT solenoid valve.

mode to OFF state.
EN02 Intake relief valve harness connector (b) Disconnect the intake relief valve harness connector
EN02.
intake bleed valve harness connector EN02 and the
terminal 8 of EMS harness connector CA01. Refer
to the table below for standard values.
(e) Use multimeter to measure the resistance between
intake relief valve harness connector EN02 terminal
2 and grounding. The Standard Value is shown in
table below.
(f) Operate the ignition switch to set the power mode in
the state ON, (Note: connectors CA01 and EN02
must be disconnected at the moment) and measure
the voltage between the terminal 2 of intake bleed
CA01 engine management system (plug-in part K) harness valve harness connector EN02 and the grounding
connector 2
point. As for standard value, please refer to the table
below.
(g) Confirm whether the measured value meets the
standard value.

Resistance between EN02(2)
Less than 1 Ω
and CA01(8)
10kΩ or higher
0V
No Repair or replace harness connector.
Yes
Step 5 Check operating power circuit of the intake bleed valve.
NL-3 01/2016

mode to OFF state.
EN02 Intake relief valve harness connector
(c) Disconnect the intake relief valve harness connector
EN02.
(d) Measure the resistance between the terminal 1 of ES
intake bleed valve harness connector EN02 and the
fuse EF10. Refer to the table below for standard
values.
intake relief valve harness connector EN02 terminal
1 and grounding. The Standard Value is shown in
table below.
(f) Confirm whether the measured value meets the
standard value.


Less than 1 Ω
and EF10

10kΩ or higher
Yes

No
Repair the faulty position
Yes
Step 7 Replace the EMS. Please refer to the section about engine ECU.
Next step
NL-3 01/2016

mode to ON state.
(c) Clear DTC.
ES (d) Start and run the engine at idle speed to warm up

Yes
NL-3 01/2016
DTC P003613 P003711 P003812 P00541E


ES
P003812 Downstream oxygen sensor heating control circuit short to power supply
P00541E Downstream oxygen sensor heating internal resistance unreasonable (bank1)
ceramic tube into voltage signal. When the sensing ceramic tube's temperature reaches 350℃, it will own solid electrolyte's
characteristics. Due to the special nature of the tube material, the oxygen ions can pass through the ceramic tube freely. The
concentration difference can be changed into potential difference and then forms electrical signal output just due to this
characteristic. If the gas mixture is a little richer. the concentration difference of the oxygen ions inside and outside the ceramic
tube is higher, the potential difference is higher, a lot of oxygen ions move from the inside to the outside, the output voltage is
higher (nearly 800mV~1000mV); if the gas mixture is a little thinner, the oxygen ions inside and outside the ceramic tube is
lower, the potential difference is lower, a small quantity of oxygen ions move from the inside to the outside, the output voltage
is lower (nearly 100mV). The signal voltage mutates near the theoretical equivalent air-fuel ratio （λ=1）.
The working voltage of the heating coil of the rear oxygen sensor is provided by EMS controlled main relay, i.e. when the
starter switch turns to “ON”, the sensor terminal 1 of the harness connector EN04 has battery voltage. EMS controls the heater
working duration via terminal 29 of harness connector CA01.

(control strategy)
- Voltage > 2.5 V

- Voltage < 5.8 V
P003711 - Circuit short to ground - Voltage < 2.5 V - Circuit

- Harness
P003812 - Current > 10 A
supply - Rear oxygen sensor
- EMS
- Internal resistance of
- Two-point type oxygen
two-point oxygen sensor
P00541E sensor internal resistance
bank 1> 550 to 131070
exceeds the limit bank 1
Ohm
NL-3 01/2016
3. Circuit diagram:
ES Rear oxygen sensor

Front oxygen
sensor
Main relay
ER05
Notice

on sensor working
(b) Heated oxygen sensor connector incoming with
water.
(c) During the engine is working under over
temperature, check whether the exhaust pipe is too
red.
Next step
Step 2 Check the rear oxygen sensor heater resistance.
NL-3 01/2016

mode to OFF state.
(b) Disconnect the rear oxygen sensor harness connector
EN04.
EN04 downstream oxygen sensor harness
connector (c) Measure resistance of the heater between terminal 1
and 2 of the rear oxygen sensor.
ES
Standard resistance: 7 ~ 125 Ω (room temperature)
(d) Connect the rear oxygen sensor harness connector
EN04.
value.
No Replace the rear oxygen sensor
Step 3 Check fuse of the oxygen sensor.

mode to OFF state.
(c) Remove oxygen sensor fuse EF11 and check whether
the fuse has blown out.
Yes Replace the fuse
Rated capacity: 10A
Yes
Step 4 Check the voltage between the terminal 1 of EN04 and the reliable grounding.

mode to OFF state.
EN04.
connector (c) Operate the starter switch to turn the power supply
mode to ON state.
(d). Measure the voltage between terminal 1 of rear
grounding.
(e) Connect the rear oxygen sensor harness connector
EN04.
value.
No Go to step 6
Yes
NL-3 01/2016
Step 5 Check rear oxygen sensor heater control terminal for continuity.

mode to OFF state.
(b) Disconnect the rear oxygen sensor harness
connector EN04.
ES EN04 downstream oxygen sensor harness
connector
(d) Measure the conductivity between terminal 2 of the
rear oxygen sensor harness connector EN04 and
terminal 29 of EMS harness connector CA01.
(e) Connect the rear oxygen sensor harness connector
EN04.
value.
Yes Go to step 7
connector 2
No
Step 6 Check heating power circuit of the oxygen sensor

mode to OFF state.
EN04 downstream oxygen sensor harness (c) Disconnect the rear oxygen sensor harness
connector connector EN04.
rear oxygen sensor harness connector EN04 and
fuse EF11. As for standard value, please refer to the
table below.
(e) Measure resistance between terminal 1 of front
grounding; the standard value is shown in the
following table.
Resistance between Less than 1 Ω

EN04(1) and EF11
Resistance between 10kΩ or higher

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(f) Does the measured value conform to standard value?

No
ES
Yes

Next step
Next step

mode to ON state.
(c) Clear DTC.

Yes
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DTC P222816 P222917 P22302F P22308F

P222816 Ambient pressure sensor voltage too high

ES
P222917 Ambient pressure sensor voltage too low
P22302F The signal of ambient pressure sensor signal is incorrect
P22308F Ambient pressure sensor signal is unreasonable
The ambient pressure sensor and the engine management system (EMS) are integrated. Signal of the ambient pressure
sensor varies with altitude and atmospheric conditions. It provides the engine management system with an indication of
current atmospheric pressure. The engine management system uses the information for many internal calculations. The
engine management system monitors whether the atmospheric pressure has abnormal voltage/pressure signal. The engine
management system compares continuous sampling to monitor stability of signal of the atmospheric pressure sensor.

(control strategy)
- Circuit diagnosis: short

P222816 - Voltage < 0.2002 V
circuit to ground
- Circuit diagnosis: short to

P222917 - Voltage > 4.9 V
power supply
- Circuit
- Deviation of ambient
- Model and actual pressure = 2 kPa - EMS
P22302F
rationality comparison
- Time delay = 20 sec
- Deviation of ambient
- Model and actual
P22308F pressure = 2 kPa- time
rationality comparison
delay = 20 sec
NL-3 01/2016
3. Circuit diagram:
Main relay
ER05 ES

interface.
mode to ON state.
scanner.
(e) Read DTC.

P222917, P22302F, No
P22308F
P222816, P222917,
Yes
P22302F, P22308F

fault codes
Yes
Step 2 Check EMS appearance.
NL-3 01/2016
(a) Check the housing and the vent hole of the engine
management system for blockage, contamination,
contaminant, snow or ice of any type.
(b) If any, clear the part carefully.
Next step
ES
Step 3 Check the EMS fuse.

mode to OFF state.
(c) Check whether fuses EF09 and IF17 have blown out.
Rated capacity: EF09 30A IF 10A
No Replace the fuse
No
Step 4 Check operating voltage of EMS.
NL-3 01/2016

mode to OFF state.
connector 2 (c) Disconnect the EMS harness connector CA01.
(d) l Connect the negative battery cable.
(e) Operate the starter switch to turn the power supply ES
mode to ON state.
(f) Measure the voltage between terminal 3/5/6 of CA01
and the reliable grounding point.
Voltage standard: 11~14V
the reliable grounding point.
Voltage standard: 11~14V
(h) Does the measured value meet the standard?
Yes

interface.
mode to ON state.
(c) Clear DTC.
(e) With the existence of operation fault diagnosis code,
operate the vehicle and confirm whether the fault
diagnosis code of the is set again.

Yes
(a) Replace EMS, please refer to “Engine ECU”.

(b) Carry out the learning of engine speed sensor.
(b) Ensure that the system is normal.
Next step
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DTC P008700 P008784 P008800 P008885 P304B00 P304C00

P008700 Fuel rail pressure is too low

ES
P008784 Fuel rail pressure is too low (exceeding the lower limit of the allowable reasonable range)
P008800 Fuel rail pressure is too high
P008885 Fuel rail pressure is too high (exceeding the lower limit of the allowable reasonable range)
P019216 Fuel rail pressure sensor signal circuit voltage too low
P019317 Fuel rail pressure sensor signal circuit voltage too high
P304B00 High pressure fuel rail pressure is too high
P304C00 High pressure fuel rail pressure is too low
Through the pressure sensor on the fuel rail, EMS controls flow of the high-pressure pump via the fuel control valve according
to the set control program to exert close-looped control of pressure inside the high-pressure fuel rail.
Notice
Fuel control valve is a part of the high-pressure fuel pump, which is not allowed to be replaced individually.

(control strategy)
- Check on - Rail pressure <200kPa

P008700 reasonableness: negative
deviation - Engine speed< 25 rpm
- Rationality diagnosis of - High pressure fuel rail

high-pressure oilpipe pressure deviation (target
P008784
control system: High pressure minus the actual
pressure is too low pressure)>2000kPa
- PID output of - PID output of

P008800 high-pressure control high-pressure control - Circuit
system system <-2000kPa - Fuel rail pressure
sensor
- Rationality diagnosis of - High pressure fuel rail
high-pressure oilpipe pressure deviation (target - High pressure oil
P008885 pump
control system: High pressure minus the actual
pressure is too high. pressure<-2000kPa) - EMS
- Voltage of pressure
P019216 - Short to the ground
sensor <0.2V
- Voltage of pressure
sensor >4.8V
- Check on - Rail pressure >1500kPa

P304B00 reasonableness: positive
deviation - Engine speed< 25 rpm
NL-3 01/2016
3. Circuit diagram:
Fuel control valve

Main relay
ER05 ES
Fuel rail pressure sensor
NL-3 01/2016

on operation of the fuel injector
(a) Check and confirm pressure of the fuel system at low
ES pressure side is correct.
Next step
Check whether the control system has DTC P008700 P008784 P008800 P008885 P304B00
Step 2
P304C00.

mode to ON state.
scanner.
code.
(e) Read DTC.

P008784, P008800,
No
P008885, P304B00,
P304C00
P008700, P008784,
P008800, P008885 Yes
P304B00, P304C00

fault codes
Next step
Step 3 Measure whether control circuit of the fuel control valve is short to the voltage end.

mode to OFF state.
(b) Disconnect fuel control valve harness connector
EN23 Fuel control valve harness connector
EN23.
mode to ON state.
control valve harness connector EN23 and the reliable
grounding.
(e) Measure the voltage between the terminal 2 of fuel
grounding.
Standard voltage value: Less than 1V
No Repair short to voltage end fault of the

fuel control valve control circuit.
Yes
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Step 4 Check the short to ground fault of fuel control valve control circuit.

mode to OFF state.
(b) Disconnect fuel control valve harness connector ES
EN23.
(c) Measure the resistance between the terminal 1 of fuel
grounding.
Standard resistance value: Less than 10kΩ
(d) Measure the resistance between the terminal 2 of fuel
grounding.
value.
No Repair short to ground fault of the fuel

control valve control circuit.
Yes
Step 5 Check short circuit fault of the fuel control valve circuit.

mode to OFF state.
EN23.
(c) Disconnect the EMS harness connector EN35.
(d) Measure the resistance between the terminal 1 and
the terminal 2 of the fuel control valve harness connector
EN23.
Standard resistance: more than 10KΩ
value.
No Short circuit fault of the fuel control

valve circuit.
Yes
Step 6 Check whether control circuit of the fuel control valve is broken.
NL-3 01/2016

mode to OFF state.
EN23.
ES (d) Measure the resistance between the terminal 1 of fuel
control valve harness connector EN23 and the terminal 4
of EMS harness connector EN35.
(e) Measure the resistance between the terminal 2 of fuel
value.

connector 1
Yes
Step 7 Check whether the fuel control valve is internally short to the ground.

mode to OFF state.
EN23.
grounding.
grounding.
value.
No Replace the high-pressure oil pump.
Yes
Step 8 Check resistance of the fuel control valve.
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mode to OFF state.
EN23.
(d) Measure the resistance between the terminal 1 and ES
the terminal 2 of the fuel control valve.
Standard resistance value: 0.49Ω
value.
No Replace the fuel control valve.
Yes
Step 9 Check the camshaft lobe.
(a) Remove high-pressure oil pump.

(b) Check whether the camshaft lobe is worn.
Yes Replace the camshaft.
No
Step 10 Replace the high-pressure oil pump.
Next step

Yes
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC.
ES (d) Start and run the engine at idle speed to warm up the

Yes
DTC P009716 P009817

P009716 Intake pressure sensor signal circuit voltage too low (in front of throttle)
P009817 Intake pressure sensor signal circuit voltage too high (in front of throttle)
The supercharging pressure sensor located at the intercooler outlet is integrated with the intake temperature sensor 2, through
which EMS measures supercharging pressure between turbocharger and throttle body as well as intake temperature. The
intake temperature sensor is a resistance with negative temperature coefficient NTC. A supercharging pressure sensor
consists of following circuits:
- A 5V reference voltage (pin 3)
- A low level reference voltage (pin 1)
- Intake pressure signal (pin 4)
- Intake temperature sensor 2 signal (pin 2)

(control strategy)
- Circuit diagnosis: short - Intake temperature sensor - Circuit

P009716
circuit to ground voltage< 0.097656V
- Intake temperature
and pressure sensor
- Circuit diagnosis: short to - Intake temperature sensor
P009817
voltage voltage> 4.902344V - EMS
NL-3 01/2016
3. Circuit diagram:
Main relay
ER05
ES
Notice

on sensor working
(a) Damage of any component.
(b)Air flow is blocked up.
(c) Any type of air leakage between turbocharger and
throttle body, including supercharge air cooler assembly.
Next step

interface.
mode to ON state.
scanner.
(e) Read DTC.
NL-3 01/2016

No
P009817
ES P009716, P009817 Yes
No
fault codes
Next step
Step 3 Check 5V reference voltage of the supercharging pressure sensor.

mode to OFF state.
(b) Disconnect harness connector CA26 of the
CA26 supercharging pressure/temperature sensor harness
connector
supercharge temperature sensor.
mode to ON state.
(d) Measure the voltage between terminal 3 of
supercharging oxygen sensor harness connector CA26
Standard voltage value: 5V
(e) Connect harness connector CA26 of the
supercharging pressure sensor.
No Go to step 8
Yes
Step 4 Check resistance of the sensor.
(a) Turn the digital multimeter to ohm position, and

connect its black probe with the terminal 1 and its red
probe with the terminal 2.
CA26 supercharging pressure/temperature sensor harness (b) Measure resistance between two terminals of intake
connector temperature sensor.
Standard resistance value: 20 ℃ (68 ℉ )2375~2625 Ω
value.
No Replace the supercharging pressure

sensor
Yes
Step 5 Check conductivity of the circuit between sensor and EMS.
NL-3 01/2016

mode to OFF state.
(b) Disconnect supercharging pressure sensor harness
CA26 supercharging pressure/temperature sensor harness connector CA26.
connector
supercharging pressure sensor harness connector CA26
and the terminal 29 of EMS harness connector EN35, and
check whether there is broken circuit. As for standard
and the reliable grounding, and check whether the circuit
is short to the ground. As for standard value, please refer
to the table below.
(f) Measure the voltage between the terminal 3 of
is short to the power supply. As for standard value, please
connector 1
refer to the table below.
CA26(3)-EN35(29) resistance Less than 1 Ω

10kΩ or higher
Voltage between CA26(3) and

0V
reliable grounding
Yes

mode to OFF state.
CA26 supercharging pressure/temperature sensor harness connector CA26.
connector (c) Disconnect the EMS harness connector EN35.
check whether there is broken circuit. As for standard
is short to the ground. As for standard value, please refer
to the table below.
is short to the power supply. As for standard value, please
refer to the table below.
NL-3 01/2016
(g) Confirm whether the measured value conforms to the

standard value.

connector 1 CA26(2)-EN35(36) resistance Less than 1 Ω
ES Resistance between CA26(2)
10kΩ or higher
Voltage between CA26(2) and

0V
reliable grounding
No Repair or replace harness
Yes

mode to OFF state.
EN35 engine management system (plug-in part A) harness (b) Disconnect supercharging pressure sensor harness
connector 1 connector CA26.
(d) Measure the resistance between terminal 1 of
and terminal 13 of EMS harness connector EN35, and
check for open circuit, otherwise repair the faulty position.
(e) Measure the voltage between terminal 1 of the
and reliable grounding. Check whether there is short
circuit to ground. Or else, repair the faulty position.
(f) Confirm whether the measured value is normal.
CA26(1)-EN35(13) resistance Less than 1 Ω

CA26 supercharging pressure/temperature sensor harness
connector Voltage between CA26(1) and
0V
reliable grounding
Yes
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Yes
ES
Next step

interface.
mode to ON state.
(c) Clear DTC.
(e) Read the control system DTCs again. Confirm system

Yes
DTC P013600 P013700 P013800 P014000 P227000 P227100 P042000


P013600 Downstream oxygen sensor signal unreasonable
P013700 Downstream oxygen sensor signal circuit voltage too low
P013800 Downstream oxygen sensor signal circuit voltage too high
P042000 Three-way catalytic converter oxygen storage capacity aging (emission over limit) (Bank 1)
The downstream sensor is installed behind the three-way catalytic converter. The three-way catalytic converter is used for
converting carbon monoxide (CO), hydrocarbon (HC) and nitric oxide (Nox) components to harmless substances. To use the
three-way catalytic converter in the most effective manner, it is a must to accurately control air-fuel ratio to be close to the
theoretical air-fuel ratio. Use of heating type oxygen sensor can help EMS to realize accurate control of the air-fuel ratio.
The downstream sensor is used for detecting oxygen concentration in the exhaust. As the sensor is integrated with heater of
the heating induction part, concentration of oxygen could be detected even when the air inflow is low (low exhaust
temperature).
Oxygen concentration in the exhaust will thicken when the air-fuel ratio is too thin. The downstream sensor will notify EMS
air-fuel ratio passing over the three-way catalytic converter is too thin (undervoltage, i.e. less than 0.45V). On the contrary,
oxygen concentration in the exhaust will thin when air-fuel ratio is larger than the theoretical air-fuel ratio. The downstream
sensor will notify EMS air-fuel ratio passing over the three-way catalytic converter is too thick (overvoltage, i.e. higher than
0.45V). The downstream sensor is able to change its output voltage substantially when the air-fuel ratio is close to the
theoretical value.
NL-3 01/2016
EMS judges the air-fuel ratio passing over the three-way catalytic converter is thick or thin according to the auxiliary
information output by the downstream sensor and controls injection time accordingly. When the downstream sensor cannot
operate normally due to fault of any terminal, then EMS cannot compensate for the deviation of initial air-fuel ratio control.

strategy)
ES
- Monitor and compare - Secondary image HO2S signal
shutdown times and offset of the output voltage is
P013600 coupling times of heating calculated every 10 ms> =
electrode of the rear 2.002 V
oxygen sensor - Quantity statistics>= 4
- Output voltage, the second
oxygen sensor signal
offset<0.0596 V
- Signal range detection - - Duration of 3s
P013700
short circuit to ground - Voltage difference between
average values, the second
HO2S signal offset loading and
unloading <0.0049 V
- Air-fuel ratio set point, HO2S
signal offset> 0.995
- Signal range detection -
P013800 short circuit to power
oxygen sensor signal
supply
offset>1.2V
- Time duration 8s
oxygen sensor signal >0.4014V
oxygen sensor signal <0.4990
V - Fuse
- Time duration 10s - Rear oxygen
- Signal range detection – sensor
P014000 - Voltage difference between
open circuit averaged values, the second - EMS
HO2S signal offset loading and
unloading >=2.9004 V
- Exhaust temperature >
1262.827 °C
- Measure HO2S signal offset>
131070 Ohm
assess output voltage of - Rear oxygen sensor output
rear oxygen sensor- the voltage< 0.5 V
P227000 time constant measured
exceeds the set threshold - Catalytic converter clean
value (oxygen clearing oxygen quantity> 1000 mg
status).
assess output voltage of - Rear oxygen sensor output
rear oxygen sensor- the voltage> 0.75 V
P227100 time constant measured
exceeds the set threshold - Catalytic converter oxygen
value (oxygen clearing storage capacity> 1000mg
status).
- Average amplitude of rear
- Beyond the maximum limit oxygen sensor signal after
P042000
value correction by critical catalytic
converter model > 0.6.
NL-3 01/2016
3. Circuit diagram:
Rear oxygen sensor Front oxygen sensor

ES
Main relay
ER05
Notice
Step 1 Connect fault diagnostic scanner.
Next step
Step 2 Start engine and turn on the fault diagnostic scanner.
Next step
Keep the engine speed at around 2500 rpm for more than 2 minutes to warm up the engine, until
Step 3
the engine coolant temperature reaches 80℃ (176 °F).
Next step
Select in the fault diagnostic scanner: engine/read data stream/ group 1 oxygen sensor voltage 2
Step 4
(rear oxygen sensor).
Next step
Step 5 Observe the oxygen sensor output voltage, the data stream should fluctuate within 0.1 ~ 0.9V.

“Check on intermittent faults”.
No
NL-3 01/2016
Step 6 Conduct oxygen sensor signal test.
(a) If the data stream shows the voltage is constantly

lower than 0.45V (mixture too thin), execute the check
procedure according to the following steps:
• Proper amount of propane gas will be injected in the
ES inlet.
• Check whether the rear oxygen sensor data stream
voltage has a significant change, in which case the
signal voltage will increase rapidly.
(b) If the data stream shows the voltage is constantly
higher than 0.45V (mixture too rich), execute the check
procedure according to the following steps:
• Make the transmission at the neutral gear.
• Pull on the parking brake switch.
• Tramp the acceleration pedal so that the engine speed
suddenly increases to 4000rpm and then suddenly
release the acceleration pedal.
• Repeat more than three times as per the above
procedure.
• Observe whether there is obvious change on the rear
oxygen sensor data stream voltage; the signal voltage
will rapidly decrease.
• • When executing the above test, the oxygen sensor
signal voltage shall significantly vary with the test.
(c) Confirm whether there are significant changes in
voltage generation.
Yes Check the cause of the engine too rich

or thin air-fuel ratio. Refer to fault
symptom table.
No
Step 7 Check whether there is other DTC output of control system.

interface.
mode to ON state.
scanner.
(e) Read DTC.
Display DTC and go to Standard value:
the step
P013700, P013800,
No
P014000 P227000,
P227100 P042000
P013600, P013700,
P013800, P014000,
Yes
P227000, P227100,
P042000

fault codes
Yes
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Step 8 Check the sealing of exhaust system.
(a) Check three-way catalytic converter appearance

intactness (whether sign of over temperature, sealing
gasket missing, etc. are available).
ES
(b) Check whether the exhaust pipe appearance and
sealing gasket is intact.
No Replace the broken component and

go to step 15
Yes
Step 9 Measure the signal output of the rear oxygen sensor.
(a) Start the engine, under idling state, when the oxygen
sensor reaches its working temperature of 350 ℃
(662 °F).
(b) Measure the change in voltage signal of the rear
oxygen sensor within 10s.
Voltage signal changes: more than 8 times
Yes Go to step 11
No
Step 10 Replace the rear oxygen sensor. Please refer to the section about rear oxygen sensor.
(a) Replace the rear oxygen sensor.
Yes Go to step 14
Step 11 Check rear oxygen sensor signal circuit.
NL-3 01/2016

mode to OFF state.
EN04.
connector
(c) Disconnect harness connector CA01 of EMS.
ES (d) Measure the resistance between the terminal 4 of rear
oxygen sensor harness connector EN04 and the terminal
there is broken circuit. As for standard value, please refer
to the table below.
(e) Measure the resistance between the terminal 4 of rear
oxygen sensor harness connector EN04 and the reliable
ground. As for standard value, please refer to the table
below.
(f) Measure the voltage between the terminal 4 of rear
oxygen sensor harness connector EN04 and the reliable
power supply. As for standard value, please refer to the
connector 2
table below.
standard value.
EN04(4)-CA01(62) Less than 1 Ω
Resistance between
EN04(4) and reliable 10kΩ or higher
grounding

0V
Yes
Step 12 Check rear oxygen sensor signal circuit.

mode to OFF state.
EN04.
connector (c) Disconnect harness connector CA01 of EMS.
(d) Measure the resistance between terminal 3 of front
oxygen sensor harness connector EN04 and terminal 33
of EMS harness connector CA01, and check for open
circuit, otherwise repair the faulty position.
(e) Measure the resistance between terminal 3 of front
grounding, and check whether the circuit is short to
ground, or else repair the faulty position.
(f) Measure the voltage between the terminal 3 of the
front oxygen sensor harness connector EN04 and reliable
grounding, and check whether there is to short circuit
power supply, or else repair the faulty position.
NL-3 01/2016

standard value.

connector 2
EN04(3)-CA01(33) Less than 1 Ω
Resistance between ES
grounding

0V
Yes Repair or replace faulty circuit
Yes

Yes Repair the faulty position.
Yes
Next step

interface.
mode to ON state.
(c) Clear DTC.

“Check on intermittent fault”.
Yes
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DTC P016929 P016961 P016964 P016992 P016993 P016994

P016929 Oilpipe monitoring fault (working mode monitoring fault)

ES
P016961 Oilpipe monitoring fault (load comparison monitoring fault)
P016964 Oilpipe monitoring fault (gas mixture monitoring fault)
P016992 Oilpipe monitoring fault (oilpipe comparison fault in the oil supply mode)
P016993 Oilpipe monitoring fault (oilpipe comparison fault in the oil supply mode)
P016994 Oilpipe monitoring fault (load forecasting monitoring fault)
The closed-loop control of fuel control valve is realized by the fuel rail pressure sensor, in order to monitor the oilpipe. When
the fuel rail pressure sensor output data exceeds the normal range, above DTCs will be reported.

(control strategy)
- Working mode monitoring

P016929
fault
- Load comparison
P016961
monitoring fault
- Gas mixture monitoring

P016964 - Circuit
fault
- Check on internal logic - EMS
- Oilpipe monitoring fault
P016992 - Fuel control valve
under the oil supply mode
- Oilpipe monitoring fault

P016993
under the oil cutting mode
- Load forecasting
P016994
monitoring fault
NL-3 01/2016
3. Circuit diagram:
Fuel control valve

Main relay
ER05 ES
Notice

on sensor working
(b) Very fine crack of fuel rail pressure sensor.
(c) The fuel pipeline is blocked up.
(d) The fuel pipeline is leaking.
Next step
Step 2
P016994.

interface.
mode to ON state.
scanner.
(e) Read DTC.
NL-3 01/2016

P016961, P016964,
No
P016992, P016993,
P016994
ES P016929, P016961,
P016964, P016992, Yes
P016993, P016994

fault codes
Next step
Step 3 Check 5V reference voltage of the oilpipe pressure sensor.

mode to OFF state.
EN49 Fuel rail pressure sensor harness connector (b) Disconnect fuel rail pressure sensor harness
connector EN49.
mode to ON state.
(d) Measure voltage between terminal 3 of fuel rail
pressure sensor harness connector EN49 and reliable
grounding.
Standard voltage: 5V
(e) Connect harness connector EN49 of fuel rail pressure
sensor.
No Go to step 6
Yes

mode to OFF state.
(b) Disconnect fuel rail pressure sensor harness
EN49 Fuel rail pressure sensor harness connector connector EN49.
rail pressure sensor harness connector EN49 and the
terminal 40 of EMS harness connector EN35, and check
whether there is broken circuit. As for standard value,
(e) Measure the resistance between the terminal 2 of the
fuel rail pressure sensor harness connector EN49 and
reliable grounding, check whether there is to ground short
circuit, or else repair the faulty element.
(f) Measure the voltage between the terminal 2 of the fuel
rail oxygen sensor harness connector EN49 and reliable
grounding, check whether there is to power supply short
circuit, or else repair the faulty element
NL-3 01/2016

standard value.

connector 1
EN49(2)-EN35(40)
Less than 1 Ω
resistance
ES
Resistance between
grounding

0V
Yes

mode to OFF state.
EN49 Fuel rail pressure sensor harness connector (b) Disconnect fuel rail pressure sensor harness
connector EN49.
(d) Measure the resistance between terminal 1 of the fuel
rail pressure sensor harness connector EN49 and
whether there is open circuit, otherwise repair the faulty
position.
(e) Measure the voltage between terminal 1 of the fuel rail
pressure sensor harness connector EN49 and reliable
grounding. Check whether there is short circuit to ground.
Or else, repair the faulty position.
EN49(1)-EN35(13)
Less than 1 Ω
EN35 engine management system (plug-in part A) harness resistance
connector 1
0V
Yes
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mode to OFF state.
EN49 Fuel rail pressure sensor harness connector
(b) Disconnect fuel rail pressure sensor harness
connector EN49.
ES (d) Measure the resistance between terminal 3 of the fuel
rail pressure sensor harness connector EN49 and
whether there is open circuit, otherwise repair the faulty
position.
fuel rail pressure sensor harness connector EN49 and
reliable grounding, check whether there is to ground short
circuit, or else repair the faulty element.
(f) Measure the voltage between the terminal 3 of the fuel
rail oxygen sensor harness connector EN49 and reliable
circuit, or else repair the faulty element

connector 1
CA26(2)-EN35(36)
Less than 1 Ω
resistance
Resistance between
grounding
Voltage between CA26(2)

0V
Yes
Step 7 Replace the fuel rail pressure sensor.
Next step

Yes
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC.
(d) Start and run the engine at idle speed to warm up the ES

Yes
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DTC P020113 P026111 P026300 P214600 P214611


ES
P026111 Cylinder No.1 fuel injector control circuit voltage too low
P026300 Cylinder No.1 fuel injector control circuit voltage unreasonable
P214600 Short circuit of high-pressure fuel injector on high and low sides of cylinder No.1
P214611 Short circuit to ground on high-pressure side of high-pressure fuel injector of cylinder No.1
The high-pressure fuel injector is applicable to direct injection engine. It is a kind of 6-hole needle valve type fuel injector that
opens and closes under the control of solenoid coil to control injection of fuel. The amount of fuel injection is dependent on fuel
rail pressure and opening time of the fuel injector. EMS controls duty ratio signal to control opening time of the fuel injector.
The fuel injector uses 65V high voltage when it is opening and 12V conventional voltage to maintain its open state.
EMS monitors the state of each fuel injector drive circuit. If EMS detects that the voltage corresponding to the drive circuit
instruction state is not correct, it will set a DTC of the fuel injector control circuit fault.

(control strategy)
- Open circuit of fuel - When system voltage is

P020113
injector equal to or higher than 8V
for more than 0.5s and
P026111 - Low side short to ground engine speed is > 50rpm - Fuse
- Engine speed > 640 to - Circuit

- Boost time out fault of fuel
P026300 840 rpm, and exceeds - EMS
injector
0.5s.
- Fuel injector of
- Short circuit at high/low - When system voltage is cylinder No. 1
P214600
side equal to or higher than 8V
P214611 - High side short to ground engine speed is > 50rpm
NL-3 01/2016
3. Circuit diagram:
Fuel injector 1 Fuel injector 2 Fuel injector 3 Fuel injector 4
Main relay ES
ER05

(a) Check whether the fuel injector harness connector
contacts poorly or is aged or loose.
(b) Check whether the fuel injector is externally damaged.
Next step
Check whether the control system has DTCs except DTC P020113 P026111 P026300 P214600
Step 2
P214611.

interface.
mode to ON state.
scanner.
(e) Read DTC.
NL-3 01/2016

P026111, P026300, P214600, No
P214611
P020113, P026111, P026300,
Yes
P214600, P214611
ES
fault codes
Next step
Step 3 Measure whether the fuel nozzle control circuit is short to the voltage end.

mode to OFF state.
(b) Disconnect cylinder No.1 fuel injector harness
connector EN48.
EN48 Fuel nozzle harness connector (c) Operate the starter switch to turn the power supply
mode to ON state.
injector harness connector EN48 of cylinder No. 1 and the
reliable grounding.
reliable grounding.
No Repair relevant short to voltage end

fault of the fuel nozzle control circuit
Yes
Step 4 Check short to ground fault of the fuel nozzle control circuit.

mode to OFF state.
connector EN48.
EN48 Fuel nozzle harness connector (c) Measure the resistance between the terminal 1 of fuel
reliable grounding.
Standard resistance: Less than 10kΩ
reliable grounding.
value.

nozzle control circuit.
Yes
Step 5 Check short circuit fault of fuel nozzle circuit.
NL-3 01/2016

mode to OFF state.
Fuel nozzle harness connector EN48

(c) Disconnect fuel injector harness connector EN48 of
cylinder No. 1.
(d) Disconnect harness connector EN35 of EMS. ES
(e) Measure the resistance between the terminal 1 and
the terminal 2 of the fuel injector harness connector EN48
of cylinder No. 1.
value.
No Repair short circuit fault of fuel nozzle

circuit.
Yes
Step 6 Check whether control circuit of the fuel nozzle valve is broken.

mode to OFF state.
EN48 Fuel nozzle harness connector connector EN48.
(d) Measure the resistance between the terminal 1 of the
fuel injector harness connector EN48 of cylinder No. 1
and the terminal 33 of EMS harness connector EN35.
value.
No Repair open circuit fault of fuel nozzle

EN35 engine management system (plug-in part A) harness control circuit.
connector 1
Yes
Step 7 Check whether the fuel nozzle is internally short to the ground.
NL-3 01/2016

mode to OFF state.
Fuel nozzle harness connector EN48

connector EN48.
ES reliable grounding.
reliable grounding.
value.
No Replace the fuel nozzle
Yes
Step 8 Check the resistance of fuel nozzle.

mode to OFF state.
connector EN48.
the terminal 2 of the fuel injector of cylinder No. 1.
20 ℃ （68 ℉）
(d) Confirm whether the resistance meets the standard
value.
Yes

Yes
Step 10 Replace the EMS. Refer to “Engine ECU”.
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC.

Yes
DTC P020213 P026411 P026600 P215500 P020213

P026411 Cylinder No. 2 fuel injector control circuit voltage is too low
P026600 Cylinder No. 2 fuel injector control circuit voltage is unreasonable

(control strategy)

P020213

injector
0.5s.
- Fuel injector of
- When system voltage is cylinder No. 2
- Short circuit at high/low equal to or higher than 8V
P215500
side for more than 0.5s and
engine speed is > 50rpm
3.
NL-3 01/2016
4. Circuit diagram:
Main relay
ER05
ES

Next step
Step 2
P020213.

interface.
mode to ON state.
scanner.
(e) Read DTC.
NL-3 01/2016

P026411, P026600, No
P215500, P020213
P020213, P026411,
P026600, P215500, Yes
P020213 ES

fault codes
Next step

mode to OFF state.
connector EN45.
EN45 Fuel nozzle 2 harness connector (c) Operate the starter switch to turn the power supply
mode to ON state.
reliable grounding.
reliable grounding.

Yes

mode to OFF state.
connector EN45.
EN45 Fuel nozzle 2 harness connector
reliable grounding.
reliable grounding.
value.

Yes
NL-3 01/2016

mode to OFF state.
EN45 Fuel nozzle 2 harness connector (c) Disconnect fuel injector harness connector EN45 of
cylinder No. 2.
ES (d) Disconnect harness connector EN35 of EMS.
of cylinder No. 1.
value.

circuit.
Yes

mode to OFF state.
connector EN45.
value.
EN35 engine management system (plug-in part A) harness No Repair open circuit fault of fuel nozzle
connector 1 control circuit.
Yes
NL-3 01/2016

mode to OFF state.
connector EN45.
reliable grounding. ES
Standard resistance: More than 10kΩ
reliable grounding.
value.
Yes

mode to OFF state.
connector EN45.
Standard resistance: 9.4~10.6Ω in temperature of 20 ℃
（68 ℉）
value.
Yes

Yes
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC.

Yes
DTC P020313 P026711 P026900 P214900

P026900 Cylinder No. 3 fuel injector control circuit voltage is unreasonable

(control strategy)

P020313

injector
0.5s.
- Fuel injector of
- When system voltage is cylinder No. 3
- Short circuit at high/low equal to or higher than 8V
P214900
side for more than 0.5s and
NL-3 01/2016
3. Circuit diagram:
Main relay ES
ER05

Next step
Step 2 Check whether the control system has other DTCs except P020313 P026711 P026900 P214900.

interface.
mode to ON state.
scanner.
(e) Read DTC.
NL-3 01/2016

DTC other than
P020313, P026711, No
P026900, P214900
P020313, P026711,
Yes
P026900, P214900
ES
fault codes
Next step

mode to OFF state.
connector EN46.
EN46 Fuel nozzle 3 harness connector (c) Operate the starter switch to turn the power supply
mode to ON state.
reliable grounding.
reliable grounding.

Yes

mode to OFF state.
connector EN46.
EN46 Fuel nozzle 3 harness connector (c) Measure the resistance between the terminal 3 of fuel
reliable grounding.
reliable grounding.
value.
Yes
NL-3 01/2016

mode to OFF state.
EN46 Fuel nozzle 3 harness connector cylinder No. 3.
(d) Disconnect harness connector EN35 of EMS. ES
of cylinder No. 1.
value.

circuit.
Yes

mode to OFF state.
connector EN46.
value.
Repair open circuit fault of fuel nozzle

No
EN35 engine management system (plug-in part A) harness control circuit.
connector 1
Yes
NL-3 01/2016

mode to OFF state.
connector EN46.
Fuel nozzle 3 harness connector EN46 (c) Measure the resistance between the terminal 3 of fuel
reliable grounding.
value.
Yes

mode to OFF state.
connector EN45.
20 ℃ （68 ℉）
value.
Yes

Yes
Step 10 Replace the EMS. Refer to the section about engine ECU.
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC.

Yes
DTC P020413 P027011 P027200 P215200 P215211

P027011 Cylinder No.4 fuel injector control circuit voltage too low
P027200 Cylinder No.4 fuel injector control circuit voltage unreasonable
P215211 Short circuit to ground on high-pressure side of high-pressure fuel injector of cylinder No.4

(control strategy)
P020413 - Open circuit of fuel injector - When system voltage is

equal to or higher than 8V
P027011 - Low side short to ground - Fuse
- Circuit
- Boost time out fault of fuel – Engine speed > 640 to 840
P027200 - EMS
injector rpm, and exceeds 0.5s.
- Fuel injector of cylinder
- When system voltage is No. 4
equal to or higher than 8V
P215200 - Short circuit at high/low side
NL-3 01/2016

(control strategy)
- Fuse
- When system voltage is - Circuit
- High side short to power equal to or higher than 8V
P215211 - EMS
ES supply for more than 0.5s and
engine speed is > 50rpm - Fuel injector of cylinder
No. 4
3. Circuit diagram:
Main relay
ER05

Next step
Step 2
P215211.
NL-3 01/2016

interface.
mode to ON state.
scanner.
ES
(e) Read DTC.

P027011, P027200, No
P215200, P215211
P020413, P027011,
P027200, P215200, Yes
P215211
No
fault codes
Next step

mode to OFF state.
(b) Disconnect cylinder No. 4 fuel injector harness
connector EN47.
Fuel nozzle 4 harness connector EN47 (c) Operate the starter switch to turn the power supply
mode to ON state.
reliable grounding.
reliable grounding.

Yes
NL-3 01/2016

mode to OFF state.
connector EN47.
Fuel nozzle 4 harness connector EN47 (c) Measure the resistance between the terminal 4 of fuel
reliable grounding.
value.

Yes

mode to OFF state.
Fuel nozzle 4 harness connector EN47 cylinder No. 4.
(d) Disconnect harness connector EN35 of EMS.
of cylinder No. 1.
Standard resistance: More than 10KΩ
value.
circuit.
Yes

mode to OFF state.
connector EN47.
Fuel nozzle 4 harness connector EN47 (c) Disconnect the EMS harness connector EN35.
value.
No
Repair open circuit fault of fuel nozzle
control circuit.
NL-3 01/2016

connector 1
ES
Yes

mode to OFF state.
connector EN47.
Fuel nozzle 4 harness connector EN47
reliable grounding.
reliable grounding.
value.
Yes

mode to OFF state.
connector EN45.
20 ℃ （68 ℉）
value.
Yes
NL-3 01/2016

ES Yes
Next step

interface.
mode to ON state.
(c) Clear DTCs.

Yes
NL-3 01/2016
DTC P021900
P021900 The engine speed is too high

ES
Engine speed is determined by the driver controlling the electronic throttle through the accelerator pedal. If the engine speed is
too high, then the throttle position must be in the full opening position. When the engine speed is higher than the designed
maximum speed, EMS will perform fuel cut-off control to reduce the engine speed.

(control strategy)
- Circuit
- Engine speed exceeds
- Crankshaft position
P021900 the maximum speed, - Engine speed >7500 rpm
sensor
unbelievable
- EMS
3. Circuit diagram:
Main relay
ER05
Engine speed sensor
Notice
Step 1 Check the intake manifold for leakage phenomenon.
NL-3 01/2016
(a) Open the engine hood and start the engine.

(b) Check the intake manifold for leakage phenomenon.
(c) Is it normal?
Yes Repair the faulty position

ES
No
Step 2 Check whether the control system has other DTCs except P021900.

interface.
mode to ON state.
scanner.
(e) Read DTC.
P021900 Yes
No
fault codes
Yes
Step 3 Read the engine speed when the accelerator pedal is depressed to the end.

(b) Slowly depress the accelerator pedal to the end, and
read the engine speed.
(c) Confirm this speed exceeds the maximum engine
speed.
Designed maximum speed: 6,000 r/min
No Go to step 7
Yes

Yes
Step 5 Replace engine speed sensor.
(a) Confirm whether the faults are eliminated
NL-3 01/2016
Yes The system is normal
No
Step 6 Replace the throttle.

ES
(a) Confirm whether the faults are eliminated
Yes
The system is normal
No

Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P022317 P210612 P210613 P210619 P210692

ES
P210619 Power drive level fault of electronic throttle (overheat or overcurrent)
P210692 Power drive level fault of electronic throttle (SPI bus or signal)
The electronic throttle position sensor installed on the throttle body assembly is used for detecting opening of the throttle. The
two sensor circuits of the throttle position sensor send throttle position signal 1 and throttle position signal 2 respectively.
Signal 1 is used for detecting throttle opening and signal 2 for detecting fault of signal 1. Sensor signal voltage varies from 0V
to 5V, of which the change amplitude is in proportion to the throttle opening. Signals will be sent to receiving terminal of EMS.
Sensor output voltage reduces when the valve is closed. Sensor output voltage increases when the valve is open. EMS
calculates throttle opening based on these signals to control throttle actuator to adapt to the driving conditions. These signals
will be used also in correction of air-fuel ratio, correction of power supply increase, fuel cutoff control and other calculations.

strategy)
- The upper limit is

P022317 - TPS2 signal voltage
exceeded
- The upper limit is

P210612 - TPS2 signal voltage - Fuse
exceeded
- Circuit
- Open circuit fault - Monitor power drive level of
P210613 - EMS
DVE
- Electronic throttle
- The upper limit is - Monitor power drive level of body
P210619
exceeded DVE
- The upper limit is - Monitor power drive level of

P210692
exceeded DVE
NL-3 01/2016
3. Circuit diagram:
Main relay
ER05
ES
Electronic throttle
Notice

on sensor working:
(b) Check whether the appearance of the sensor is
damaged.
Next step

interface.
mode to ON state.
scanner.
(e) Read DTC.
NL-3 01/2016

P022216, P022317, P210612, No
P210613, P210619, P210692
P022129, P022216, P022317,
P210612, P210613, P210619, Yes
ES P210692
No
fault codes
Yes
Step 3 Measure throttle position sensor 2 signal output circuit.
(a) (Connect electronic throttle harness connector EN22)

turn digital multimeter to DC voltage position, with the
black probe connected to terminal 2, and the red probe to
EN22 Electronic throttle harness connector
terminal 5.
(c) Under engine idling state, measure the voltage
between terminal 2 and terminal 5.
Standard value of the voltage: 4.3~4.7V
(d) Shut down the engine and operate the ignition switch
to turn power supply to ON mode. Open the throttle fully,
and measure the voltage between terminal 5 and terminal
2.
Standard value of the voltage: 0.6~1.0V
Yes Go to step 7
No
Step 4 Measure 5V reference voltage of throttle position sensor 2.

mode to OFF state.
EN22 Electronic throttle harness connector EN22.
mode to ON state.
(d) Measure the voltage between terminals 3 of electronic
throttle EN22 and reliable grounding.
(e) Connect the electronic throttle harness connector
EN22.
No Go to step 6
Yes
NL-3 01/2016
Step 5 Measure the throttle position sensor 2 grounding.

mode to OFF state.
(b) Disconnect harness connector EN22 of the electronic
throttle sensor.
(c) Measure the resistance between terminal 2 of ES
electronic throttle harness connector EN22 and reliable
grounding.
value.
Yes
Step 6 Check 5 V reference voltage circuit of throttle position sensor 2.

mode to OFF state.
EN22.
electronic throttle harness connector EN22 and terminal
12 of EMS harness connector EN35, and check whether
there is open circuit, otherwise repair the faulty position.
else repair the faulty position.
(f) Measure the voltage between terminal 3 of electronic
throttle harness connector EN22 and reliable grounding,
and check whether there is short circuit to power supply,
or else repair the faulty position.
connector 1 Measured items Standard value
EN22(3)-EN35(12) resistance Less than 1 Ω

10kΩ or higher
Voltage between EN22(3) and

0V
reliable grounding
Yes
Step 7 Check the throttle position sensor 2 signal circuit.
NL-3 01/2016

mode to OFF state.
throttle temperature sensor.
ES (d) Measure the resistance between terminal 5 of

10kΩ or higher

0V
reliable grounding
Yes

mode to OFF state.
throttle temperature sensor.
NL-3 01/2016
EN35 engine management system (plug-in part A) harness EN22(2)-EN35(44)

connector 1
Less than 1 Ω
resistance
grounding

0V
Yes

Yes
Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P023400 P024313 P024511 P024612

P023400 Pipe of exhaust gas control valve to the relief valve pressure chamber leaks or falls off
ES
P024313 The driving circuit fault of exhaust control valve
P024511 The voltage of driving circuit of exhaust control valve is too low
P024612 The voltage of driving circuit of exhaust control valve is too high
When the supercharging pressure arrives at the desired pressure set by EMS, the exhaust control calve works and makes
supercharging pressure and atmospheric pressure jointly push the exhaust control valve actuator to work and open the
exhaust bypass valve so as to make the supercharging pressure up to EMS requirement.
(control strategy)
- Supercharging pressure - The maximum allowable
P023400 of supercharger is too deviation of supercharge
high control is 350-400hPa
P024313 - The circuit is open - Engine speed >= 80 rpm
P024511 - Short to the ground - System voltage >= 9V - Circuit
- Control duty ratio of - Exhaust control valve
supercharge exhaust - EMS
valve >= 5%
- Control duty ratio of
supercharge exhaust
valve <= 95%
3. Circuit diagram:
Intake relief Exhaust control

Main relay
valve valve
ER05
NL-3 01/2016
Notice

ES
(a) Any damaged components, including turbocharger,
supercharge air cooler and turbocharger exhaust control
valve.
(b) Any very fine crack of supercharging pressure sensor
housing.
(c) Any component is loose or incorrectly installed.
(d) Air flow is blocked up.
(e) Vacuum leakage.
(f) Any small hole or crack on the 3 vacuum hoes
connected to the turbocharger exhaust control valve.
(g) Any blockage of the 3 vacuum hoes connected to the
turbocharger exhaust control valve.
(h) Any type of air leakage between turbocharger and
(i) Check and confirm no leakage of exhaust exists,
including the leakage in the junction area between
turbocharger and exhaust manifold.
Next step
Step 2 Measure the intake bleed valve fuse.

mode to OFF state.
(c) Remove EF10 fuse and check whether the fuse has
blown out.
Yes Replace the fuse with the rated

capacity of 10A
No
Step 3 Measure operating power supply of the exhaust control valve.
NL-3 01/2016

mode to OFF state.
(b) Disconnect exhaust gas control valve harness
connector EN03.
EN03 Exhaust gas control valve harness (c) Operate the starter switch to turn the power supply
connector
mode to ON state.
ES (d) Measure the voltage between the terminal 1 of
exhaust control valve harness connector EN03 and the
(e) Connect harness connector of the intake bleed valve.
No Go to step 5
Yes
Step 4 Check exhaust control valve control circuit.

mode to OFF state.
(b) Disconnect exhaust gas control valve harness
connector 1 connector EN03.
EN03 Exhaust gas control valve (c) Disconnect the EMS harness connector EN35.
exhaust control valve harness connector EN03 and the
terminal 18 of EMS harness connector EN35. Refer to the
table below for standard values.
(e) Measure the resistance between terminal 2 of exhaust
gas control valve harness connector EN03 and
grounding; the standard value is shown in the following
table.
(f) Operate the ignition switch to set the power mode in
the state ON, (Note: connectors EN35 and EN03 must be
disconnected at the moment) and measure the voltage
between the terminal 2 of intake bleed valve harness
connector EN03 and the grounding point.
EN35 engine management system (plug-in part A) harness Refer to the table below for standard values.
connector 1
standard value.

Resistance between EN03(2) and
Less than 1 Ω
EN35(18)
Resistance between EN03(2) and
10kΩ or higher
reliable grounding
0V
reliable grounding
Yes
Step 5 Check operating power circuit of the intake bleed valve.
NL-3 01/2016

mode to OFF state.
EN03 Exhaust gas control valve harness (c) Disconnect the intake relief valve harness connector
connector EN03.
intake bleed valve harness connector EN03 and the fuse
EF10. Refer to the table below for standard values.
intake relief valve harness connector EN03 terminal 1 and
grounding. The Standard Value is shown in table below.
standard value.
Engine compartment fuse, relay box Resistance between

Less than 1 Ω
EN03(1) and EF10
Resistance between
grounding
Yes

Yes
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P023621 P023622 P023623 P023624 P023716 P023817

P023621 Turbocharge pressure sensor signal is less than the minimum limit
ES
P023622 Turbocharge pressure sensor signal is greater than the maximum limit
P023623 Turbocharge pressure sensor signal fault
P023624 Turbocharge pressure sensor signal unreasonable fault
P023716 Supercharging pressure sensor signal voltage is too low
P023817 Supercharging pressure sensor signal voltage is too high
The supercharging pressure sensor located at the intercooler outlet is integrated with the intake temperature sensor 2, through
which EMS measures supercharging pressure between turbocharger and throttle body as well as intake temperature. A
supercharging pressure sensor consists of following circuits:

strategy)
- Supercharging pressure
- Supercharging pressure<
P023621 exceeds the lower limit
500hPa
of rationality
- Exceed the upper limit

- Supercharging pressure>
P023622 of reasonableness of
2400hPa
supercharging pressure
- Supercharging pressure - The standard of diagnosis

P023623 exceeds the rationality and calculation is to
dynamic lower limit compare the difference - Fuse
between supercharging - Circuit
pressure and ambient
pressure: (measured value - Supercharging
of supercharging pressure) pressure sensor
- Supercharging pressure – (signal tolerance of - EMS
P023624 of supercharger is too supercharging pressure
high sensor) < (measured value
of ambient pressure) –
(signal tolerance of ambient
pressure sensor)
P023716 - Short to the ground - Sensor voltage< 0.20V
- Short to the power

P023817 - Sensor voltage> 4.88V
supply
NL-3 01/2016
3. Circuit diagram:
Main relay
ER05
ES
Notice

on sensor working
(b) Very fine crack of supercharging pressure sensor
housing.
(c) Very fine crack of intake pressure sensor.
(d) Air flow is blocked up.
(e) Vacuum leakage.
(f) Any type of air leakage between turbocharger and
(g) Check and confirm no leakage of exhaust exists,
Next step
Step 2
P023817.
NL-3 01/2016

interface.
mode to ON state.
scanner.
ES
(e) Read DTC.

P023622, P023623,
No
P023624, P023716,
P023817
P023621, P023622,
P023623, P023624, Yes
P023716, P023817
No
fault codes
Yes
Step 3 Check 5V reference voltage of the supercharging pressure sensor.

mode to OFF state.
(b) Disconnect harness connector CA26 of the
CA26 supercharging pressure/temperature sensor supercharge temperature sensor.
harness connector
mode to ON state.
(d) Measure the voltage between terminal 3 of
No Go to step 6
Yes
NL-3 01/2016
(a) Turn the digital multimeter to direct voltage position,

and connect its black probe with the reliable grounding
and its red probe with the terminal 4.
CA26 supercharging pressure/temperature sensor
harness connector (c) Quickly open the throttle, and observe whether the
voltage at terminal 4 can instantly reach 4.5V and then
ES drops to 3.9V.
(d) Confirm whether the above is normal.
No Go to step 7
Yes
Step 5 Check grounding circuit of the supercharging pressure sensor.

mode to OFF state.
connector CA26.
CA26 supercharging pressure/temperature sensor (c) Operate the starter switch to turn the power supply
harness connector mode to ON state.
value.
No Go to step 8
Yes

mode to OFF state.
connector CA26.
CA26 supercharging pressure/temperature sensor (d) Measure the resistance between terminal 3 of
harness connector supercharging pressure sensor harness connector CA26
and reliable grounding, and check whether the circuit is
short to ground, or else repair the faulty position.
and reliable grounding, and check whether there is to
short circuit power supply, or else repair the faulty
position.
NL-3 01/2016

CA26(3)-EN35(29)
resistance
grounding

0V
No Go to Step 9.
Yes

mode to OFF state.
connector CA26.
harness connector (c) Disconnect the EMS harness connector EN35.
and reliable grounding, and check whether the circuit is
short to ground, or else repair the faulty position.
position.
EN35 engine management system (plug-in part A) harness (g) Confirm whether the measured value conforms to the
connector 1 standard value.
CA26(4)-EN35(39)
Less than 1 Ω
resistance
Resistance between
grounding

0V
No Go to step 9
Yes
NL-3 01/2016

mode to OFF state.
connector CA26.
harness connector (c) Disconnect the EMS harness connector EN35.
ES (d) Measure the resistance between terminal 1 of
(e) Measure the voltage between terminal 1 of the
and reliable grounding. Check whether there is short
circuit to ground. Or else, repair the faulty position.
EN22(2)-EN35(44)
Less than 1 Ω
resistance
connector 1
Resistance between
EN22(2) and reliable 0V
grounding
Yes
Step 9 Replace the turbocharger pressure sensor.
(a) Is the fault exists still?
No Troubleshooting
Yes

Yes
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P025111 P025113 P025212 P025311 P025412

P025111 Flow control valve drive circuit is short to ground (high pressure side)
ES
P025113 Flow control valve drive circuit is open
P025212 Flow control valve drive circuit is short to power supply (high pressure side)
P025311 Flow control valve drive circuit is short to ground (low pressure side)
P025412 Flow control valve drive circuit is short to power supply (low pressure side)
Through the pressure sensor on the fuel rail, EMS controls flow of the high-pressure pump via the fuel control valve according
to the set control program to exert close-looped control of pressure inside the high-pressure fuel rail.
Notice
Fuel control valve is a part of the high-pressure fuel pump, which is not allowed to be replaced individually.

strategy)
- MSV valve high side

P025111 - Current = 40 A
short to the ground
- MSV valve low side

P025113 - Current < 2 A
open
- MSV valve high side - Circuit

P025212 short to the power - Current > 2 A
- Fuel control valve
supply
- EMS
P025311 - Current = 40 A
short to the ground

P025412 short to the power - Current > 2 A
supply
NL-3 01/2016
3. Circuit diagram:
Fuel control valve

Main relay
ER05
ES

(a) Check and confirm pressure of the fuel system at low
pressure side is correct.
Next step
Step 2
P025412.

interface.
mode to ON state.
scanner.
(e) Read DTC.

P025113, P025212, No
P025311, P025412
P025111, P025113,
P025212, P025311, Yes
P025412
NL-3 01/2016

No
fault codes
Yes
Step 3 Measure whether control circuit of the fuel control valve is short to the voltage end.
ES
mode to OFF state.
EN23.
mode to ON state.
grounding.
grounding.
No Repair short circuit fault
Yes
Step 4 Check the short to ground fault of fuel control valve control circuit.

mode to OFF state.
EN23.
grounding.
grounding.
value.
No Repair short circuit fault
Yes
Step 5 Check short circuit fault of the fuel control valve circuit.
NL-3 01/2016

mode to OFF state.
EN23.
the terminal 2 of the fuel control valve harness connector
EN23. ES
value.
No Short circuit fault of the fuel control

valve circuit
Yes
Step 6 Check whether control circuit of the fuel control valve is broken.

mode to OFF state.
EN23.
(e) Measure the resistance between the terminal 2 of fuel

value.
No Repair open circuit fault

connector 1
Yes
Step 7 Check whether the fuel control valve is internally short to the ground.
NL-3 01/2016

mode to OFF state.
EN23.
ES grounding.
grounding.
value.
No Replace the high-pressure oil pump
Yes
Step 8 Check resistance of the fuel control valve.

mode to OFF state.
EN23.
the terminal 2 of fuel control valve.
Standard resistance value: 0.49Ω
value.
No Replace the high-pressure oil pump
Yes

Yes
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTCs.

Yes
NL-3 01/2016
DTC P030000 P030100 P030200 P030300 P030400 P130B00


ES
P130B00 The misfiring fault caused by damage of catalytic converter
EMS uses information from engine speed sensor and camshaft position sensor to determine whether misfire is available in the
engine. If a certain cylinder doesn't work normally, EMS can detect crankshaft speed variation; the misfire of a certain cylinder
is calculated just by detecting the crankshaft speed variation during the power stroke. In case of misfire, the combustible
mixture that has not combusted in cylinder drained to the exhaust system and finally combusted in the three-way catalytic
converter (TWC). It may lead to overheating of the converter or even damage TWC. In case of overheating of the three-way
catalytic converter, the malfunction indicator lamp (MIL) will always light on or flash. Meanwhile set the corresponding DTC.

strategy)
P030000 - Misfire fault counter relevant

to the damage of each
P030100 cylinder catalyst
P030200 - The threshold value of

misfiring rate caused by
P030300 damage of three-way
catalytic
P030400 converter >6.5%-23%
- Misfiring fault counter
related to emission of every
- Misfire rate destroying - Circuit
cylinder that deteriorates
the catalyst
emission - The threshold - EMS
- Misfire rate aggravating value of misfiring rate that
the emission deteriorates emission >3.7% - Spark plug
- Non-trusted error - After startup, relevant - Ignition coil

emission misfire fault count
P130B00 in the first count cycle.
- The threshold value of
misfiring rate that
deteriorates emission >3.7%
- Engine speed: 500 <speed
<5800
- Intake temperature: >
-30°C
NL-3 01/2016
3. Circuit diagram:
Main Cylinder No.1 ignition coil Cylinder No.2 ignition Cylinder No.3 ignition Cylinder No.4 ignition
relay coil coil coil ES
ER05
Notice
- If the control system saves all the other DTCs besides misfire DTC, firstly conduct troubleshooting for these DTCs.
- If there is no misfire when the vehicle is sent to the maintenance station, road test the vehicle again to make misfire fault
reappear. And use the fault diagnostic scanner to record EMS data during misfire to be favorable for fault cause analysis.
- In case of road test of the vehicle for a long period, if the DTC related to misfire still fails to be saved, the fault may be
caused by the following reasons:
- The fuel tank is too full; misfire is caused when the mixture is too rich since the fuel enters the evaporation emission control
system.
- Improper fuel combustion leads to misfire.
- Spark plug stain leads to misfire due to failed ignition.
- According to the faulty position of the DTC, conduct basic system check.
- After repair, road test the vehicle to confirm the DTC not saved.
(a) Check whether the harness connector contacts poorly

or is aged or loose.
(b) Check whether the vacuum pipe has damage,
loosening, air leakage, etc.
Next step
NL-3 01/2016

interface.
mode to ON state.
scanner.
ES
(e) Read DTC.

P030100, P030200,
No
P030300, P030400,
P130B00
P030000, P030100,
P030200, P030300, Yes
P030400, P130B00

fault codes
Yes
Step 3 Check vacuum pipe and intake system.
(a) Check whether carbon canister solenoid valve

vacuum pipe connection is not correct, air leakage.
(b) Check whether brake vacuum booster vacuum pipe
connection is not correct, air leakage.
(c) Check whether pipeline of intake
pressure/temperature sensor is incorrectly connected and
with air leakage.
(d) Check whether pipeline of air mass flowmeter is
incorrectly connected and with air leakage.
(e) Check whether pipeline of supercharging pressure
sensor is incorrectly connected and with air leakage.
(f) Check whether the connection of positive crankcase
ventilation valve and ventilation pipe is incorrect, air
leakage.
(g) Check whether the intake system has air leakage.
(h) Are the above faults available?
Yes Handle faulty position and go to step

17.
No
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(a) Remove the spark plug in the misfire cylinder.

(b) Check whether the spark plug clearance is too big or
small.
Standard clearance: 0.8~0.9mm (0.031~0.035in)
(c) Check whether the spark plug's electrode eroded,
damaged.
(d) Check whether the spark plug skirt and electrode are ES
humid, or with serious gasoline smell.
(e) Reinstall the spark plug.
(f) Confirm whether the above faults are available
Yes Replace the spark plug
No
Step 5 Check whether the spark plug arcing is normal.

(a) Conduct spark test.
(b) Remove ignition wire of the misfire cylinder.
(c) Disconnect all cylinder fuel injector connectors.
(d) Install the spark plug to the ignition conductor.
(e) Start the engine (engine running time no more than
5s) and check arcing state.
(f) Reconnect all cylinder fuel injector connectors.
(g) Mount ignition wire
(h) Confirm whether the spark plug arcing is normal.
Notices
The following conditions shall be met before executing
this procedure:
2. Engine startup time no more than 5s.
No Go to step 9
Yes
Step 6 Check compression pressure of the misfire cylinder.
(a) For specific steps, please refer to check on cylinder

pressure.
(b) Confirm whether cylinder compression pressure is
normal.
Yes Go to step 10
No
Check the reason for low cylinder compression pressure. Please refer to the section about check
Step 7
on cylinder pressure.
Yes
Step 8 Check fuel and fuel injector of the misfire cylinder.
NL-3 01/2016
(a) Check whether the fuel injector has leakage,

blockage.
(b) Check whether oil is abnormal.
(c) Are the above faults available?
Notices
ES The following conditions shall be met before executing
this procedure:
2. Engine startup time no more than 5s.
Yes Handle faulty position and go to step

17.
No
Step 9 Check whether the misfire cylinder is arcing with normal spark plug.
(a) Replace the mounted spark plug with the normal spark
plug.
(b) Conduct spark plug test
(c) Remove ignition wire of the misfire cylinder.
(d) Disconnect all cylinder fuel injector connectors.
(e) Mount the spark plug to the ignition wire
(f) Start the engine (engine running time no more than 5s)
and check arcing state.
(g) Reconnect all cylinder fuel injector connectors.
(h) Mount ignition wire
(i) Confirm whether the spark plug arcing is normal.
No Check ignition coil and wire and go to

Step 17
Yes
Replace the spark plugs, and go to
Step 17
Next step
Step 10 Check EMS control terminal voltage of the misfire cylinder fuel injector.
NL-3 01/2016

mode to OFF state.
(b) Disconnect the EMS harness connector EN35.
EN35 engine management system (plug-in part A) harness (c) Operate the starter switch to turn the power supply
connector 1 mode to ON state.
(d) Measure terminal voltage of EMS harness connector ES
EN35 according to the table below.
Connector terminal Standard value

11~14V
No Check fuel injector circuit
Yes
Step 11 Check the misfire cylinder valve clearance.
(a) Confirm whether valve clearance is normal
No Adjust valve clearance and go to step

17
Yes
Step 12 Check the timing system.
(a) Refer to timing chain and tensioner and confirm

whether valve timing is normal.
No Adjust timing and go to the step 17.
Yes
(a) Refer to fuel pressure test procedure to confirm

whether the fuel pressure is normal.
No Check fuel system, high/low fuel

pump, fuel filter and fuel pipeline and
go to the step 17.
Yes
Step 14 Check whether the data display is normal in the list of data stream.
NL-3 01/2016
(a) Check data of intake pressure/temperature sensor.

(b) Check data of air mass flowmeter.
(c) Check data of supercharging pressure sensor.
(d) Check the engine coolant temperature sensor data.
(e) Check electronic throttle position sensor.
ES
(f) Confirm whether the above components are normal.
No Replace the broken component and

go to step 17
Yes

Yes
Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
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DTC DTC P032100 P032200

P032100 Crankshaft TDC tooth missing signal unreasonable

ES
The speed sensor is an element inside the engine management system. The sensor installed on the engine body is used for
detecting crankshaft position and speed. Rotation of signal wheel gives rise to alternation of the magnetic field at internal
induction point of the speed sensor. The alternating magnetic field is sensed by differential Hall chip and alternating magnetic
signals sensed are converted to electric signals by the processing circuit inside the sensor and then output.
The speed sensor circuits consist of following circuits:
- Reference voltage circuit: EMS provides reference voltage to the terminal 2 of the speed sensor harness connector EN29
through the terminal 7 of EMS harness connector EN35.
- Signal circuit: EMS receives signal voltage from the terminal 1 of speed sensor harness connector EN29 through the
terminal 23 of EMS harness connector EN35.
- Low reference voltage circuit: EMS provides low reference voltage circuit to the terminal 3 of speed sensor harness
connector EN29 through the terminal 22 of EMS harness connector EN35.

(control strategy)
- Speed signal is interfered - Signal error event

P032100
counter> 12
- Circuit
- Camshaft revolutions
without detected speed - Crankshaft position
signal >6 sensor
P032200 - The speed signal is lost
- Engine speed: > 400r/min - EMS
- Vehicle speed< 1km/h
or > 25km/h
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3. Circuit diagram:
Engine speed sensor
ES Main
relay
ER05
Notice

on sensor working
(a) Check whether sensor harness connector is correctly
connected, and the existence of loose, poor connection
and so on.
(b) Check whether the sensor is correctly mounted.
Yes
Step 2 Read engine data (engine speed) in the fault diagnostic scanner.
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interface.
mode to ON state.
scanner.
(d) Select following menu items: engine/engine data
flow/engine speed data. ES
Standard value: normal data, refer to datasheet/active
test
(e) If the engine can't start, check the data when the
engine is running.
(f) If the fault diagnostic scanner shows the engine speed
at "0", it indicates the harness between the speed sensor
and EMS has open circuit or short circuit.
(g) Confirm whether the data flow complies with standard.
No Intermittent fault. Please refer to the

section about check on intermittent
faults.
Yes

mode to OFF state.
(b) Disconnect the speed sensor harness connector
EN29.
EN29 Engine speed sensor harness connector (c) Operate the starter switch to turn the power supply
mode to ON state.
(d) Measure the voltage between terminal 1 of vehicle
speed sensor harness connector EN29 and reliable
grounding.
(e) Connect speed sensor harness connector EN29.
No Go to step 7
Yes
Step 4 Check sensor internal low reference circuit.

mode to OFF state.
EN29.
EN29 Engine speed sensor harness connector
(c) Measure the resistance between terminal 3 of the
grounding
(d) Connect speed sensor harness connector EN29.
value.
No
Go to step 9
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Yes
Step 5 Measure sensor signal output.
(a) Start the engine. Use a vehicle use oscilloscope to

check whether the signal waveform output from the
ES terminal 2 of speed sensor EN29 is normal.
(b) Confirm whether the above is normal.
No Go to step 8
Yes

mode to OFF state.
EN29.
(d) Measure the resistance between terminal 1 of speed
sensor harness connector EN29 and terminal 7 of EMS
harness connector EN35, and check for open circuit.
(e) Measure the resistance between terminal 1 of the
grounding, and check whether the circuit is short to
ground.
(f) Measure the voltage between terminal 1 of the speed
sensor harness connector EN29 and reliable grounding,
and check whether the circuit is short to power supply.

connector 1 EN29(1)-EN35(7) Less than 1 Ω
resistance
Resistance between 10kΩ or higher

EN29(1) and reliable
grounding
Voltage between EN29(1) 0V

Next step
NL-3 01/2016
Step 7 Check signal circuit of the speed sensor.

mode to OFF state.
EN29.
EN29 Engine speed sensor harness connector (c) Disconnect the EMS harness connector EN35. ES
speed sensor harness connector EN29 and the terminal
there is broken circuit, or repair the faulty part.
(e) Measure the resistance between terminal 2 of speed
and check whether the circuit is short to ground, or else
repair the faulty position.
grounding, and check whether there is to short circuit
connector 1
EN29(1)-EN35(23)
Less than 1 Ω
resistance
Resistance between
grounding

0V
Next step
Step 8 Check low voltage reference circuit of sensor.

mode to OFF state.
EN29.
EN29 Engine speed sensor harness connector (c) Disconnect the EMS harness connector EN35.
speed sensor harness connector EN29 and the terminal
there is broken circuit, or repair the faulty part.
(e) Measure the voltage between terminal 3 of speed
and check whether the circuit is short to power supply, or
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EN29(3)-EN35(22)
Less than 1 Ω
resistance
connector 1
0V
ES
Yes

shortage, etc.
(b) Check whether the installation position of signal disc
teeth is correct.
Yes
Step 10 Refer to “Replacement of crankshaft position sensor” to replace sppeed sensor.
Next step

Yes
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P032516 P032517 P032700 P032714 P032800 P032815 P138600


ES
P032517 Knock sensor signal circuit voltage too high
P032700 Multiple circuit fault in signal end of knock sensor (too low voltage)
P032714 Multiple circuit fault in signal end of knock sensor (too low voltage)
P032800 Multiple circuit fault in signal end of knock sensor (too high voltage)
P032815 Multiple circuit fault in signal end of knock sensor (too high voltage)
P138600 Knock signal control unreasonable
KS sensor's feedback signal on EMS enables EMS's control over the ignition timing at the most ideal state; the ignition system
reaches the optimum performance and meanwhile prevents the potential knock damage on the engine. The knock sensor is
located on the cylinder block of engine. The AC signal voltage generated by the knock sensor varies with the vibration level
during the running of the engine. The engine management system adjusts the ignition timing according to the amplitude and
frequency of knock sensor signal.
EMS receives signal from terminal 1 and 2 of knock sensor harness connector EN30 via terminal 25 and 10 of EMS harness
connector EN35.
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(control strategy)
- Knock identification
reference voltage:
0.2V-1V, thresholds are ES
different for different
speeds.
- Number of consecutive
- Detected signal scope
P032516 occurrences: 30
lower
- Water temperature: >
40°C
- Speed: > 2800 U/min
- Identification of cylinder
No. 1: valid
- Knock identification
reference voltage: 320V,
the upper limit diagnosis is
turned off.
P032517 occurrences: 30
higher
- Speed: non-dynamic
- Load: non-dynamic
- - The knock control circuit - Circuit
is free from fault. - EMS
P032700 - Average voltage at knock - Shock sensor
sensor port:'<-0.7V
lower - Load: non-dynamic
P032714
- Limp home: not activated
- - Speed > 1,000r/min
P032800 - Average voltage at knock

sensor port:>1 V
P032815
higher - Load: non-dynamic
- Limp home: not activated
- - Speed > 1,000r/min
occurrences: 24
- Knock integral signal abnormalities in 100
P138600 monitoring combustion cycles.
- Knock window monitoring - Number of consecutive
occurrences: 2
abnormalities in 3s.
NL-3 01/2016
3. Circuit diagram:
Knock sensor
ES
Notice

on sensor working
(a) Check whether knock sensor has physical damage.
(b) Check whether the knock sensor is correctly installed;
too tight or loose torque will lead to set DTC.
(c) Whether knock sensor's installing surface has burr,
cast trimming and foreign substance.
(d) The knock sensor must stay away from the hose,
bracket and engine circuits.
(e) Confirm whether the above components are normal.
No Handle faulty position and go to step 9
Yes
Step 2 Read engine data (engine speed) in the fault diagnostic scanner.
NL-3 01/2016

interface.
mode to ON state.
(c) Select "Engine"/"Read data stream"/"Knock sensor
signal 1".
(d) Start the engine and make it operate in the normal ES
operation temperature.
(e) During vehicle road test, read the engine speed data
displayed by the fault diagnosis scanner.
Standard value: normal data, refer to datasheet/active
test
(f) Confirm whether the data is normal.
No Go to step 4
Yes
Step 3 Intermittent fault. Please refer to “Check on intermittent fault”.
Next step
Step 4 Measure resistance between two terminals of the knock sensor

mode to OFF state.
(b) Disconnect knock sensor harness connector EN30.
(c) Measure the resistance between two terminals of
knock sensor.
EN30 Knock sensor harness connector
Standard resistance value: 4.9±20%MΩ
(d) Connect knock sensor harness connector EN30.
value.
No Replace the knock sensor. Please

refer to “Knock sensor “and go to the
step 9
Yes

mode to OFF state.
(b) Disconnect harness connector EN30 of the knock
sensor.
EN30 Knock sensor harness connector (d) Measure the resistance between terminal 1 of knock
harness connector EN35, and check for open circuit,
otherwise repair the faulty position.
knock sensor harness connector EN30 and reliable
grounding, check whether there is to ground short circuit,
knock sensor harness connector EN30 and reliable
circuit, or else repair the faulty position.
NL-3 01/2016

standard value.
Test item: Standard value:

connector 1
ES Resistance between EN30(1)
10kΩ or higher

0V
reliable grounding
No Repair the faulty position, and go to

Step 9.
Yes

mode to OFF state.
(b) Disconnect knock sensor harness connector EN30.
EN30 Knock sensor harness connector
(d) Measure the resistance between terminal 2 of knock
harness connector EN35, and check for open circuit.
(e) Measure the resistance between terminal 2 of knock
and check whether the circuit is short to ground.
(f) Measure the voltage between terminal 2 of knock
and check whether the circuit is short to power supply.
(g) Confirm whether the values meet standard values.

connector 1 10kΩ or higher

0V
reliable grounding
No Repair the faulty position, and go to

Step 9.
Yes
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Yes
ES
Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P044413 P045811 P045912

P044413 Carbon column control valve control circuit open

ES
P045811 Canister control valve control circuit voltage too low
P045912 Canister control valve control circuit voltage too high
Canister solenoid valve functions to intake the fuel steam into the intake manifold from the evaporation emission canister.
Canister solenoid valve uses the pulse width modulation (PWM) control mode. The circuit composition is:
- Operation voltage: the battery arrives at terminal 2 of the canister solenoid valve harness connector EN16 via terminal 87 of
the EMS controlled main relay.
- EMS control circuit: conductivity between the terminal 1 of carbon canister solenoid valve harness connector EN16 and the
terminal 35 of EMS harness connector EN35. EMS interior is equipped with a drive circuit to control the solenoid valve
grounding. The drive circuit is equipped with a feedback circuit to EMS; EMS determines whether the control circuit is open,
short to ground or power supply via feedback voltage monitor.

(control strategy)
- Voltage:> 2.5 V and <5.8

V
- System voltage: > 10.7 V
- Connecting circuit
and <16.01 V
- Fuel rail pressure
- Voltage: < 2.5 V sensor
P045811 - Circuit short to ground - System voltage: > 10.7 V - High pressure oil
and <16.01 V pump
- EMS
- Current: > 4 A
P045912 - System voltage:> 10.7 V
supply
and <16.01V
NL-3 01/2016
3. Circuit diagram:
Carbon
canister solenoid
Main relay
ER05
ES
Notice
Step 1 Use the fault diagnostic scanner to conduct active test on the canister solenoid valve.

interface.
(b) Disconnect the vacuum pipe between the carbon
canister solenoid valve and the carbon canister vacuum
pipe.
(c) Start engine and open the fault diagnostic scanner.
(d) Enter query of menu: “engine”/”action test”/“carbon
canister solenoid valve”.
(e) Use the fault diagnostic scanner to open "Canister
solenoid valve", and press the control valve vacuum
interface with finger and check whether there is suction
force.

No
Step 2 Measure the resistance of carbon canister control valve assembly.
NL-3 01/2016

mode to OFF state.
(b) Disconnect canister solenoid valve harness connector
EN16.
(c) Measure the resistance between two terminals of the
carbon canister solenoid valve.
ES
Standard resistance: 20 ℃ （68 ℉）22~30Ω
(d) Connect harness connector EN16 of the carbon
canister solenoid valve.
value.
No Replace the carbon canister solenoid

valve and go to the step 7
Yes
Step 3 Measure operating power supply of the exhaust control valve.

mode to OFF state.
EN16.
EN16 Carbon canister control valve harness connector
mode to ON state.
(d) Measure the voltage between the terminal 2 of carbon
canister solenoid valve EN16 and the reliable grounding.
(e) Connect harness connector EN16 of the carbon
canister solenoid valve.
No Go to step 6
Yes
Step 4 Check control circuit of carbon canister solenoid valve.

mode to OFF state.
EN16.
EN16 Carbon canister control valve harness
connector (c) Disconnect the EMS harness connector EN35.
carbon canister solenoid valve harness connector EN16
check whether there is broken circuit, or repair the faulty
part.
and reliable grounding, check whether the circuit is short
to ground, or else repair the faulty position.
position.
NL-3 01/2016

standard value.

connector 1 EN16(1)-EN35(35) resistance Less than 1 Ω
Resistance between EN16(1) ES

10kΩ or higher

0V
reliable grounding
Yes
Step 5 Measure operating power circuit of the control valve.

mode to OFF state.
(b) Disconnect the EN16 carbon canister control valve
EN16 Carbon canister control valve harness harness connector.
connector
(c) Disconnect the EMS main relay ER05.
and terminal 87 of main relay, check whether there is
open circuit, otherwise repair the fault position.
(e). Measure the resistance value between terminal 2 of
and reliable grounding, check whether there is open
circuit, otherwise repair the fault position.
(f) Measure the voltage value between terminal 2 of
and reliable grounding, check whether there is open
Engine compartment fuse relay box circuit, otherwise repair the fault position.
EN16 (2)- main relay (87) Less than 1 Ω

10kΩ or higher

0V
reliable grounding
Yes
NL-3 01/2016

ES Yes
Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P048013 P06344B P069111 P069212


ES
P06344B Low-speed fan internal chip temperature too high
P069212 Cooling fan relay control circuit voltage is too high (low speed)
operation of the relay via terminal 27, 28 of the harness connector CA01. EMS interior is equipped with a drive circuit to control

strategy)
- System voltage:> 2.5 V and

<5.8 V
and <16.01 V
P06344B - Circuit temperature too - System voltage: > 10.7 V

high and <16.01 V - Circuit
- EMS
- Voltage < 2.5 V
- Fan relay
P069111 - Circuit short to ground - System voltage: > 10.7 V
and <16.01 V
- Current > 4 A
P069212 - Circuit short to power
supply - System voltage: > 10.7 V
and <16.01 V
NL-3 01/2016
3. Circuit diagram:
ES
Main relay
ER05

Cooling
fan

interface.
mode to ON state.
scanner.
(e) Read DTC.

No
P06344B, P069111, P069212
P048013, P06344B, P069111,
Yes
P069212

fault codes
Yes
Step 2 Check fuse EF08 of low-speed fan.
NL-3 01/2016
(a) Whether fuse EF08 of the low-speed fan has blown

Engine compartment fuse relay box out.
No Go to step 4
ES
Yes
Step 3 Overhaul the circuit of low-speed fan fuse EF08.
(a) Check circuit of low-speed fan fuse EF08.

Engine compartment fuse relay box (b) Repair short to ground fault of the low-speed fan
power circuit.
(d) Whether the cooling fan works normally.
No
Step 4 Check the voltage of the terminal 30 of low-speed fan relay ER04.
(a) Operate starter switch to ON state.

Engine compartment fuse, relay box (b) At the same time, use a multimeter to check the
voltage of the terminal 30 of low-speed fan relay ER04.
Yes Go to step 6
NL-3 01/2016
No
(a) Use a multimeter to check the voltage of the terminal

ES Engine compartment fuse, relay box 85 of the low-speed fan relay ER04.
(b) Does the voltage conform to the standard value?
Yes Go to step 7
No
Check the open circuit fault between the terminal 30 of low-speed fan relay ER04 and low-speed
Step 6
fan fuse EF08.
(a) Check the open circuit fault between the terminal 30 of

low-speed fan relay ER04 and low-speed fan fuse EF08.
(b) Whether the cooling fan works normally.
No
Check the conduction between terminal 26 of EMS harness connector CA01 and the grounding
Step 7
circuit.
(a) Operate the ignition switch so as to set the mode ON.

(b) Connect a test lamp between EMS harness connector
CA01 terminal 26 and the body grounding circuit.
connector 2 (c) Use a diagnostic scanner to carry out "Action test" on
pump relay.
(g) Does test lamp light up?
No Go to step 9
Yes
Step 8 Replace low speed fan relay ER04.
NL-3 01/2016
(a) Replace low speed fan relay ER04.

No
ES

Engine compartment fuse, relay box 87 of the low-speed fan relay ER04.
No
Go to step 11
Yes
Step 10 Check the voltage of the terminal 1 of cooling fan harness connector CA28.
(a) Use a multimeter to check the voltage of the terminal 1

of the cooling fan harness connector CA28.
CA28 Cooling fan harness connector
Yes Go to step 12
No
Check the circuit between the terminal 1 of cooling fan harness connector CA28 and the terminal
Step 11
87 of low-speed fan relay ER04.
NL-3 01/2016
(a) Check the circuit between the terminal 1 of cooling fan

harness connector CA28 and the terminal 87 of
low-speed fan relay ER04.
(b) Repair open circuit fault between the terminal 1 of
CA28 Cooling fan harness connector cooling fan harness connector CA28 and the terminal 87
of low-speed fan relay ER04.
ES (c) Whether the cooling fan works normally.
No
Check the circuit between the terminal 3 of cooling fan harness connector CA28 and the grounding
Step 12
point on vehicle body.
(a)Check resistance between cooling fan harness

connector CA28 terminal 3 and the body grounding with a
multimeter to confirm the grounding circuit continuity.
CA28 Cooling fan harness connector Standard resistance value: less than 1 Ω
(b) Whether grounding circuit of the cooling fan is normal.
Yes Go to step 14
No
Repair the circuit between the terminal 3 of cooling fan harness connector CA28 and the grounding
Step 13
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cooling fan harness connector CA28 and the grounding

ES
No
Step 14 Replace cooling fan.
(a) Replace cooling fan.

Next step
(a) Replace EMS, please refer to ”Engine ECU”.
No

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P048113 P063449 P069311 P069412


ES
P063449 High-speed fan internal chip temperature is too high
P069412 Cooling fan relay control circuit voltage is too high (high speed)
operation of the relay via terminal 27, 28 of the harness connector CA01. EMS interior is equipped with a drive circuit to control

strategy)
- System voltage:> 2.5 V and

<5.8 V
and <16.01 V
- Circuit temperature too - System voltage: > 10.7 V

P063449 - Circuit
high and <16.01 V
- EMS
- Voltage < 2.5 V
- Fan relay
and <16.01 V
- Current > 4 A
P069412 - System voltage: > 10.7 V
supply
and <16.01 V
NL-3 01/2016
3. Circuit diagram:
ES
Main relay ER05

Cooling
fan

interface.
mode to ON state.
scanner.
(e) Read DTC.

P063449, P069311, No
P069412
P048113, P063449,
Yes
P069311, P069412

fault codes
Yes
Step 2 Check high-speed fan fuse EF07.
NL-3 01/2016
(a) Whether fuse EF07 of the high-speed fan has blown

out.
No Go to step 4
ES
Yes
Step 3 Check circuit of high-speed fan fuse EF07.
(a) Check circuit of low-speed fan fuse EF07.

(b) Repair short to ground fault of the low-speed fan
power circuit.
(d) Whether the cooling fan works normally.
No
Step 4 Check the voltage of the terminal 30 of high-speed fan relay ER03.
(a) Operate starter switch to ON state.

Engine compartment fuse relay box (b) At the same time, use a multimeter to check the
voltage of the terminal 30 of high-speed fan relay ER03.
Yes Go to step 6
NL-3 01/2016
No

86 of the high-speed fan relay ER03.
Engine compartment fuse relay box ES
Yes Go to step 7
No
Check the open circuit fault between the terminal 30 of high-speed fan relay ER03 and the
Step 6
low-speed fan fuse EF07.

Engine compartment fuse relay box high-speed fan relay ER04 and the high-speed fan fuse
EF08.
No
Step 7
circuit.
NL-3 01/2016

connector 2
(c) Use a diagnostic scanner to carry out "Action test" on
pump relay.
ES (g) Does test lamp light up?
No Go to step 9
Yes
Step 8 Replace high speed fan relay ER03.
(a) Replace high speed fan relay ER03.

No

87 of the high-speed fan relay ER03.
No
Go to step 11
Yes
Step 10 Check the voltage of the terminal 2 of cooling fan harness connector CA28.
NL-3 01/2016
(a) Use a multimeter to check the voltage of the terminal 2

of the cooling fan harness connector CA28.
CA28 Cooling fan harness connector (b) Does the voltage conform to the standard value?
Yes Go to step 12 ES
No
Check the circuit between the terminal 2 of cooling fan harness connector CA28 and the terminal
Step 11
87 of high-speed fan relay ER03.
(a) Check the circuit between the terminal 2 of cooling fan

harness connector CA28 and the terminal 87 of
high-speed fan relay ER03.
(b) Repair open circuit fault between the terminal 2 of
cooling fan harness connector CA28 and the terminal 87
of high-speed fan relay ER03.
(c) Whether the cooling fan works normally. Check the
circuit between the terminal 2 of cooling fan harness
connector CA28 and the terminal 87 of high-speed fan
relay ER03.
No
Check the circuit between the terminal 3 of cooling fan harness connector CA28 and the grounding
Step 12
NL-3 01/2016
(a)Check resistance between cooling fan harness

connector CA28 terminal 3 and the body grounding with a

(b) Whether grounding circuit of the cooling fan is normal.
ES
Yes Go to step 14
No
Repair the circuit between the terminal 3 of cooling fan harness connector CA28 and the grounding
Step 13

cooling fan harness connector CA28 and the grounding
No
Step 14 Replace the cooling fan.
(a) Replace cooling fan.

Next step
No
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P050022 P050029 P050123 P05012F

P050022 The vehicle speed exceeds the maximum permissible value

ES
P050029 The vehicle speed signal from CAN is in fault
P050123 Vehicle speed sensor signal delay
P05012F Vehicle speed sensor signal unreasonable fault
The vehicle speed signal is used to monitor the vehicle running speed, and is one of the reference signals for EMS to control
fuel cut-off during sudden deceleration. The vehicle speed signal is provided by the wheel speed sensor to ABS and ABS
further sends to engine management system EMS after calculation.

strategy)
Vehicle speed exceeds the
P050022 Speed: more than 275 km/h
reasonable range.
The vehicle speed signal - EMS
P050029 Monitor vehicle speed signal
comes from CAN
- Circuit
Monitor power drive level of
P050123 SPI bus or signal fault - ESP
DVE
Monitor power drive level of
P05012F SPI bus or signal fault
DVE
3. Circuit diagram:
Gateway
NL-3 01/2016
Step 1 Carry out road test, and confirm whether the vehicle speed displays on the instrument properly.
(a) If the vehicle speed displayed in the instrument is

normal, the vehicle speed signal output and circuit are
normal.
(b) If the vehicle speed displayed in the instrument is not ES
normal, there may be fault on vehicle speed signal output
or circuit.
(c) Confirm whether the instrument displayed vehicle
speed is normal.
Yes Go to step 3
No

interface.
mode to ON state.
scanner.
(e) Read DTC.

P050029, P050123, No
P05012F
P050022, P050029,
Yes
P050123, P05012F
fault codes
Yes

Yes
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTCs.

Yes
NL-3 01/2016
DTC P050600 P050700

P050600 Idle control speed lower than target idle speed

ES
P050700 Idle control speed higher than target idle speed
The throttle actuator control motor is under the control of engine management system (EMS). Throttle valve body internal DC
motor drives throttle. In order to reduce idle speed and meanwhile change the ignition time and fuel supply, engine
management system commands the throttle to close. By reducing the air flow into the engine, idle speed is lowered. In order to
increase idle speed, the engine management system commands the throttle to open, so that more air flow passes through the
throttle.
Engine management system (EMS) calculates and controls engine idle speed target based on coolant temperature, vehicle
speed compensation, deceleration adjustment, A/C compensation and voltage compensation.

(control strategy)
- Positive deviation
between target value and
actual value> 100 rpm
- Duration> 7 s
- Idle speed is lower than - Altitude correction factor>
P050600
the target speed. 0.72
- Altitude < 2,700 m - Circuit
- Intake temperature > 0 °C - EMS
- Time after starting>= 2 s - Electronic throttle
- Carbon canister
- Positive deviation solenoid valve
between target value and
actual value> 100 rpm - Fuel pressure and so
- Duration> 7 s forth
- Idle speed is higher than - Altitude correction factor>
P050700
the target speed. 0.72
- Altitude < 2,700 m
- Intake temperature > 0 °C
- Time after starting>= 2 s
NL-3 01/2016
3. Circuit diagram:
Main
ES relay
ER05
Electronic throttle
Notice

interface.
mode to ON state.
scanner.
(e) Read DTC.

No
P050700
P050600, P050700 Yes

fault codes
Yes
NL-3 01/2016
Step 2 Check the vacuum hose and intake manifold for damage and leakage phenomenon.
(a) Check the vacuum hose and intake manifold for

damage and leakage phenomenon.
b) Confirm the relevant intake hose for leakage.
(c) Is it normal?
ES
No Repair or replace faulty position
Yes
Step 3 Make the throttle relearn.
(a) Connect fault diagnostic scanner and make the

electronic throttle learn again.
No
Step 4 Check the fuel pressure, is it normal?
(a) Detect fuel pressure.

(b) Check the fuel pressure, is it normal?
No Overhaul the fuel system
Yes
Step 5 Check the circuit of EMS power supply.

Yes
Step 6 Is canister solenoid valve working properly?
(a) Is canister solenoid valve working properly?
No Replace the canister solenoid valve
Yes
Step 7 Replace the electronic throttle body.
(a) Replace the electronic throttle body and check

whether the fault is eliminated.
Yes
Troubleshooting.
NL-3 01/2016
No

ES (b) Carry out the learning of engine speed sensor.
Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P010184 P010185 P010216 P010317

The flow through the air flowmeter is too low (exceeding the lower limit of the allowable
P010184 ES
reasonable range)
The flow through the air flowmeter is too high (exceeding the upper limit of the allowable
P010185
reasonable range)
P010216 Mass air flowmeter circuit voltage is too low
P010317 Mass air flowmeter circuit voltage is too high
The air mass flowmeter (HFM) functions to measure air mass flow sucked by the engine. There is a heating diaphragm at the
center of the sensor chip and temperature declines linearly from the heating diaphragm to the edge of chip. Two thermistors
are arranged symmetrically at two sides of the heating diaphragm. When no air flows by, temperature at positions of two
thermistors is the same and thus they have the same resistance; when air flows by, the upstream area will be cooled by the air,
air temperature above the two thermistors become different and thus the two thermistors have different resistances.
Resistance difference of the two thermistors is processed by the aftertreatment circuit to voltage or frequency signal related to
air flow value and sent to EMS.
- Temperature sensor (pin 1)
- Flowmeter 12V power supply (pin 2)
- Flowmeter grounding (pin 3)
- Signal output (pin 5)

(control strategy)
- Air inflow deviation:

compare the difference
between air inflow passing
over the throttle and the
maximum air inflow
obtained from model
calculation:
- (A) * (B) > (C) ,(A) - the air
inflow passing by the
- The intake flow through throttle - Circuit
the throttle exceeds the
P010184 - (B) - the maximum - EMS
maximum intake flow
calculated by the model allowable deviation for air - Sensor
inflow coming from HFM;
- (C) - the maximum air
inflow obtained from
model calculation.
- Air flowmeter signal circuit
is effective.
- Crankshaft revolutions>
400
NL-3 01/2016

(control strategy)
- Air inflow deviation:

compare the difference
between air inflow passing
over the throttle and the
ES
minimum air inflow
obtained from model
calculation:
- (A) * (B) < (C) ,(A) - the air
inflow passing by the
- The intake flow through throttle
the throttle exceeds the
P010185 - (B) - the maximum
minimum intake flow
calculated by the model allowable deviation for air
inflow coming from HFM;
- (C) - the minimum air
inflow obtained from - Circuit
model calculation - EMS
- Air flowmeter signal circuit - Sensor
is effective.
- Crankshaft revolutions>
400
- Intake flow signal cycle

- After starting the engine,
from HFM <50us
the intake flow exceeds
P010216
the limit due to the HFM - Engine start complete
short to ground
- System voltage > 10 V
- Intake flow signal cycle

- After starting the engine,
from HFM >800us
the intake flow exceeds
P010317
the limit due to the HFM - Engine start complete
short to power supply
- System voltage > 10 V
NL-3 01/2016
3. Circuit diagram:
Air mass flowmeter

Main relay
ER05 ES
Notice

on sensor working
(b)Air flow is blocked up.
(c) Loose or improperly installed.
(d) Water ingress into the sensor.
Next step
Step 2 Measure 12V power supply of the sensor.
NL-3 01/2016

mode to OFF state.
(b) Disconnect harness connector EN25 of the air mass
flowmeter.
EN25 air mass flowmeter harness connector (c) Operate the starter switch to turn the power supply
mode to ON state.
ES
(d) Measure the voltage between terminal 2 of air mass
flow eter harness connector EN25 and reliable grounding.
(e) Connect harness connector EN25 of the air mass
flowmeter.
No Go to step 6
Yes

mode to OFF state.
flowmeter.
mode to ON state.
(d) Measure the voltage between terminal 4 of air mass
flow eter harness connector EN25 and reliable grounding.
flowmeter.
No Go to step 7
Yes
Step 4 Measure the sensor grounding circuit.

mode to OFF state.
flowmeter.
mode to ON state.
(d) Measure the resistance between terminal 3 of the air
mass flowmeter harness connector EN25 and reliable
grounding.
flowmeter.
value.
No Go to step 9
NL-3 01/2016
Yes
Step 5 Check heating resistance of the air mass flowmeter.

mode to OFF state.
ES
(b) Disconnect the air flowmeter harness connector
EN25.
(c) Measure resistance of the heater between terminal 1
and 3 of the air flowmeter.
Standard value: 1~6 Ω
(d) Connect the air flowmeter harness connector.
value.
No Go to step 10
Yes
Step 6 Measure 12V operating power circuit of the air mass flowmeter.

mode to OFF state.
flowmeter.
EN25 air mass flowmeter harness connector

(d) Measure the resistance between the terminal 2 of air
mass flowmeter harness connector EN25 and the
terminal 87 of main relay, and check whether there is
broken circuit, or repair the faulty part.
air mass flowmeter harness connector EN25 and reliable
grounding, and check whether there is short circuit to
ground, otherwise repair the faulty position.
(f) Measure the voltage between the terminal 2 of the air
Engine compartment fuse, relay box power supply, otherwise repair the faulty position.
standard value.

EN25 (2)- main relay (87) Less than 1 Ω
Resistance between
grounding
0V
Next step
NL-3 01/2016

mode to OFF state.
flowmeter.

ES (d) Measure the resistance between terminal 4 of air
mass flowmeter harness connector EN25 and terminal 7
of EMS harness connector EN35, and check whether
power supply, otherwise repair the faulty position.
EN35 engine management system (plug-in part A) harness Measured items Standard value
connector 1
EN25(4)-EN35(7)
Less than 1 Ω
resistance
Resistance between
grounding

0V
No
Yes

mode to OFF state.
flowmeter.

(d) Measure the resistance between terminal 5 of air
standard value.
NL-3 01/2016
EN25(5)-EN35(55)
EN35 engine management system (plug-in part A) harness Less than 1 Ω
connector 1
resistance
Resistance between
ES
grounding

0V
Yes

mode to OFF state.
flowmeter.
EN25 air mass flowmeter harness connector (c) Disconnect the EMS harness connector EN35.
(d) Measure the resistance between terminal 3 of air
(e) Measure the voltage between the terminal 3 of the air
EN25(3)-EN35(59)
Less than 1 Ω
connector 1
0V
Yes
Step 10 Replace air mass flowmeter.
NL-3 01/2016
Yes

ES (b) Check whether EMS grounding circuit is normal.
Yes
Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P010500 P010621 P010622 P010684 P010685 P010716 P010817

P010500 Intake pressure sensor signal no fluctuations

ES
P010621 Intake pressure sensor signal is less than the minimum limit
P010622 Intake pressure sensor signal is greater than the maximum limit
P010684 Intake pressure sensor signal is less than the model minimum pressure value
P010685 Intake pressure sensor signal is more than the model maximum pressure value
P010716 Intake pressure sensor signal circuit voltage too low
P010817 Intake pressure sensor signal circuit voltage too high
The intake pressure/temperature sensor is located on the intake manifold. Pressure sensor and intake temperature sensor are
integrated, through which EMS monitors absolute pressure and intake temperature inside the intake manifold at the rear of the
throttle. The intake pressure sensor consists of following circuits:
NL-3 01/2016

(control strategy)
- (A) - (B) < (C), (A) - the

maximum manifold
ES pressure detected; (B)-the
minimum manifold
pressure detected; (C)-
threshold value of stuck
P010500 - Adhesion rationality check
fault
- Engine temperature>
-5.3 °C
- Engine coolant
temperature> 30 °C
- Higher than the maximum - Intake pressure< 15 kPa

P010621
range - Engine speed > 80 rpm
- Lower than the minimum - Intake pressure> 110 kPa

P010622
range - Engine speed > 80 rpm
- Circuit
- (A) + (B) < (C), (A) - intake
- EMS
manifold pressure; (B) -
- Rationality check: deviation of intake - Air mass flowmeter
P010684 measured value is less manifold pressure; (C) - sensor
than the model value model value of intake
manifold pressure
- Engine speed > 80 rpm
- (A) + (B) < (C), (A) - intake

manifold pressure; (B) -
- Rationality check: deviation of intake
P010685 measured value is greater manifold pressure; (C) -
than the model value model value of intake
manifold pressure
- (SCG) circuit diagnosis: - Voltage < 0.15 V

P010716
short circuit to ground - Engine speed > 80 rpm
- (SCB) circuit diagnosis: - Voltage > 4.87 V

P010817
short to power supply - Engine speed > 80 rpm
NL-3 01/2016
3. Circuit diagram:
Intake temperature and pressure sensor
Main relay
ER05 ES
Notice

on sensor working
(b) Very fine crack of supercharge pressure sensor.
(c) Very fine crack of intake pressure/temperature sensor.
(d) The intake air flow is blocked up.
(e) Vacuum leakage.
(f) Leakage of air inflow.
(g) Check and confirm no leakage of exhaust exists,
Next step
NL-3 01/2016

mode to OFF state.
(b) Disconnect intake air pressure temperature sensor
harness connector EN17.
EN17 Intake pressure and temperature sensor harness
mode to ON state.
ES
(d) Measure the voltage between terminal 3 of the intake
air temperature pressure sensor harness connector EN17
(e) Connect intake air pressure and temperature sensor
No Go to step 5
Yes
Step 3 Check the sensor signal circuit
(a) Turn the digital multimeter to direct voltage position,

and connect its black probe with the reliable grounding
and its red probe with the terminal 4 of intake
pressure/temperature sensor.
EN17 Intake pressure and temperature sensor harness (b) Start the engine.
connector
(c) Quickly open the throttle and measure whether
voltage of the terminal 4 of intake pressure/temperature
sensor could reach 4.5V just in a moment and then
reduce to 1.5V.
(d) Confirm whether the above is normal.
No Go to step 6
Yes
Step 4 Measure the intake pressure and temperature sensor grounding circuit.

mode to OFF state.
mode to ON state.
pressure temperature sensor harness connector EN17
value.
No Go to step 7
NL-3 01/2016
Yes

mode to OFF state.
ES
connector (d) Measure the resistance between terminal 3 of the
intake pressure and temperature sensor harness
connector EN17 and terminal 58 of EMS harness
connector CA01, and check whether there is open circuit,
pressure and temperature sensor harness connector
EN17 and reliable grounding, and check whether the
circuit is short to ground, or else repair the faulty position.
(f) Measure the voltage between terminal 3 of the intake
air pressure and temperature sensor harness connector
EN17 and reliable grounding. Check whether there is
short circuit to power supply. Or else, repair the faulty
position.
connector 2
EN17(3)-CA01(58)
Less than 1 Ω
resistance
Resistance between
grounding

0V
No Go to Step 9.
Yes

mode to OFF state.
connector (d) Measure the resistance between terminal 4 of the
(f). Measure the voltage between terminal 4 of the intake
position.
NL-3 01/2016

standard value.
CA01 engine management system (plug-in part K) harness Measured items Standard value
connector 2
EN17(4)-CA01(63)
Less than 1 Ω
resistance
ES
Resistance between
grounding

0V
No Go to step 9
Yes

mode to OFF state.
(d) Measure the resistance between terminal 1 of the
(e) Measure the voltage between terminal 1 of the intake
position.

connector 2 EN17(1)-CA01(14)
Less than 1 Ω
resistance

0V
No
Yes
Next step
NL-3 01/2016

ES
Yes
Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P011216 P011317 P011100

P011216 Intake temperature sensor signal circuit voltage too low

ES
P011317 Intake temperature sensor signal circuit voltage too high
P011100 Intake temperature sensor signal unreasonable
The intake pressure/temperature sensor is located on the intake manifold. Pressure sensor and intake temperature sensor are
integrated, through which EMS monitors absolute pressure and intake temperature inside the intake manifold at the rear of the
throttle. Temperature sensor element is a resistance with negative temperature coefficient NTC. The intake pressure sensor
consists of following circuits:
A 5V reference voltage (pin 3)
A low level reference voltage (pin 1)
Intake pressure signal (pin 4)
Intake temperature sensor 2 signal (pin 2)

(control strategy)
- Intake temperature sensor

- (SCG) circuit diagnosis: voltage < 0.097656V
P011216
short circuit to ground - Starter switch mode ON
(2s)
- Circuit
- Intake temperature sensor
- EMS
- (SCB) circuit diagnosis: voltage> 4.902344V
P011317 - Sensor
short to voltage - Starter switch mode ON
(2s)
- Circuit fault of intake - Unreasonable signal of

P011100
temperature sensor intake temperature sensor
NL-3 01/2016
3. Circuit diagram:
Intake temperature and

pressure sensor
Main
relay
ER05 ES
Notice

on sensor working
(b) Very fine crack of intake pressure/temperature sensor.
(c) The intake air flow is blocked up.
(d) Vacuum leakage.
(e) Leakage of air inflow.
Next step
NL-3 01/2016

mode to OFF state.
EN17 Intake pressure and temperature sensor harness connector
mode to ON state.
ES
(d) Measure the voltage between terminal 3 of the intake
air temperature pressure sensor harness connector EN17
No Go to step 5
Yes
Step 3 Check the sensor signal circuit

mode to OFF state.
EN17 Intake pressure and temperature sensor harness connector (c) Measure the resistance between the terminal 1 and
the terminal 2 of the intake pressure/temperature sensor.
Standard resistance value:20 ℃ （68 ℉）2375~2625Ω
value.
No Go to step 8.
Yes
Step 4 Measure the intake pressure and temperature sensor grounding circuit.

mode to OFF state.
EN17 Intake pressure and temperature sensor harness connector (c) Operate the starter switch to turn the power supply
mode to ON state.
pressure temperature sensor harness connector EN17
value.
No Go to step 7.
NL-3 01/2016
Yes

mode to OFF state. ES
EN17 Intake pressure and temperature sensor harness connector (c) Disconnect the EMS harness connector CA01.
position.
connector 2 (g) Confirm whether the measured value is normal.

EN17(3)-CA01(58)
Less than 1 Ω
resistance
Resistance between
grounding
0V
Yes

mode to OFF state.
EN17 Intake pressure and temperature sensor harness connector (d) Measure the resistance between terminal 2 of the
connector EN35, and check whether there is open circuit,
position.
NL-3 01/2016
EN17(2)-EN35(38)
Less than 1 Ω
connector 1 resistance
ES Resistance between
grounding

0V
Yes

mode to OFF state.
EN17 Intake pressure and temperature sensor harness connector

(e) Measure the voltage between terminal 1 of the intake
position.

EN17(1)-CA01(14)
resistance

0V
No
Next step
Next step
NL-3 01/2016


ES
Yes
Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P011600 P011716 P011817

P011600 Engine coolant temperature sensor signal unreasonable

ES
P011716 Engine coolant temperature sensor circuit voltage is too low
P011817 Engine coolant temperature sensor circuit voltage is too high
Engine coolant temperature sensor is a variable resistance with negative temperature coefficient to measure the engine water
temperature. EMS obtains voltage signals through the terminal 14 of its harness connector EN35 to judge the water
temperature is high or low and provides its internal low reference voltage to the terminal 3 of engine coolant temperature
sensor connector EN50 through the terminal 57 of EN35. EMS will constantly record signals of the temperature sensor
internally and collects signals of the temperature sensor to judge on and off time of the cooling fan so as to make the engine
always in the optimal working state. Through the engine coolant temperature sensor, EMS can judge also whether engine
works normally.

(control strategy)
- (A) - (B)> (C) with

calculation deviation, (A) -
model temperature;(B) -
- Check on low temperature Measured temperature;
P011600 (C) - threshold
rationality
- Maximum reference value
of water temperature:
60 °C - Circuit
- Engine coolant sensor - EMS

- (SCG) circuit short to voltage< 0.097656V - Sensor
P011716
ground - Starter switch mode ON
(2s)
- Engine coolant sensor

- (SCB) circuit short to voltage> 4.902344V
P011817
power supply - Starter switch mode ON
(2s)
NL-3 01/2016
3. Circuit diagram:

Main
relay ES
ER05
Warning!
Refer to “Cooling system maintenance warning” in “Warnings and notices”.
Notice
Notices
Never use the combustible anti-freezer under any circumstance, such as alcohol. The combustible anti-freeze may lead to
serious fire accident.

on sensor working:
(a) Check whether the engine coolant temperature sensor
has erosion sign or the engine coolant leakage through
the sensor.
(b) Check whether the engine coolant level in the cooling
system storage tank is correct.
Next step
Step 2 Measure engine coolant temperature sensor resistance.
NL-3 01/2016

mode to OFF state.
(b) Disconnect engine coolant temperature sensor
the terminal 3 of the engine coolant temperature sensor.
ES
Standard resistance value:20 ℃ （68 ℉）1371~1649Ω
(d) Connect engine coolant temperature sensor harness
connector EN50.
value.
No Replace engine coolant temperature

sensor and go to Step 9.
Yes
Step 3 Measure engine coolant temperature sensor grounding circuit.

mode to OFF state.
EN50 Water temperature sensor harness harness connector EN50.
connector
mode to ON state.
engine coolant temperature sensor harness connector
EN50 and reliable grounding.
(e) Connect engine coolant temperature sensor harness
connector EN50.
value.
No Go to step 5
Yes
Step 4 Check the engine coolant temperature sensor signal circuit.

mode to OFF state.
EN50 Water temperature sensor harness
connector
EN50 and terminal 14 of EMS harness connector EN35,
check whether there is open circuit, or else, repair the
faulty position.
short circuit to ground. Or else, repair the faulty position.
(f) Measure the voltage between terminal 1 of the engine
coolant temperature sensor harness connector EN50 and
reliable grounding. Check whether there is short circuit to
power supply. Or else, repair the faulty position.
NL-3 01/2016
EN50(1)-EN35(14)
Less than 1 Ω
connector 1 resistance
grounding

0V
No Repair or replace faulty circuit.
Yes
Step 5 Check the engine coolant temperature sensor grounding circuit.

mode to OFF state.
EN50 Water temperature sensor harness harness connector EN50.
connector
EN50 and terminal 57 of EMS harness connector EN35,
check whether there is open circuit, or else, repair the
faulty position.
(d) Measure the voltage between terminal 3 of the engine
coolant temperature sensor harness connector EN50 and
reliable grounding. Check whether there is short circuit to
power supply. Or else, repair the faulty position.
(e) Confirm whether the measured value is normal.
EN50(3)-EN35(57)
Less than 1 Ω
connector 1
0V
No Repair or replace faulty circuit
Yes
NL-3 01/2016

ES Yes
Step 7 Replace the water temperature sensor.
Next step
Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P012129 P012216 P012317

P012129 Signal of electronic throttle position sensor 1 unreasonable

ES
P012216 Electronic throttle position sensor 1 signal circuit voltage too low

(control strategy)
- |TPS1-TPS2|>6.3 %
- |wdk1g-wdk3g|>|wdk2gwd
P012129 - Reasonableness check
k3g|
- |wdk1g-wdk3g|>9.0 V - Sensor circuit
- Signal voltage - Electronic throttle

- The upper limit is TPS2<0.176 V
P012216 - EMS
exceeded
- Time after starting>12.0 s
- The lower limit is - Signal voltage

P012317
exceeded TPS2>4.629 V
NL-3 01/2016
3. Circuit diagram:
Main
relay
ES ER05
Electronic throttle
Notice

on sensor working:
damaged.
Next step

interface.
mode to ON state.
scanner.
(e) Read DTC.
(f) Confirm that there is no other fault code.
NL-3 01/2016

No
P012216, P012317
P012129, P012216,
Yes
P012317
ES
fault codes
Yes

EN22 Electronic throttle harness connector terminal 6.
(d) Shut down the engine and set the ignition switch to
ON mode. Open the throttle fully, and measure the
voltage between terminal 6 and terminal 2.
No Go to step 7
No

mode to OFF state.
EN22.
mode to ON state.
EN22.
No Go to step 6
Yes
Step 5 Measure the throttle position sensor 1 grounding.
NL-3 01/2016

mode to OFF state.
EN22 Electronic throttle harness connector (b) Disconnect harness connector EN22 of the electronic
throttle sensor.
(c) Measure the resistance between terminal 2 of
ES grounding.
(d) Connect the electronic throttle harness connector
EN22.
value.
No Go to step 8
Yes
Step 6 Measure 5V reference voltage circuit of throttle position sensor 1.

mode to OFF state.
EN22 Electronic throttle harness connector EN22.
EN22(3)-EN35(12)
Less than 1 Ω
resistance
connector 1 Resistance between
grounding

0V
Next step
Step 7 Measure the throttle position sensor 1 signal circuit.
NL-3 01/2016

mode to OFF state.
EN22.
(d) Measure the resistance between terminal 6 of ES
EN22(6)-EN35(24)
Less than 1 Ω
resistance
Resistance between
grounding

0V
No
Next step
Step 8 Measure the throttle position sensor 1 grounding circuit.

mode to OFF state.
EN22 Electronic throttle harness connector throttle temperature sensor.
NL-3 01/2016

standard value?

connector 1 EN22(2)-EN35(44)
Less than 1 Ω
resistance
ES
Resistance between
grounding

0V
Yes

Yes
Next step
Next step
interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P013029 P013116 P013217 P013300 P219500 P219600 P223100 P224300 P225100 P309691
P309692 P309694 P309696 P241400 P262600

ES
P013029 Open IA circuit of upstream oxygen sensor
P013116 Upstream oxygen sensor signal circuit voltage too low
P013217 Upstream oxygen sensor signal circuit voltage too high
P013300 Upstream oxygen sensor dynamic response slow
P219500 Upstream oxygen sensor signal unreasonable - signal continuously too thin （Bank1）
P219600 Upstream oxygen sensor signal unreasonable - signal continuously too rich (Bank1)
P223100 The upstream oxygen sensor signal line is coupled with the heater wire (Bank2)
P224300 Open UN circuit of upstream oxygen sensor
P225100 Open VM circuit of upstream oxygen sensor
P309691 Maximum fault of upstream oxygen sensor CJ chip
P309692 Upstream oxygen sensor CJ chip signal fault
P309694 Minimum fault of upstream oxygen sensor CJ chip
P309696 Upstream oxygen sensor CJ chip unreasonable fault
P241400 Upstream oxygen sensor output voltage unreasonable
P262600 Open IP circuit of upstream oxygen sensor
Compared with the switching heating type oxygen sensor, the broadband heating type oxygen sensor (HO2S) can measure
oxygen content in the exhaust flow in a faster and more accurate manner. The broadband sensor consists of oxygen sensing
unit, oxygen pumping unit and heater. The exhaust is sampled through the bell-like gap between sensing unit and oxygen
pumping unit. The engine management system (EMS) provides signal voltage to the heating type oxygen sensor and uses the
voltage as the reference value for oxygen content inside the exhaust system. The electronic circuit inside the engine
management system controls pumping current passing over the oxygen pumping unit to make the signal voltage constant.
The engine management system monitors voltage change of the signal circuit and tries to increase or decrease current
magnitude or change current direction to the oxygen pumping unit to keep the voltage constant. The engine management
system could decide oxygen concentration in the exhaust by measuring current direction and current magnitude required to
keep the signal voltage constant.
The signal voltage is indicated by λ. When λ is 1, the theoretical air-fuel ratio is 14.7:1. λ keeps around 1 in normal operating
state. λ will be high or larger than 1 when air mixture in the fuel system is thin and oxygen content is high. λ will be low or
smaller than 1 when air mixture in the fuel system is thick and oxygen content is low. The engine management system just
uses the information to maintain correct air-fuel ratio.
The broadband heating type oxygen sensor consists of following circuits:
- Pumping current (pin 1)
- Low level reference voltage (grounding) (pin 2)
- Heater low level control (pin 3)
- Heater power voltage (pin 4)
- Regulating current (pin 5)
- Reference voltage (signal)(pin 6)
NL-3 01/2016

(control strategy)
- Front oxygen sensor

voltage (bank 1)> 4.8 V,
ES time of 10s
- Output voltage of the - Exhaust temperature of
P013029
oxygen sensor front oxygen sensor
<750.006 °C
and <16.1 V

- Integrated chip VM line
internal fault is detected
(minimum fault)（bank 1）
- Voltage of VM line< 1.75 V
- Integrated chip UN line
- VM/UN/IA line voltage (minimum fault)（bank 1）
P013116
comparison
- UN line voltage < 1.5 V
- Integrated chip IA line
- Voltage of IA line< 0.3 V
- Sensor circuit
- System voltage: <16.1 V
and >10.7 V - Sensor
- EMS
- Integrated chip VM line
- Voltage of VM line> 3.25 V
- Integrated chip UN line
- VM/UN/IA line voltage (minimum fault)（bank 1）
P013217
comparison
- UN line voltage > 4.4 V
- Integrated chip IA line
- Voltage of IA line> 7 V
- System voltage: <16.1 V
and >10.7 V
- Current air-fuel ratio

P219500 deviation>
0.099976(npl) >0.07(max)
- In excess of the scope
- Current air-fuel ratio
P219600 deviation<
-0.099976(sig)<-0.07(min)
NL-3 01/2016

(control strategy)
P223100 - Front oxygen sensor

output voltage（bank 1）
P224300 <= 1.50977V
P013300 - Front oxygen sensor ES
output voltage（bank 1）>=
P225100 1.49023V
- Duration>= 10 s
- Air-fuel ratio control output
change rate (bank 1)>
0.100006
- Change the air-fuel ratio
- System voltage: < 16.1 V
control and oxygen sensor
and > 10.7 V
voltage
- The absolute amplitude
value required for air-fuel
P262600 ratio control is (bank 1)>=
0.007996
- Temperature of ceramic
body of front oxygen
sensor （ bank
1）>=755.006 °C
- Heating duty cycle output
- Sensor circuit
of the oxygen sensor
during warm-up - Sensor
process>= 100%
- EMS
- Front oxygen sensor in
the air: front oxygen
sensor voltage after
deviation
correction>3.70117 V
the air: voltage deviation
after deviation
correction<4.80957 V
- Target air-fuel ratio< 1.6
- Check on reasonableness - Front oxygen sensor in air
P241400 of voltage signal of front and characteristic curve
oxygen sensor gain of the sensor is lower
(air-fuel ratio> 1.05 or
<0.95)
the air: front oxygen
sensor voltage after
deviation correction>2.5 V
the air: voltage deviation
after deviation
correction<3.06006 V
NL-3 01/2016
3. Circuit diagram:
ES Rear oxygen sensor Front oxygen sensor
Main
relay
ER05
Notice

on sensor working
(c) During the engine is working under over temperature,
check whether the exhaust pipe is too red.
Next step
Step 2 Check high level signal circuit.
NL-3 01/2016

mode to OFF state.
EN05 upstream oxygen sensor harness EN05.
connector
mode to ON state.
ES
(d) Measure the front oxygen sensor harness connector
EN05 terminal 6 to ground voltage.
Standard voltage value: 2.9V
Yes Go to step 11
No
Step 3 Check the fault of high level signal circuit.
(a) Check the fault of high level signal circuit.

(b) Check whether the circuit is short to the voltage end if
higher than the standard value.
(c) Check whether the circuit is open or short to the
ground if lower than the specified value.
(d) Confirm the circuit fault is eliminated.
Next step
Step 4 Check low level signal circuit.

mode to OFF state.
EN05 upstream oxygen sensor harness (b) Disconnect front oxygen sensor harness connector
connector EN05.
mode to ON state.
Yes Go to step 11
No
Step 5 Check the fault of low level signal circuit.
(a) Check the fault of low level signal circuit.

Next step
NL-3 01/2016
Step 6 Check the output pumping current circuit.

mode to OFF state.
EN05 upstream oxygen sensor harness (b) Disconnect front oxygen sensor harness connector
connector EN05.
ES (c) Operate the starter switch to turn the power supply
mode to ON state.
Yes Go to step 11
No
Step 7 Check the fault of output pumping current circuit.
(a) Check the fault of output pumping current circuit.

(d) Confirm the circuit fault is eliminated.
Next step
Step 8 Check the input pumping current circuit.

mode to OFF state.
EN05 upstream oxygen sensor harness

connector EN05.
mode to ON state.
Yes Go to step 11
No
Step 9 Check the fault of input pumping current circuit.
NL-3 01/2016
(a) Check the fault of input pumping current circuit.

(d) Confirm the circuit fault is eliminated. ES
Next step
Step 10 Check signal circuit.

mode to OFF state.
CA01 engine management system (plug-in part K) harness EN05.
connector 2
(d) Measure the resistance among terminals 1, 2, 5 and 6
of the front oxygen sensor harness connector EN05.
EN05.
value.
No Check short circuit fault of the signal

circuit.
EN05 upstream oxygen sensor harness
connector
Yes

Next step
Step 12 Replace the front oxygen sensor.
Next step
NL-3 01/2016
Next step
ES
interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P056000 P056200 P056300 U300384 U300385

P056000 System battery voltage signal unreasonable

ES
P056200 System battery voltage too low
P056300 System battery voltage too high
U300384 The voltage of battery is lower than limit (CAN diagnosis)
U300385 The voltage of battery is higher than limit (CAN diagnosis)

- Constant power supply of the battery arrives at the terminal 12 of EMS harness connector CA01 through EF03 10A fuse.
- Operate the ignition switch to set the power mode in the state ON. Power supply of the battery arrives at IF15 10A fuse
through the ignition relay 1 and finally comes to the terminal 13 of EMS harness connector CA01.
- When EMS monitors that terminal 13 of the EMS harness connector CA01 has battery voltage, EMS controls terminal 14 of
the CA01 to pass the internal grounding, since terminal 14 of the CA01 is connected with terminal 86 of the main relay, the
main relay closes.
- After the main relay is closed, battery power supply reaches terminals 44, 45 and 63 of EMS harness connector CA01
through terminal 30 of the main relay.

(control strategy)
- System voltage < 2.54 V

P056000 - Reasonableness check - Starter switch is in the ON
state
- System voltage < 9 V

- Check the low voltage is - Engine idle speed> 640 to
P056200
low 840 rpm
- Time after starting> 180 s
- System voltage > 16.01 V

- EMS
- Engine idle speed> 640 to
- Generator
- Check the low voltage is 840 rpm
P056300 - Circuit
high - Time after starting> 180 s
- Vehicle speed> 20.00
Kmph
- Battery voltage is lower

- ECM receives low voltage
U300384 than the limit value (CAN
alarm from CAN network
diagnosis)
- Battery voltage is higher - ECM receives high

U300385 than the limit value (CAN voltage alarm from CAN
diagnosis) network
NL-3 01/2016
3. Circuit diagram:
Main
ES relay
ER05
Step 1 Check the EF09 fuse.

(b) Remove fuse EF09 from the engine compartment fuse
box.
connected.
(d) Confirm whether it is connected.
No Check whether there is short circuit,

and replace the fuse.
Yes
NL-3 01/2016

mode to OFF state.
CA01 engine management system (plug-in part K) harness (c) Operate the starter switch to turn the power supply
connector 2
mode to ON state.
(d) Measure the voltage between the terminal 69/3/5/6 of ES
EMS harness connector CA01 and the reliable grounding.
No Go to step 4
Yes

mode to OFF state.
connector 2
(c) Measure the resistance between terminal 1 of EMS
harness connector CA01 and reliable grounding.
Standard resistance: Less than 1 Ω
EMS harness connector CA01 and reliable grounding.
Standard resistance: Less than 1 Ω
No
EMS grounding circuit is faulty. Repair
the faulty position.
Yes
Step 4 Check the charging system.

Yes
NL-3 01/2016

Next step
ES Step 6 Use fault diagnostic scanner to confirm whether DTC is stored again.

interface.
mode to ON state.
(c) Clear DTCs.

Yes
NL-3 01/2016
DTC P057129

ES
The brake lamp switch is a signal transmission switch. When the brake pedal is trod, the brake lamp switch provides EMS with
a signal from the terminal 1 to the terminal 19 of EMS and controls connection of the brake lamp circuit.

(control strategy)
- Brake lamp switch signal

is disconnected.
- Brake switch
- EMS does not receive - Vehicle braking, system
P057129 signal of the brake lamp enters the diagnostic - Circuit
switch window.
- EMS
- DTCs appear after
repeatedly brakes.
3. Circuit diagram:
Main relay
ER05
Brake lamp
switch
Operate the ignition switch to set the power mode in the ON state and tread the brake pedal to
Step 1
observe whether the high-mounted brake lamp is on.
(a) Tread the brake pedal to observe whether the

high-mounted brake lamp is on.
NL-3 01/2016
Yes Go to step 5
No
Step 2 Check IF17 and IF29.

ES
(a) Set the ignition switch to OFF mode.
Indoor fuse, relay box (b) Check whether IF17 and IF29 have blown out.
Yes Replace the damaged fuse
Rated capacity: IF17 10A IF29 10A
No
Step 3 Measure the conductivity between pin 3 and pin 1 of the brake switch.
(a) Disconnect brake switch harness connector CA09.

(b) Depress the brake pedal.
(c) Measure the resistance between the pin 3 and the pin
1 of the brake switch.
(d) Confirm whether the measured value meets the
standard value.
No Replace the brake switch.
Yes
Step 4 Check circuit between terminal 3 of brake lamp switch CA09 and fuse IF29.
(a) Measure resistance between terminal 3 of brake

switch CA09 and fuse IF29.
(b) Confirm whether the resistance meets the standard
CA09 brake pedal harness connector
value.
No Check harness open fault.
NL-3 01/2016
ES
Yes
Step 5 Check the circuit between brake switch and engine EMS.

mode to OFF state.
(b) Disconnect brake switch harness connector CA09.
(c) Disconnect engine harness connector CA01.
brake switch harness connector CA09 and the terminal
19 of EMS harness connector CA01 and check whether
the circuit is short.
brake switch harness connector CA09 and the reliable
ground.
Standard resistance value: 10 kΩ or higher
(f) Measure the voltage between the terminal 1 of brake
switch harness connector CA09 and the reliable
power supply.
connector 2 Standard voltage value: 0V
standard value.
Yes
Step 6 Measure the conductivity between pin 2 and pin 4 of the brake switch.
NL-3 01/2016
(a) Disconnect brake switch harness connector CA09.

(b) Measure the resistance between the pin 2 and the pin
4 of the brake switch.
CA09 brake pedal harness connector (c) Confirm whether the measured value meets the
ES standard value.
No Replace the brake switch.
Yes
Check the circuit between the terminal 4 of brake switch harness connector CA09 and the fuse
Step 7
IF17.
(a) Measure the resistance between the terminal 4 of the

brake switch harness connector CA09 and the fuse IF17.
Standard resistance value: less than 1Ω
CA09 brake pedal harness connector value.
Yes
Step 8 Check the circuit between brake switch and engine EMS.
NL-3 01/2016

mode to OFF state.
(b) Disconnect brake switch harness connector CA09.
(c) Disconnect engine harness connector CA01.
brake switch harness connector CA09 and the terminal ES
24 of EMS harness connector CA01 and check whether
the circuit is short.
brake switch harness connector CA09 and the reliable
ground.
Standard resistance value: 10 kΩ or higher
(f) Measure the voltage between the terminal 2 of brake
switch harness connector CA09 and the reliable
power supply.
connector 2 Standard voltage value: 0V
standard value.
Yes
Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P060616 P060617 P060644 P060645 P060143 P060149 P060100

ES DTC Fault descriptions
P060616 ECU controller fault (5V undervoltage fault)
P060617 ECU controller fault (5V overvoltage fault)
P060143 Electronic control unit RAM fault (EEP reading fault)
P060149 Electronic control unit RAM fault (EEP writing fault)
P060100 The calculation of checksum of EEPROM for wiring configuration is in fault (unreasonable)
The diagnostic program is used for checking whether microprocessors inside engine management system (EMS) and throttle
actuator control (TAC) system are under good conditions. The diagnostic program can diagnose also whether engine
management system is programmed.
The engine management system monitors capacity of its own read-write memory. It monitors counting function too.
Processor of the engine management system and the control processor of throttle actuator are used to monitor data of throttle
control system. The two processors monitor data of each other mutually to confirm whether the calculated value of accelerator
pedal position is correct.

(control strategy)
- 5V overvoltage monitoring
P060616 - Check on internal logic
fault
- 5V undervoltage
P060617 - Check on internal logic
monitoring fault
- Internal logic and

P060644 - Software rest (type 1) verification and check
error
- EMS
- DSM software reset (type
P060645 - Internal logic check failure
2)
P060143 - Check on internal logic - EEP reading fault
P060149 - Check on internal logic - EEP writing fault
P060100 - Check on internal logic - Calculation fault
NL-3 01/2016
3. Circuit diagram:
Main relay
ER05 ES

interface.
mode to ON state.
scanner.
(e) Read DTC.

P060617, P060644,
No
P060645, P060143,
P060149, P060100
P060616, P060617,
P060644, P060645,
Yes
P060143, P060149,
P060100

fault codes
NL-3 01/2016
Yes

ES (b) Check whether EMS grounding circuit is normal.
No
Repair the faulty position
Yes
(a) Replace EMS, please refer to the section about

“Engine ECU”.
(b) Confirm that the system is normal.
Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P060629 P060647 P060648 P060649 P060661 P060662 P060663 P060691 P060692 P060693
P060694 P060696 P060697 P133600

ES
P060629 Fault of electronic throttle security monitoring function (first layer safe fuel cutting-off monitoring
fault)
P060647 Fault of electronic throttle security monitoring function (monitoring model feedback fault)
P060648 Fault of electronic throttle security monitoring function (monitoring erroneous response fault)
P060649 Fault of electronic throttle security monitoring function (monitoring model inquiry fault)
P060661 Fault of electronic throttle security monitoring function (ignition angle signal, harness or ECU fault)
P060662 Fault of electronic throttle security monitoring function (reasonableness fault of second layer
accelerator pedal signal)
P060691 Electronic throttle safety monitoring function fault (overvoltage causes DVE drive shutdown fault)
P060692 Fault of electronic throttle security monitoring function (second layer engine speed monitoring
fault)
P060693 Fault of electronic throttle security monitoring function (second layer safe fuel cutting-off
monitoring fault)
P060694 Fault of electronic throttle security monitoring function (second layer torque monitoring fault)
P060663 The safety monitoring function fault for electronic throttle (start/stop monitoring fault )
P060696 Fault of electronic throttle security monitoring function (AD converter monitoring fault)
P060697 Electronic throttle valve safety monitoring fault (AD given voltage test fault)
P133600 Electronic throttle safety monitoring torque limit function
NL-3 01/2016

(control strategy)
P060400
- Verification and
ES P060443 calculation fault of offline
configuration EEPROM
P060449
- Software reset DSM

software reset (Type 1) - Internal logic and
P060616 verification and check
- Software reset DSM
software reset (Type 1) error
- - Internal logic check
- Torque protection error failure
- EMS controller fault (5V
overvoltage monitoring - EMS
P060617 fault)
- EMS controller fault (5V
undervoltage monitoring
fault)
- The first layer of safety

- First level safety fuel
P060629 monitoring engine speed
cutoff monitoring fault
exceeds the limit.
P060644 - Software reset DSM - Internal logic and

software reset (Type 1) verification and check
error
P060645 - Software reset DSM
software reset (Type 1) - Internal logic check failure
- Feedback fault of
P060647
monitoring module
- Monitoring false response

P060648
fault
- Inquiry fault of monitoring

P060649
module
- Monitoring false response

P060661
fault - Internal logic check failure
- Second level accelerator

P060662 pedal signal
reasonableness fault
- EMS
- Overvoltage leads to fault
P060691
of DVE drive cutoff
- Second level engine

P060692
speed monitoring fault
P060693
- Second layer of safety
- Second level safety fuel
P060694 monitoring engine speed
cutoff monitoring fault
exceeds the limit
P060696
- Monitoring fault in given - Set voltage is <4.727[V]

P060697 voltage test of AD or >4.829[V] during test of
converter digital analog converter
NL-3 01/2016
3. Circuit diagram:
Main relay
ER05 ES
Electronic throttle
Notice

on sensor working:
damaged.
Next step

interface.
mode to ON state.
scanner.
(e) Read DTC.
NL-3 01/2016

P060647, P060648,
P060649, P060661,
P060662, P060663,
No
P060691, P060692,
ES P060693, P060694,
P060696, P060697,
P133600
P060629, P060647,
P060648, P060649,
P060661, P060662,
P060663, P060691, Yes
P060692, P060693,
P060694, P060696,
P060697, P133600

fault codes
Yes

terminal 6.
(d) Shut down the engine and operate the ignition switch
to turn power supply to ON mode. Open the throttle fully,
and measure the voltage between terminal 6 and terminal
2.
Yes Go to step 7
No
NL-3 01/2016

mode to OFF state.
EN22.
mode to ON state.
ES
EN22.
No Go to step 6
Yes
Step 5 Measure the throttle position sensor grounding.

mode to OFF state.
throttle sensor.
(c) Measure the resistance between terminal 2 of
grounding.
(d) Connect the electronic throttle harness connector
EN22.
value.
No Go to step 8
Yes
Step 6 Measure 5V reference voltage of throttle position sensor.

mode to OFF state.
EN22.
NL-3 01/2016
EN35 engine management system (plug-in part A) harness EN22(3)-EN35(12) resistance Less than 1 Ω
connector 1
ES 10kΩ or higher

0V
reliable grounding
Next step
Step 7 Measure the throttle position sensor signal circuit.

mode to OFF state.
EN22.

10kΩ or higher

0V
reliable grounding
Next step
Step 8 Measure the throttle position sensor grounding circuit.
NL-3 01/2016

mode to OFF state.
EN22.
(d) Measure the resistance between terminal 6 of ES
EN22(2)-EN35(44)
Less than 1 Ω
resistance
Resistance between
grounding

0V
Yes

Yes
Next step
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P062713 P062811 P062912


ES
P062912 Fuel pump relay control circuit voltage too high
The coil working power supply of the fuel pump relay is supplied by EMS controlled main relay. EMS controls fuel pump relay
terminal 85 grounding via terminal 28 of EMS harness connector CA01; the fuel pump relay engages. EMS interior is equipped
with a drive circuit to control relay coil grounding; the drive circuit is equipped with a feedback circuit to EMS; EMS determines
whether the control circuit is open, short to ground or to power supply via feedback voltage monitor.

(control strategy)
P062713 - Open power circuit - 2.5 V> Voltage < 5.8 V

- Relay circuit
P062811 - Circuit short to ground - Voltage < 2.5 V
- Relay
- Circuit short to power - EMS
P062912 - Current > 4 A
supply
3. Circuit diagram:
Main relay
ER05
Fuel pump relay

ER09
Fuel Pump
NL-3 01/2016

interface.
ES mode to ON state.
scanner.
(e) Read DTC.

No
P062811 and P062912
P062713, P062811,
Yes
P062912

fault codes
Next step
(a) Is the fuel pump fuse EF20 blown out?

No Go to step 3
Yes
Step 3 Repair-fuel pump fuse EF20 circuit.
NL-3 01/2016
(a) Check fuel pump fuse EF20 circuit.

Engine compartment fuse relay box (b) Repair-fuel pump power supply circuit short to ground
fault.
Rated capacity: 15A
(d) Is the fuel pump working properly? ES
No

mode to ON state.
(b) At the same time, use a multimeter to check the
voltage between the terminal 3 of fuel pump relay ER09
Yes Go to step 10
No
Step 5 Check open circuit fault between terminal 30 of fuel pump relay ER09 and fuel pump fuse EF20.
(a) Check open circuit fault between terminal 3 of fuel

Engine compartment fuse relay box pump relay ER09 and fuel pump fuse EF20.
NL-3 01/2016

ES
No

Engine compartment fuse relay box mode to ON state.
(b) Use a multimeter to check the voltage between the
terminal 1 of fuel pump relay ER09 and the reliable
grounding point.
Yes Go to step 10.
No
Step 7 Repair the main relay circuit fault.
(a)Repair the main relay circuit fault.

No
Step 8
circuit.
NL-3 01/2016

connector 2 (c) Use a diagnostic scanner to carry out "Action test" on
pump relay.
(d) Does test lamp light up? ES
No Go to step 11.
Yes

No
(a) Check the fuel pump relay ER09 terminal 87 voltage

with a multimeter.
Yes Go to step 11.
No
Step 11 Replace the fuel pump relay ER09.
(a) Replace the fuel pump relay ER09.

No
NL-3 01/2016
(a) Use a multimeter to check the voltage between the

terminal 1 of fuel pump harness connector SO26 and the
ES S026 Fuel pump harness connector
Yes Go to step 14.
No
Overhaul the circuit between fuel pump harness connector SO26 terminal 1 and fuel pump relay
Step 13
ER09 terminal 87.
(a) Check circuit between fuel pump harness connector

SO26 terminal 1 and the fuel pump relay ER09 terminals
5.
(b) Repair open circuit fault between fuel pump harness
S026 Fuel pump harness connector connector SO26 terminal 1 and the fuel pump relay ER09
terminal 5.
(c) Is the fuel pump working properly?
No
NL-3 01/2016
(a)Check resistance between fuel pump harness

connector SO26 terminal 4 and the body grounding with a
(b) Is fuel pump grounding circuit normal?
Yes
ES
Go to step 15.
No
Step 15 Repair the circuit between terminal 4 of fuel pump harness connector SO26 and body grounding.
(a)Repair circuit open fault between fuel pump harness

connector SO26 terminal 4 and the body ground.
S026 Fuel pump harness connector Yes The system is normal.
No
(a) Replace the fuel pump.

Next step
Step 17 The system is normal.
NL-3 01/2016
DTC P062B08 P062B29 P062B86

P062B08 High pressure fuel injector drive level signal fault

ES
P062B29 High pressure fuel injector drive level unreasonable fault
P062B86 High-pressure fuel injector drive level minimum fault
The diagnostic program is used for checking whether microprocessor inside the engine management system (EMS) is under
good conditions. EMS could detect fault of control equipment inside the high pressure fuel injector.

(control strategy)
P062B08
- Communication fault of - Engine speed > 1,200 rpm
P062B29 internal control module of - EMS
high pressure fuel injector - System voltage > 7 V
P062B86
3. Circuit diagram:
Main relay
ER05
NL-3 01/2016

interface.
mode to ON state.
scanner.
ES
(e) Read DTC.
(f) Confirm that there is no other fault code.

DTC other than P062B08,
No
P062B29, P062B86
P062B08, P062B29, P062B86 Yes

fault codes
Yes

Yes

Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P063491 P064513 P064611 P064712

P063491 The temperature of A/C compressor internal chip is too high

ES
P064712 A/C compressor replay control circuit voltage too high
A/C compressor relay working power supply is provided by main relay which is controlled by EMS. EMS controls A/C
compressor relay internal grounding via terminal 42 of EMS harness connector CA01; the relay engages. EMS interior is

(control strategy)
- Circuit temperature too - System voltage:> 10.7 V - A/C compressor inside

P063491
high and <16.01 V, takes 0.5s Chip
- System voltage:> 2.5 V

and <5.8 V
and <16.01 V
- Circuit
- Voltage > 2.5 V
- EMS
and <16.01 V - Relay
- Voltage > 4 V
P064712 - System voltage: > 10.7 V
supply
and <16.01 V
NL-3 01/2016
3. Circuit diagram:
Main relay ES
ER05
A/C control panel
A/C pressure switch A/C relay

ER02
A/C
compressor
clutch
Step 1 Check DTC relevant to A/C system
(a) Read the fault code relating to A/C system.

(b) Repair DTC indicated faults.
(c) Clear DTC fault code.
(d) Whether the A/C clutch is working normally?
No
Step 2 Identify the fault of A/C system.
(a) Perform maintenance according to the following fault symptom table.
Symptoms Suspected faulty position Maintenance plan
1. ECT sensor fault 1. Replace ECT

2. ECT sensor harness fault 2. Repair ECT harness
Engine coolant temperature 3. The engine cooling 3. Replace thermostat
is too low system operation in the
4. Overhaul EMS, if
large circulation state
necessary, replace it
4. EMS fault
NL-3 01/2016
1. The pressure switch 1. Replace the pressure
shows the signal of the A/C switch
pressure not conforming to 2. Repair the pressure
A/C pressure switch signal
the standard value switch harness
abnormality
2. Pressure switch harness 3. Overhaul EMS, if
fault necessary, replace it
3. EMS fault
ES 1. Replace outdoor
1. Display of outdoor
temperature sensor
temperature sensor
2. Repair outdoor
Temperature is lower than
Outdoor temperature temperature sensor
4 ℃
sensor signal abnormality harness
2. Outdoor temperature
3. Overhaul A/C control
module, and replace it if
necessary.
1. Evaporator temperature 1. Replace the evaporator
sensor displays that the temperature sensor
temperature is lower than 2. Evaporator outdoor
Evaporator temperature 2 ℃ (35.6℉ ) temperature sensor
sensor signal abnormality harness
2. Evaporator temperature 3. Overhaul A/C control
sensor harness fault module, and replace it if
3. A/C control module fault necessary.
1. Drain the excessive filled
refrigerant
2. Maintain bad cooling fault
1. The high pressure of A/C of the vehicle
is higher than 3.14MPa 3. Maintain bad operation
Coolant pressure
(455.4psi) fault of the engine
abnormality
2. A/C low pressure is lower 4. Overhaul interior
than 0.196MPa (28.4 psi) blockage fault of the A/C
system
5. Overhaul A/C system
leakage fault.
(b) Determine fault repair finished
(c) Whether the A/C clutch is working normally?
No
Step 3 Check compressor fuse
(a) Check compressor fuse EF06

Engine compartment fuse relay box Rated value of the fuse: 10A
(b)Confirm whether fuse is burn-out.
Yes Replace compressor fuse EF06.
No
NL-3 01/2016
(a) Check whether compressor clutch power supply circuit

is short to ground.
(b) Whether the A/C clutch is working normally?
Yes The system is normal. ES
No
Step 5 Detect compressor clutch power supply terminal voltage
(a) Start up engine, press A/C control switch (A/C switch)

and check voltage of the terminal 1 of compressor
Standard voltage value: 11-14V
EN21 A/C compressor clutch harness connector
Yes Replace compressor clutch.
No

(b) Remove the compressor relay ER02.
(c) Disconnect compressor harness connector EN21.
compressor relay ER02 and the terminal 1 of compressor
NL-3 01/2016
EN21 A/C compressor clutch harness connector
ES
Yes
Step 7 Check the performance of compressor relay ER02.

mode to OFF state.
(b) Remove and replace the compressor relay ER02.
(c) Check whether the clutch works normally.
No Replace the compressor relay ER02.
Yes
Step 8 Check the supply voltage of compressor relay ER02.
(a) Measure the supply voltage of terminal 3 of

Engine compartment fuse relay box compressor relay ER02.
Standard voltage value: 11-14V
Yes
Step 9 Check the electromagnetic clutch of compressor.
(a) Connect the positive pole of battery with the binding

post, and connect the negative pole with the casing of
compressor.
(b) Check the electromagnetic clutch which is powered
on.
(c) Confirm whether the A/C clutch works normally.
NL-3 01/2016
No Replace the electromagnetic clutch.
Yes
Step 10 Check the EMS control circuit fuse EF10. ES
(a) Check whether the fuse EF10 in fuse box of engine

compartment has blown out, and whether the connecting
line of fuse is normal.
When replacing the fuse, please

No
check and repair the fuse harness if
necessary.
Yes
Step 11 Check the conductivity of harness between EMS and compressor relay ER02.

(b) Disconnect harness connector CA01 of EMS engine
management system.
ER02.
value.
NL-3 01/2016

connector 2
ES
Yes
Step 12 Check the conductivity of harness between compressor relay and fuse EF10.

mode to OFF state.
(b) Remove fuse EFL10.
(d) Measure the resistance between the fuse EF10 and
the terminal1 of relay ER02.
(e) Confirm whether the resistance meets standard value.
Yes
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(a) Replace EMS.

No
ES
Step 14 Check the conductivity of harness between A/C pressure switch and EMS.

mode to OFF state.
Harness connector 2 of CA01 engine management system (K)
plug-in part (c) Disconnect A/C pressure switch harness connector
EN09.
EMS harness connector CA01 and the terminal 3 of A/C
pressure switch harness connector EN09.
EMS harness connector CA01 and the terminal 4 of A/C
pressure switch harness connector EN09.
value.
EN09 A/C pressure switch harness connector No Check and repair the relevant harness
or terminal.
Yes
Step 15 Replace air conditioning pressure switch
(a) Replace A/C pressure switch

No
Step 16 Check the grounding circuit of A/C pressure switch.
NL-3 01/2016
(a) Remove the A/C pressure switch harness connector.

(b) Measure the resistance between terminal 2 of A/C
pressure switch harness connector EN09 and grounding.
EN09 A/C pressure switch harness connector
ES
Yes
Step 17 Check the harness between A/C pressure switch and A/C control panel.

mode to OFF state.
(b) Remove A/C pressure switch harness connector
EN09 A/C pressure switch harness connector EN09.
(c) Remove the A/C control panel harness connector
IP29.
(d) Measure the resistance between the air conditioning
pressure switch harness connector EN09 terminal 1 and
air conditioning control panel IP29 terminal 14.
value.
IP29 A/C control module harness connector
Yes
Step 18 Replace the A/C control panel.
NL-3 01/2016
(a) Replace the A/C control module.

Next step
Step 19 Troubleshooting. ES
NL-3 01/2016
DTC P064100 P065100 P069700 P069000


ES
P064100 System reference circuit A is open
P065100 System reference circuit B is open
P069700 System reference circuit C is open
P069000 Main relay output voltage is too high
The engine management system (EMS) has 3 internal 5V reference voltage buses, namely 5V reference voltage 1, 5V
reference voltage 2 and 5V reference voltage 3, where every reference voltage bus provides 5V reference voltage circuit to a
number of sensors. Therefore, fault of any 5V reference voltage circuit will affect other 5V reference voltage circuits connected
to the reference bus. The engine management system monitors voltage of 5V reference voltage bus.
(control strategy)
- Sensor power supply fault

P064100
(Type 1)
- Sensor power supply fault - Power supply mode is in

P065100 - Circuit
(Type 2) the ON state
- Sensor power supply fault

P069700
(Type 3)
3. Circuit diagram:
Main relay
ER05
NL-3 01/2016
(a) Check whether the main relay harness connector is

loose.
(b) Check whether the appearance of the main relay is
damaged. ES
(c) Check the housing and the vent hole of the engine
management system for blockage, contamination,
contaminant, snow or ice of any type.
(d) If any, clear the part carefully.
Yes Deal with the faulty position.
No

interface.
mode to ON state.
scanner.
(e) Read DTC.

P065100, P069700, No
P069000
P064100, P065100,
Yes
P069700, P069000
Yes Please refer to the table of diagnostic

fault codes
No
Step 3 Check the EMS fuse.

mode to OFF state.
(c) Check whether fuses EF09 and IF17 have blown out.
Rated capacity: EF09 30A IF17 10A
Yes Replace fuse.
NL-3 01/2016
ES
No
Step 4 Check operating voltage of EMS.

mode to OFF state.
Harness connector 2 of CA01 engine management system (K) plug-in (b) Disconnect the negative battery cable.
part
(d) l Connect the negative battery cable.
(e) Operate the starter switch to turn the power supply
mode to ON state.
(f) Measure the voltage between terminal 3/5/6 of CA01
the reliable grounding point.
(h) Does the measured value meet the standard?
No Repair or replace harness.
Yes

mode to OFF state.
Harness connector 2 of CA01 engine management system (K) plug-in
part (c) Disconnect the EMS harness connector CA01.
(d) Measure the resistance between the terminal 1/2/4 of
CA01 and the reliable grounding point.
Standard resistance value: less than 1 ohm
NL-3 01/2016
Yes
Step 6 Replace main relay.
Next step
ES

Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P154500 P154521 P154522 P155800 P155900 P155929 P157900 P156400 P156500 P156800
P156821 P156822 P157900

ES P154500 The position of electronic throttle is incorrect
P155800 Return spring check minimum fault
P155900 Self-learning fault for electronic throttle
P155929 The repeated self-learning fault for mechanical bottom dead center of electronic throttle
P157900 Electronic throttle self-learning condition not meet
P156400 System pressure cannot meet the requirements for electronic throttle self-learning
P156500 The initial self-learning fault for bottom dead center of electronic throttle
Electronic throttle valve body is a key component of the engine intake system in EMS system, and its main function is to adjust
the intake passage area according to driver's driving intention, thereby controlling the intake quantity and meeting intake
demand under different engine working conditions. At the same time, it feeds back the position signal of the throttle valve plate
to the control unit to achieve precise control.

(control strategy)
P156400 Power on, but do not start.
Check of voltage condition
P156500 Signal voltage
TPS1<0.212V>0.865V
Monitor learning position of
Signal voltage
P156821 the lower mechanical dead
TPS2<4.142V>4.841[V]
center
Self-learning activated
P155800
Initialization self-learning
P155900 completed - EMS
P155929 Duty ratio is >79.9988% - Electronic throttle

valve body dirty
P154500 Power on, but do not start.
- Electronic throttle
Test threshold value 3% valve mechanical fault
P154521
Monitor PID setup range Intake temperature 5.3°C - Electronic throttle
P156800 Environmental condition Speed: 0km/h valve circuit
P154522 check Off time > 0.3s
P157900 Test threshold value 0.3906
-2.4902[%]
Off time > 0.56s
P156822 Test threshold value
1.4893%
Speed <=250U/min
NL-3 01/2016
3. Circuit diagram:
Main relay
ER05
ES
Electronic throttle

mode to OFF state.
(c) Confirm whether the voltage meets standard value.
No Check the fault of charging system.
Yes

interface.
mode to ON state.
scanner.
(e) Read DTC.
NL-3 01/2016

P154521, P154522,
P155800, P155900,
P155929, P157900, No
P156400, P156500,
ES P156800, P156821,
P156822, P157900
P154500, P154521,
P154522, P155800,
P155900, P155929,
P157900, P156400, Yes
P156500, P156800,
P156821, P156822,
P157900

fault codes
Yes
Step 3 Clean electronic throttle valve body.
(a) Remove the electronic throttle body. Please refer to

“Electronic throttle body”.
(b) Clean electronic throttle valve body.
Next step
Step 4 Self-learning of electronic throttle body.
Next step

mode to OFF state.
EN35 engine management system (plug-in part A) harness EN22.
connector 1
(d) Measure the resistance between terminal 1 of EN22
Standard resistance value:10kΩ or higher
(e) Measure the voltage between terminal 1 of EN22 and
reliable grounding.
(f) Measure the conductivity between EN22 terminal 1
and EN35 terminal 20.
(g) Measure the voltage between terminal 4 of EN22 and
reliable grounding.
Standard resistance value:10kΩ or higher
(h) Measure the voltage between terminal 4 of EN22 and
reliable grounding.
NL-3 01/2016
(i) Measure the conductivity between EN22 terminal 4

and EN35 terminal 19.
EN22 Electronic throttle harness connector (j) Confirm whether the values meet standard value.
No Repair faulty position. ES
Yes

No
Yes
Next step
Next step

interface.
mode to ON state.
(c) Clear DTC.

Next step
NL-3 01/2016
DTC P212216 P212317

P212216 Electronic accelerator pedal position sensor 1 signal voltage too low
ES
- A 5V reference voltage circuit
- A low level reference voltage circuit
- A signal circuit
(control strategy)

- Deviation 1 between the
- The lower limit is - Circuit
P212216 pedal signals 1 and 2
exceeded
- EMS
- Signal voltage of pedal
position sensor 2>1.113V - Electronic accelerator
Pedal Position Sensor
- The upper limit is - Signal voltage >4.824 V
P212317
exceeded position sensor
NL-3 01/2016
3. Circuit diagram:
Accelerator pedal
ES
Notice

interface.
mode to ON state.
scanner.
(e) Read DTC.

No
P212317
P212216, P212317 Yes

fault codes
Yes
NL-3 01/2016
Check voltage of harness connector CA10 terminal 2 of electronic accelerator pedal position
Step 2
sensor.

mode to OFF state.
(b) Disconnect electronic accelerator pedal position
ES sensor harness connector CA10.
CA10 accelerator pedal harness
connector
mode to ON state.
reliable grounding.
No Go to step 6.
Yes
Step 3 Check resistance of harness connector CA10 terminal 3 of electronic accelerator pedal position
sensor to ground.

mode to OFF state.
CA10 accelerator pedal harness connector CA10.
connector
mode to ON state.
accelerator pedal CA10 and the reliable grounding point.
value.
No Go to step 6.
Yes
NL-3 01/2016

mode to OFF state.
CA01 engine management system (plug-in part K) harness connector CA10.
connector 2 (c) Disconnect the EMS harness connector CA01.
accelerator pedal harness connector CA10 and the ES
terminal 83 of EMS harness connector CA01, and check
whether there is broken circuit. As for standard value,
accelerator pedal harness connector CA10 and the
reliable grounding, and check whether the circuit is short
to the ground. As for standard value, please refer to the
table below.
reliable grounding point, and check whether the circuit is
short to power supply. As for standard value, please refer
to the table below.
CA10 accelerator pedal harness Measured items Standard value

connector
CA10(4)-CA01(83)
Less than 1 Ω
resistance
Resistance between
grounding

0V
No Circuit is faulty; repair the faulty

position.
Yes
Check output voltage of terminal 4 of harness connector CA10 of electronic accelerator pedal
Step 5
position sensor.
(a) Check output voltage of terminal 4 of electronic

accelerator pedal position sensor, refer to the standard
value.

connector
(b) Confirm whether the output voltage conforms to
standard value.
No Replace electronic accelerator pedal

position sensor. Please refer
to”Electronic accelerator pedal”.
Yes
NL-3 01/2016

mode to OFF state.
sensor harness connector CA10.
ES (d) Operate the power switch so as to set the power mode
in the state ON.
(e) Measure the voltage between terminal 2 of CA10 and
reliable grounding.
(f) Measure the conductivity between CA10 terminal 2
and CA01 terminal 82.
reliable grounding.
(h) Measure the conductivity between CA10 terminal 3
CA01 engine management system (plug-in part K) harness Measured items Standard value
connector 2
Resistance between
grounding
CA10(2)-CA01(82)
Less than 1 Ω
resistance
0V
CA10(3)-CA01(35)
Less than 1 Ω
resistance

position.
Next step

EMS are normal.
Yes
Next step
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC.

“Check on intermittent fault.
Yes
NL-3 01/2016
DTC P212716 P212817

ES
P212817 Electronic accelerator pedal position sensor 2 signal voltage too high
- A 5V reference voltage circuit
- A low level reference voltage circuit
- A signal circuit
(control strategy)
- The lower limit is - Circuit

P212716 - Signal voltage <0.586 [V]
exceeded
- EMS
- The upper limit is - Electronic accelerator
P212817 - Signal voltage >4.824 [V]
exceeded Pedal Position Sensor
NL-3 01/2016
3. Circuit diagram:
Accelerator pedal
ES
Notice

interface.
mode to ON state.
scanner.
(e) Read DTC.

No
P212817
P212716, P212817 Yes

fault codes
Yes
NL-3 01/2016
Check voltage of harness connector CA10 terminal 1 of electronic accelerator pedal position
Step 2
sensor.

mode to OFF state.
ES sensor harness connector CA10.
CA10 accelerator pedal harness (c) Operate the starter switch to turn the power supply
connector
mode to ON state.
reliable grounding.
If the voltage is higher than the

standard value, the circuit is short to
No power supply; if the voltage is lower
than the standard value, go to Step 5.
Yes
Check resistance of harness connector CA10 terminal 5 of electronic accelerator pedal position
Step 3
sensor to ground.

mode to OFF state.
connector CA10.
mode to ON state.
accelerator pedal CA10 and the reliable grounding point.
value.
No Go to step 5.
Yes

mode to OFF state.
connector CA10.
terminal 61 of EMS harness connector CA01, and check
whether there is broken circuit, or repair the faulty part.
accelerator pedal harness connector CA10 and reliable
NL-3 01/2016

accelerator pedal harness connector CA10 and reliable
connector
Measured items Standard value ES
CA10(6)-CA01(61)
Less than 1 Ω
resistance
Resistance between
grounding

0V

position.
connector 2
Next step
Check output voltage of terminal 6 of harness connector CA10 of electronic accelerator pedal
Step 5
position sensor.
(a) Check output voltage of terminal 6 of electronic

accelerator pedal position sensor.
(b) Confirm whether the output voltage is normal.

connector Replace electronic accelerator pedal
No
position sensor. Please refer to
“Electronic accelerator pedal”.
Next step
NL-3 01/2016

mode to OFF state.
sensor harness connector CA10.
ES (d) Operate the power switch so as to set the power mode
in the state ON.
(e) Measure the resistance between terminal 1 of CA10
(f) Measure the conductivity between CA10 terminal 1
reliable grounding.
(h) Measure the conductivity between CA10 terminal 5
connector 2
Resistance between
grounding
CA10(1)-CA01(81)
Less than 1 Ω
resistance
0V
CA10(5)-CA01(11)
Less than 1 Ω
resistance

position.
Next step

EMS are normal.
Yes
Step 8 Replace the EMS. Please refer to t”Engine ECU”.
Next step
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P213829
P213829 Electronic accelerator pedal position sensor signal unreasonable

ES
EMS compares input signals of electronic accelerator pedal position sensor 1 and the electronic accelerator pedal position
sensor 2. The input signal of electronic accelerator pedal position sensor 2 is close to twice that of the electronic accelerator
pedal position sensor 1 at any time. If EMS monitors that this rule is not satisfied by input signal between electronic accelerator
pedal position sensor 1 and electronic accelerator pedal position sensor 2, the DTC will be reported.
(control strategy)
- Signal voltage comparison

of pedal position sensors - Circuit
1 and 2 - EMS
P213829 - Reasonableness check
- Signal voltage of pedal - Electronic accelerator
position sensor 2>0.459 Pedal Position Sensor
[V]
3. Circuit diagram:
Accelerator pedal
Notice
NL-3 01/2016

interface.
(b) Operate the starter switch to turn the power supply ES
mode to ON state.
scanner.
(e) Read DTC.
P213829 Yes

fault codes
Yes
Check the output voltage signals of the accelerator pedal position sensor 1 and electronic
Step 2
accelerator pedal position sensor 2.
(a) For technical parameters. Please refer to

datasheet/active test.
(b) Confirm whether output voltage of electronic
accelerator pedal position sensor 1 and electronic
CA10 accelerator pedal harness accelerator pedal position sensor 2 meets the standard.
connector
No
Replace electronic accelerator pedal
position sensor. Please refer to
“Electronic accelerator pedal”.
Yes

EMS are normal.
Yes
Next step
NL-3 01/2016
Next step
ES
interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC P217700 P218700

P217700 The air-fuel ratio closed-loop control self-learning value is beyond the upper limit (middle load
area) (Bank 1) ES
P218700 The air-fuel ratio closed-loop control self-learning value is beyond the upper limit (low load area)
(Bank 1)
The engine management system (EMS) controls the closed-loop air-fuel ratio measure coefficient to realize optimum match of
the maneuverability, fuel economy and emission control. In the closed-loop mode, the engine control module detects the front
oxygen sensor (HO2S) signal voltage and adjusts the fuel supply according to it. The fuel supply variation will change
long-term and short-term fuel adjustment value. The short-term fuel adjustment value will rapidly vary with the front oxygen
sensor signal voltage. Such changes will fine tune the engine fuel supply. The long-term fuel adjustment value varies with the
(control strategy)
- Adaptive
- Fuel correction exceeding value >FRADX：1.23
P217700
the upper limit - Self-learning of air-fuel
- Connecting circuit
ratio starts
- Sensor
- Adaptive
- EMS
- Fuel correction exceeding value >FRADX：7
P218700
the upper limit - Self-learning of air-fuel
ratio starts
Notice

interface.
mode to ON state.
scanner.
(e) Read DTC.
(f) Confirm whether there are DTCs except for P217700
P218700.

fault codes.
No
Step 2 Check data flow of intake pressure/temperature sensor
NL-3 01/2016

mode to OFF state.
(c) Star the vehicle and run it at the idle speed.
(d) Check data flow related to intake absolute pressure of
intake pressure/temperature sensor.
ES
(e) Confirm whether the reading of intake absolute
pressure indicated on the fault diagnostic scanner is
within the normal scope.
No Check the reason for abnormal data.
Yes
Step 3 Check data flow of air mass flow sensor.

mode to OFF state.
(d) Check air flow data of air mass flow sensor.
(e) Confirm whether the reading of air flow indicated on
the fault diagnostic scanner is within the normal scope.
Yes

(c) Use the fault diagnostic scanner to view throttle
position sensor data stream.
normal.
Yes

(c) Use the fault diagnostic scanner to view the front
Front oxygen sensor standard data value: 0.1~1.0V
(d) Confirm whether the front oxygen sensor data is
normal.
Yes
Step 6 Observe long-term fuel correction.
NL-3 01/2016

(c) Use the fault diagnostic scanner to view the long-term
fuel correction parameter.
(d) Confirm whether the long-term fuel correction
parameter is normal. ES
No
(a) Check crack, twist and incorrect connection of the

vacuum hose.
(b) Check for scant fuel inside the fuel tank.
(c) Check for fuel underpressure.
(d) Check for the condition that concentration of ethanol
exceeds 15%.
(f) Check fault of fuel injector
(g) Check for loss, looseness or leakage of the exhaust
component at the leading end of the heating type oxygen
sensor.
(h) Check vacuum leakage of intake manifold and throttle
body.
(i) Check for leakage of intake system and intake pipe or
loss of air filter core.
(j) Check for crack of evaporative emission carbon
canister.
(k) Check for blockage or leakage of evaporative
emission pipe.
(l) Check crankshaft ventilation system leakage state.
(m) Check for improper installation of the heating type
oxygen sensor, possible corrosion and water ingress of
electrical harness or connector or contact with the
exhaust system.
(n) Check for incorrect pressing force of harness
connector terminal.
(o) Check for looseness, corrosion or dislocation of
grounding connection.
(p) Check for open circuit, short circuit to the ground or
short circuit to the low level reference voltage circuit of the
heating type oxygen sensor signal circuit.
(q) Confirm whether the engine system is normal.
No
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC.
ES (d) Start the engine.
diagnosis code of the engine management system is set
again.

No
Step 10 The system is normal
NL-3 01/2016
DTC P217800 P218800

The air-fuel ratio closed-loop control self-learning value is beyond the lower limit (middle load
P217800 ES
area) (Bank 1)
The air-fuel ratio closed-loop control self-learning value is beyond the lower limit (low load area)
P218800
(Bank 1)
The engine management system (EMS) controls the closed-loop air-fuel ratio measure coefficient to realize optimum match of
the maneuverability, fuel economy and emission control. In the closed-loop mode, the engine control module detects the front
oxygen sensor signal voltage and adjusts the fuel supply according to it. The fuel supply variation will change long-term and
short-term fuel adjustment value. The short-term fuel adjustment value will rapidly vary with the front oxygen sensor signal
voltage. Such changes will fine tune the engine fuel supply. The long-term fuel adjustment value varies with the short-term fuel
adjustment trend. The long-term fuel adjustment will roughly adjust the fuel supply to go back to the short-term fuel
adjustment's center value and restore control over the short-term fuel adjustment. The ideal fuel adjustment value is
DTC No. DTC detection strategy DTC setting condition (control Fault component
strategy)
- Adaptive value <FRADN: 0.77
- Fuel correction
- Engine speed and
P217800 exceeding the lower
coordination demand torque is
limit - Connecting circuit
located in self-learning area.
- Sensor
- Adaptive value <ORADN: -7
- Fuel correction - EMS
- Engine speed and
P218800 exceeding the lower
coordination demand torque is
limit
located in self-learning area.
Notice

interface.
mode to ON state.
scanner.
(e) Read DTC.
(f) Confirm whether there are DTCs except for P217800
P218800.

fault codes.
No
Step 2 Check data flow of intake pressure/temperature sensor
NL-3 01/2016

mode to OFF state.
(d) Check data flow related to intake absolute pressure of
intake pressure/temperature sensor.
ES
(e) Confirm whether the reading of intake absolute
pressure indicated on the fault diagnostic scanner is
within the normal scope.
Yes
Step 3 Check data flow of air mass flow sensor.

mode to OFF state.
(d) Check air flow data of air mass flow sensor.
(e) Confirm whether the reading of air flow indicated on
the fault diagnostic scanner is within the normal scope.
Yes

(c) Use the fault diagnostic scanner to view throttle
position sensor data stream.
normal.
Yes

(c) Use the fault diagnostic scanner to view the front
Front oxygen sensor standard data value: 0.1~1.0V
(d) Confirm whether the front oxygen sensor data is
normal.
Yes
Step 6 Observe long-term fuel correction.
NL-3 01/2016

(c) Use the fault diagnostic scanner to view the long-term
fuel correction parameter.
(d) Confirm whether the long-term fuel correction
parameter is normal. ES
No
(a) Check crack, twist and incorrect connection of the

vacuum hose.
(b) Check for collapse or blockage of intake pipe.
(c) Check for leakage of the intake system between
turbocharger outlet and throttle body inlet, including
leakage of the supercharge air cooler.
(d) Check for dirtiness or blockage of air filter.
(e) Check for the condition that the throttle body or the air
flow sensor is blocked up by foreign matters.
(f) Check for the condition that there is too much fuel in
the crankcase due to leakage of the fuel injector.
(g) Check for abnormal working conditions of the
evaporative emission control system.
(h) Check for excessive fuel pressure.
(i) Check for fault of the fuel injector.
(j) Check fuel contamination.
(k) Check for loss, looseness or leakage of the exhaust
component at the leading end of the heating type oxygen
sensor.
(l) Check for improper installation of the heating type
oxygen sensor, possible corrosion and water ingress of
electrical harness or connector or contact with the
exhaust system.
(m) Check for incorrect pressing force of harness
connector terminal.
(n) Check for looseness, corrosion or dislocation of
grounding connection.
(o) Check for blockage of the exhaust system.
(p) Check for open circuit, short circuit to the ground or
short circuit to the low level reference voltage circuit of the
heating type oxygen sensor signal circuit.
(q) Confirm whether the engine system is normal.
No
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC.
ES (d) Start the engine.
diagnosis code of the engine management system is set
again.

No
Step 10 The system is normal
NL-3 01/2016
DTC P161000 P161100 P161200 P161300 P161400


ES
P161200 The certification reply of PEPS is incorrect, and the anti-theft certification fails
EMS communicates with anti-theft control module of the chip through CAN-H line of the terminal 45 of EMS harness connector
CA01 and CAN-L line of the terminal 44 of harness connector CA01. For specific working principle, please refer to the section
about data communication fault.
(control strategy)
P161000
P161100 - Circuit
- EMS
- Anti-theft device
P161200 - Check anti-theft inside - PEPS module
authentication error
- Data link (PCANH line
P161300 and PCAN-L line)
P161400
NL-3 01/2016
3. Circuit diagram:
ES
Gateway

interface.
mode to ON state.
scanner.
(e) Read DTC.
P161100, P161200, No
P161300, P161400
P161000, P161100,
P161200, P161300, Yes
P161400

fault codes.
Yes
NL-3 01/2016
Step 2 Check CAN bus network integrity.
(a) Check integrity of CAN bus,

ES
Yes

Yes
Next step
(a) Carry out learning on programming of anti-theft

system,
Next step
Next step
NL-3 01/2016
DTC P168300 P168386

P168300 The CAN receives any collision signal

ES
EMS communicates with airbag control module through CAN-H line of the terminal 45 of EMS harness connector CA01 and
CAN-L line of the terminal 44 of harness connector CA01. For specific working principle, please refer to the section about data
communication fault.
NL-3 01/2016
3. Circuit diagram:
ES
Gateway

interface.
mode to ON state.
scanner.
(e) Read DTC.

No
P168386
P168300, P168386 Yes

fault codes
Yes
Step 2 Check CAN bus network integrity.
NL-3 01/2016
(a) Check integrity of CAN bus,

ES Yes

Yes
Next step
(a) Carry out learning on programming of anti-theft

system,
Next step
Next step
NL-3 01/2016
DTC U007300

ES
On NL-3 vehicle, there are 5 CAN buses, which are connected by gateways, namely: B-CAN, which is connected with rear
camera module (RCM), A/C controller (HVAC), body control module (BCM), emergency telecommunication box (T-BOX),
Notice
Operate the ignition switch to set the power mode to OFF state and then measure resistance of CAN bus.
Before measuring the resistance, do not make any operation to the vehicle and do not operate ignition switch, any other switch
or the door within at least 1 minute. When it is necessary to open the door to check the connector, open the door and keep it
open.

interface.
mode to ON state.
scanner.
(d) Read DTC.
DTC other than U007300 No
U007300 Yes

fault codes
Yes
Step 2 Check for open circuit of CAN bus.
NL-3 01/2016

mode to OFF state.
(b) Disconnect EMS module harness connector CA01.
CA01 engine management system (plug-in part K) harness (c) Measure the resistance between the terminal 44 and
connector 2
the terminal 45 of EMS module harness connector CA01.
ES Standard resistance value: 110 ~ 125 Ω
value.
Yes
Step 3 Check power circuit and grounding circuit of EMS module.
(a) Check power circuit and grounding circuit of EMS

module.
(b) Confirm whether power supply and grounding circuit
of EMS module is normal.
Next step
Next step

interface.
mode to ON state.
(c) Clear DTC.

Yes
NL-3 01/2016
DTC U007300 U010187 U012287 U014087 U015187 U010387 U014187 U010182 U010183 U012282
U012283 U015182 U015183 U010182 U010183

ES
U010187 Communication with TCU is lost (AT vehicle)
U012287 Communication with ABS_ESP control module is lost.
U015187 The communication with ACU is lost or the signal is abnormal
U010387 The communication with PEPS is lost or the signal is abnormal
U013187 The communication with EPS is lost or the signal is abnormal
On Geely NL-3 vehicle, there are 5 CAN buses, which are connected by gateways, namely: B-CAN, which is connected with
rear camera module (RCM), A/C controller (HVAC), body control module (BCM), emergency telecommunication box (T-BOX),
1. The oscilloscope double-channel input can be used for signals monitoring which transits on CAN bus. The signals shall
have the following features:
(a) The voltage signal on CAN H line is 2.5~3.5V, and the voltage signal on the CAN L line is 1.5~2.5V.
(b) Two signals are mirror image of each other.
(c) The signal transmission starts while the starter switch is turned on, but stops 2s after the starter switch is switched off.
NL-3 01/2016
DTC P070400
P070400 Signal of clutch position sensor is unreasonable (MT model)

ES
2. Circuit schematic:
Clutch
switch
Gateway MT model

interface.
mode to ON state.
scanner.
(d) Read DTC.
P070400 Yes
NL-3 01/2016

fault codes
Yes
Step 2 Check for open circuit of CAN bus. ES

mode to OFF state.
(b) Disconnect EMS module harness connector CA01.
connector 2
the terminal 45 of EMS module harness connector CA01.
Standard resistance value: 110 ~ 125 Ω
value.
Yes

module.
Yes
Step 4 Check the harness between clutch switch and PEPS.
NL-3 01/2016

mode to OFF state.
IP54 PEPS harness connector 1
(b) Disconnect the PEPS harness connector IP54.
(c) Disconnect clutch switch harness connector CA47.
(d) Use a multimeter to measure the resistance between
ES the terminal 14 of PEPS harness connector IP54 and the
terminal 2 of clutch switch harness connector CA47.
value.
CA47 clutch switch harness connector (MT

model)
Yes
Step 5 Check the grounding circuit of clutch switch.

mode to OFF state.
CA47 clutch switch harness connector (MT (b) Disconnect the clutch switch harness connector CA47.
model)
(c) Use a multimeter to measure the resistance between
the terminal 1 of clutch switch harness connector CA47
and the reliable grounding of vehicle body.
value.
Yes Replace the clutch switch.
No
Next step
NL-3 01/2016

interface.
mode to ON state.
(c) Clear DTC. ES

“Check on intermittent faults”.
Yes
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properly.
1. Fault description:
The vehicle adopts CAN network, and engine malfunction indicator lamp is controlled by the instrument. When EMS has set
DTC and need to light engine malfunction indicator lamp at the same time, EMS sends a “light the malfunction indicator lamp”
ES instruction to instrument via CAN network. The instrument lights the engine malfunction indicator lamp via internal circuit after
receiving the instruction.
2. Circuit diagram:
Gateway
Step 1 Check the working of other malfunction indicator lamps in the instrument.

mode to ON state.
(b) Check whether the working of other malfunction
indicator lamps in the instrument is normal.
Yes Go to step 6
No
Step 2 Check fuses IF17 and IF23 in indoor fuse relay box.
NL-3 01/2016

mode to OFF state.
(b) Remove the fuse IF17, IF23 from indoor fuse relay
box
connected.
(d) Confirm whether it is conductive. ES
Check whether there are short

No
circuits. Replace the fuses.
Yes
Step 3 Check the combination instrument power supply voltage.

mode to OFF state.
IP17 Combination instrument harness
connector IP17.
mode to ON state.
(d) Measure the voltage between the combination
grounding.
(e) Measure the voltage between the combination
grounding.
Next step
Step 4 Check the combination instrument grounding circuit.

mode to OFF state.
IP17 Combination instrument harness connector IP17.
connector
mode to ON state.
(d) Measure the resistance between combination
grounding.
(e) Measure the resistance between the combination
grounding.
value.
Combination instrument grounding

No circuit is faulty and handle the faulty
position.
Next step
NL-3 01/2016

ES Standard voltage value: 11.5~14.5 V
(c) Confirm whether they are normal.
Yes
Step 6 Check the instrument DTC.

mode to ON state.
(c) Read instrument DTC.
(d) Confirm whether there are CAN related DTC.
Yes Go to step 8
No
Step 7 Malfunction indicator lamp test.
(a) Connect fault diagnosis scanner.

mode to ON state.
(c) Select on the fault diagnostic scanner “Malfunction
indicator lamp test” within the “Function test” menu.
(d) Confirm whether the malfunction indicator lamp is
normally light up.
Yes Go to step 9
No
Step 8 Replace the combination instrument assembly.
(a) Replace combination instrument assembly.

No
Step 9 Check and repair the network communication between the instrument and the EMS.
(a) Check and repair the fault in network communication

between instrument and EMS.
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No

ES
module.
Yes
Next step

interface.
mode to ON state.
(c) Clear DTC.

Next step
NL-3 01/2016
Crankshaft rotation is normal, but the engine can not start

Notice
Before carrying out the repair and diagnosis steps, make sure engine oil is up to the requirement of the manufacturer, ensure
there is adequate fuel inside the fuel tank and electric quantity of the battery complies with engine start requirement, observe
list of data of the fault diagnostic scanner and analyze accuracy of each item of data, which is conducive to quickly elimination
ES of fault.
Diagnostic steps:
Step 1 Check the fuel pump fuse.
(a) Check whether the fuel pump fuse is faulty.

Engine compartment fuse relay box (b) Check and repair-fuel pump fuse power supply circuit.
(c) If necessary, replace the faulty fuel pump fuse.
(d) Check whether the fault is eliminated.
No
Step 2 Read the engine DTC with the fault diagnostic scanner.

mode to ON state.
scanner.
(e) Read DTC.
(f) To repair any fault code and fault part related to the fuel
system, please refer to the table of diagnosis fault codes.
(g) Clear EMS DTC.
(h) Start the engine and confirm whether the fault has
been eliminated.
No
Step 3 Check the fuel pump relay.

mode to ON state.
(c) Select “Fuel pump relay” of the fault diagnostic
scanner “Action test” to drive the fuel pump relay
forcefully.
(d) Confirm whether the fuel pump relay is working
properly.
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Yes Go to step 6
No
Step 4 Repair the fuel pump relay. ES

(a) Replace fuel pump relay.
(b) Overhaul fuel pump relay circuits and repair the circuit
fault.
(c) Start the engine and confirm whether the fault has
been eliminated.
No
Step 5 Check the fuel pump circuit.

mode to OFF state.
S026 Fuel pump harness connector (c) Connect fault diagnostic scanner.
(d) Operate the power switch so as to set the power mode
in the state ON.
(e) Select “Fuel pump relay” of the fault diagnostic
scanner “Action test” to drive the fuel pump relay
forcefully.
(f) Use a test lamp to connect SO26 terminals no. 1 and
4.
(g) Confirm whether test lamp normally lights up.
Yes Go to step 8
Yes
Step 6 Repair the fuel pump circuit.
NL-3 01/2016

mode to ON state.
(b) Check fuel pump working circuit, repair the pump
SO26 terminals 1 and fuel pump relay terminal 5 for open
circuit fault.
ES been eliminated.
No
(d) Operate the starter switch to turn the power supply

mode to OFF state.
(e) Install fuel pressure gauge, and connect fault
diagnostic scanner.
(f) Operate the starter switch to turn the power supply
mode to ON state.
(g) Connect the fault diagnostic scanner, select "Fuel
Pump Relay" in the "Action Test" to drive the fuel pump
relay forcefully.
Standard fuel pressure value: 350 kPa
(h) Confirm whether the fuel pressure conforms to the
standard value.
Yes Go to step 9
No
Step 8 Replace the fuel pump assembly.

mode to OFF state.
(b) Replace the fuel pump assembly.
been eliminated.
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No
Step 9 Check (repair) fuel injectors.

(a) Check (repair) the fuel injector, and if necessary ES
replace the fuel injector in fault.
(b) Start the engine and confirm whether the fault has
been eliminated.
Yes
Step 10 Check the ignition coil.

mode to OFF state.
(b) Remove ignition wires of cylinder No.1, and connect
the intact spark plug at the ignition wires, so that the spark
plug is reliably grounding.
(c) Remove the fuel pump fuse.
(e) Confirm whether the ignition of the spark plug is
normal.
Yes Go to step 13
No
Step 11 Replace the ignition coil.

mode to OFF state.
(b) Replace the ignition coil.
been eliminated.
No
Step 12 Check the speed sensor and circuit.

(a) Measure speed sensor resistance.
(b) Check the sensor circuit, repair the parts in fault, and if
necessary replace speed sensor ,
been eliminated.
Yes
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Step 13 Test cylinder pressure.
(a) Carry out the cylinder compression pressure test.

Standard cylinder pressure: 1,000 kPa
(b) Confirm whether all cylinders compression pressure is
equal to or higher than the standard value.
ES
Yes Go to step 16
No
Step 14 Check the alignment of timing chain.
(c) Operate the power switch so as to set the power mode

in the state OFF.
(d) Check the positioning of timing chain. Please refer to
“Timing chain and tensioner”.
(c) Confirm whether the alignment of timing chain is
normal.
Yes Go to step 16
No

mode to OFF state.
(b) Re-install the timing chain. Please refer to “Timing
chain and tensioner”.
been eliminated.
No
(a) Remove the engine.

(b) Check engine interior mechanical parts. If necessary,
repair the damaged interior components.
(c) Confirm the engine interior damaged components
repair has been completed.
Next step
NL-3 01/2016
Electronic Throttle Control (ETC) Self-adaptive Learning Program

Notice
After cleaning and serving for the throttle body, carry out ETC self-adaptive learn. Otherwise there will be idle instable, jitter
and so on.
ES
1. The accelerator pedal is released.
2. There is no fault relating to throttle body.
3. Battery voltage greater than threshold value (8 V)
4. The intake temperature is higher than 5.25°C.
5. The temperature of engine coolant is 5.25 - 100°C.
Next step
Next step
Step 3 Turn on the diagnosis instrument and enter into the engine management system.
Next step
Step 4 Enter special function.
Next step
Step 5 Carry out the learning of mechanical and electrical position for electronic throttle.
Next step
Step 6 Confirm the execution conditions.
(a) The command is in resetting state.

(b) The system exits after the resetting is completed.
Next step
Step 7 The learning for mechanical and electrical position of electronic throttle is completed.
NL-3 01/2016
Learning of speed sensor (CKP)

Notice
After replacing the speed sensor, replacing the EMS or dismantling/installing the engine, please carry out the self-adaptive
learning for speed sensor; otherwise the fault lamp will always be lit.
ES
1. Make sure the engine coolant temperature is above 60°C (140 ºF)
2. A/C switch is not turned on.
3. 10 s after starting the engine.
Next step
Next step
Step 3 Enter into the learning page on diagnosis instrument, and click “Start”
Next step
Step 4 Depress the accelerator pedal to 80% and hold.
Next step
After the engine speed jumps from 1,300rpm to 4,500rpm back and forth for 3~5 cycles, the speed
Step 5
is stabilized at 4,000rpm or more.
Next step
Release the accelerator pedal, and operate the ignition switch to set the power mode in the state
Step 6
OFF.
Next step
Step 7 Complete the learning, and clear fault codes.
NL-3 01/2016
JLE-4G18TDB Engine Control System - Engine oil control valve (OCV) ES-341
Engine oil control valve (OCV)

Component
ES
Trim cover of
engine
Engine assembly (4G18TD)
OCV valve
component
NL-3 01/2016
ES-342 JLE-4G18TDB Engine Control System - Engine oil control valve (OCV)
Removal
Warning!
Before repairing any electrical component, the ignition
switch shall be set at the position of OFF or LOCK and all
electrical loads shall be OFF (turned off), unless
ES otherwise specified in the procedure. Disconnect the
battery negative cable if a tool or any equipment easily
comes in contact with an exposed electrical terminal.
Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
compartment”.
cover of engine”
6. Remove engine oil control valve (intake side)
1) Disconnect harness connector of the engine oil

control valve at the intake side.
2) Remove fixing bolts of the engine oil control valve at

the intake side.
3) Remove the engine oil control valve at the intake
side.
NL-3 01/2016
7. Remove the engine oil control valve (exhaust side)
1) Disconnect harness connector of the engine oil

ES
2) Remove fixing bolts of the engine oil control valve at

the exhaust side.
3) Remove the engine oil control valve at the exhaust
side.
Check
1. Check the operation of engine oil control valve.
1) Connect the positive and negative poles of battery

with 2 terminals of engine oil control valve respectively,
and check the operation of engine oil control valve.
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Clean
1. Clean up the engine oil control valve

1) Clean the filter screen on the oil control valve with
cleaning agents.
ES Notice
During cleaning, ensure oil control valve harness
connection end is upward and oil control valve is in
vertical state, or else, the detergent may easily come
into oil control valve interior and cause damage to oil
control valve.
2) Clean oil control valve's oil holes and filter screen via
air gun and remove the remained detergent.
3) Constantly power on/off the oil control valve to make

it operated under open/close state; clean it with air gun
and repeat the procedure 23 times.
Notice
Each power on time shall not exceed 2s, or else, it may
possibly damage oil control valve.
Installation
NL-3 01/2016
1. Install the engine oil control valve (exhaust side)
1) Determine the intactness of the new oil control valve

seal ring; apply a little engine lubricant to the seal ring.
ES
2) Install the engine oil control valve at the exhaust

side.
3) Install and tighten up fixing bolts of the engine oil
control valve at the exhaust side.
4) Connect harness connector of the engine oil control

valve at the exhaust side.
NL-3 01/2016
2. Install the engine oil control valve (intake side)
1) Determine the intactness of the new oil control valve

seal ring; apply a little engine lubricant to the seal ring.
ES
2) Install engine oil control valve at the intake side.

3) Install and tighten up fixing bolts of engine oil control
valve at the intake side.
Torque: 6-8N·m (metric) 4.4-5.9lb-ft (English)
4) Connect harness connector 1 of the engine oil

NL-3 01/2016
JLE-4G18TDB Engine Control System - Electronic throttle body ES-347

Component
ES
Engine assembly
(4G18TD)
NL-3 01/2016
ES-348 JLE-4G18TDB Engine Control System - Electronic throttle body
Removal
Warning!
Before repairing any electrical component, the starter
switch must be in the OFF or LOCK position and all
electrical loads must be "OFF (off)," unless otherwise
ES specified in the procedure. Disconnect the battery
negative cable if a tool or any equipment easily comes in
contact with an exposed electrical terminal. Failure to
follow these precautions may result in personal injury
refer to “Engine compartment decorative & covering
parts”
3. Remove the left/right connecting plate bracket. Please
compartment.
cover of engine”
6. Remove the electronic throttle valve body.
1) Loosen the type-A worm-driven hose hoop, and

separate the intake hose of engine from the electronic
throttle body.
2) Disconnect the electronic throttle valve body

harness connector.
NL-3 01/2016
JLE-4G18TDB Engine Control System - Electronic throttle body ES-349
3) Remove four hexagonal flange bolts of the

electronic throttle body.
4) Remove the electronic throttle body from the intake
manifold.
ES
Check

copper winding on both ends of DC motor between pin
1 and pin 4 at the normal temperature.
Standard parameters: 2.0~2.5Ω
NL-3 01/2016
ES-350 JLE-4G18TDB Engine Control System - Electronic throttle body
Installation
1) Install a new gasket onto electronic throttle body and
install the throttle body.
ES 2) Install and tighten up four hexagonal flange bolts.
Torque: 10.5N·m (metric) 7.7lb-ft (English)
3) Connect the electronic throttle valve body harness

connector.
4) Connect the intake pipe of engine to the electronic

throttle body, and then fix the type-A worm-driven hose
hoop.
4. Install left/right connecting plate bracket
NL-3 01/2016
JLE-4G18TDB Engine Control System - Intake air temperature sensor ES-351
Intake air temperature sensor

Component
ES
NL-3 01/2016
ES-352 JLE-4G18TDB Engine Control System - Intake air temperature sensor
On-board Check
1. Check intake pressure/temperature sensor.
2) Read pressure and temperature values of intake
pressure/temperature sensor. Check whether it is
ES normal.
Warning!
specified in the procedure. Disconnect the battery
compartment”.
4. Remove the upper trim panel of left fender. Please
compartment”
cover of engine”
7. Remove intake pressure/temperature sensor (on the
intake manifold)
1) Disconnect intake pressure and temperature sensor

harness connector.
NL-3 01/2016

temperature sensor.
ES
8. Remove the battery. Please refer to “Battery cable”.

9. Remove the battery bracket. Please refer to “Battery
cable”.
10. Remove intake pressure/temperature sensor (on air
outlet pipe of the intercooler)
1) Disconnect intake pressure and temperature sensor

harness connector.

temperature sensor.
NL-3 01/2016
ES-354 JLE-4G18TDB Engine Control System - Intake air temperature sensor
Check
between the pin 1 (grounding) and the pin 2
(temperature signal) of intake pressure/temperature
ES sensor
Standard resistance: 2.5kΩ±5% （20 ）
℃
1. Install the intake pressure/temperature sensor (on air
outlet pipe of the intercooler)
1) Install intake pressure/temperature sensor onto air

outlet hose of the intercooler.
2) Tighten up hexagonal flange fixing bolts.
Torque: 10.5N·m (metric) 6.6-8.85lb-ft (English)

harness connector.
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2. Install the battery bracket

3. Install battery
4. Install the intake pressure/temperature sensor (on the
intake manifold)
1) Install intake pressure/temperature sensor onto the

intake manifold. ES
2) Tighten up hexagonal flange fixing bolts.

harness connector.
NL-3 01/2016
ES-356 JLE-4G18TDB Engine Control System - Water temperature sensor

Component
ES
NL-3 01/2016
JLE-4G18TDB Engine Control System - Water temperature sensor ES-357
ES
Intake manifold assembly and

Carbon canister control fuel injector harness
valve
Electronic throttle
body
Oil filter

NL-3 01/2016
Removal
Warning!
ES negative cable if a tool or any equipment easily comes in
Warning!
As long as there is pressure in the cooling system, even
though the solution in the radiator is not boiled, the
solution temperature will be much higher than the water
boiling point. If the fluid reservoir cap is removed while the
engine is still hot and under high pressure during
maintenance, the engine coolant will boil immediately and
spray into the operator's body, causing serious burns.

compartment”.
compartment”.
5. Remove the upper trim panel of right fender. Please
compartment”.
cover of engine”
8. Remove the carbon canister solenoid valve. Please
refer to “Carbon canister control valve”
9. Remove the electronic throttle. Please refer to
“Electronic throttle body”
10. Remove the intake pressure temperature sensor.
Please refer to “Intake pressure temperature sensor”
11. Remove the engine oil filter. Please refer to “Engine
oil and engine oil filter”.
12. Remove the intake manifold assembly and fuel
injector harness. Please refer to “Intake manifold
assembly.
13. Remove water temperature sensor
1) Disconnect the water temperature sensor harness

connector.
NL-3 01/2016
JLE-4G18TDB Engine Control System - Water temperature sensor ES-359
2) Remove water temperature sensor
ES
Check
1. Measure the resistance
1) According to the figure, put the sensor in the

thermostatic bath, match 7V operating voltage,
connect 55Ω instrument internal resistance with sensor
in series and measure resistance parameters of the
sensor under the conditions.
Resistance-temperature characteristic standard
Resistance at end AC: 17.31~16.49KΩ(-20±0.1 ）
℃
1.825~2.155KΩ(25±0.1 ℃ ）
0.303~0.326KΩ(80±0.1 ）
℃
0.1383~0.1451KΩ(110±0.1 ）
℃
Resistance at end B: 176~280Ω(50±0.2 ）
℃
63.4~81.4Ω(80±0.2 ）
℃
24.6~30.6Ω(110±0.2 ℃
1. Install water temperature sensor
1) Please apply a small amount of sealant onto thread

and sealing gasket of water temperature sensor.
2) Install and tighten up the water temperature sensor.
NL-3 01/2016
3) Connect the water temperature sensor harness

connector.
2. Install intake manifold assembly and fuel injector
harness
3. Install engine oil filter
ES 4. Install the electronic throttle valve body
5. Install the canister solenoid valve
7. Check and fill the coolant until the appropriate level is
reached.
10. Install the upper trim panel of right fender
NL-3 01/2016
JLE-4G18TDB Engine Control System - Camshaft Phase Sensor ES-361
Camshaft phase sensor

Component
ES
Camshaft phase sensor Camshaft phase sensor
NL-3 01/2016
ES-362 JLE-4G18TDB Engine Control System - Camshaft Phase Sensor
Warning!
ES specified in the procedure. Disconnect the battery
cover of engine”
4. Remove camshaft phase sensor (intake side)
1) Disconnect the camshaft phase sensor harness

connector.
2) Remove hexagonal flange fixing bolts.

3) Remove the camshaft phase sensor.
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5. Remove camshaft phase sensor (exhaust side)
1) Disconnect the camshaft phase sensor harness

connector.
ES
2) Remove hexagonal flange fixing bolts.

3) Remove the camshaft phase sensor.
Check
frequency 10kHz), and connect the two pins with pins 1
and 3 of sensor respectively, so as to measure the
resistance
Notice
range, please replace the phase sensor
Sensor
NL-3 01/2016
ES-364 JLE-4G18TDB Engine Control System - Camshaft Phase Sensor
1. Install the camshaft phase sensor (exhaust side)
1) Install the camshaft phase sensor onto the cylinder

head.
ES 2) Tighten up fixing bolts.

3) Connect the camshaft phase sensor harness

connector.
2. Install the camshaft phase sensor (intake side)
1) Install the camshaft phase sensor onto the high

pressure oil pump seat assembly.
2) Tighten up fixing bolts.
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3) Connect the camshaft phase sensor harness

connector.
ES
NL-3 01/2016
ES-366 JLE-4G18TDB Engine Control System - Crankshaft Position Sensor

Component
ES
Protective plate assembly on bottom

of engine
NL-3 01/2016
JLE-4G18TDB Engine Control System - Crankshaft Position Sensor ES-367
Warning!
specified in the procedure. Disconnect the battery ES
refer to “Left and right guard plate on bottom of engine”.
5. Remove the crankshaft position sensor
1) Disconnect the crankshaft position sensor harness

connector.
2) Remove the crankshaft position sensor fixing bolt.

3) Remove the crankshaft position sensor.
Notice
After removing the sensor, plug the sensor mounting
hole to prevent debris falling into it.
NL-3 01/2016
ES-368 JLE-4G18TDB Engine Control System - Crankshaft Position Sensor
Check
frequency 10kHz), and connect the two pins with pins 1
and 3 of sensor respectively, so as to measure the
ES resistance
Notice
range, please replace the crankshaft position sensor
1. Install the crankshaft position sensor
1) Install the crankshaft position sensor into installation

hole of the engine cylinder block.
2) Tighten up hexagonal flange fixing bolts of the
crankshaft position sensor.
3) Connect the crankshaft position sensor harness

connector.
2. Install the engine bottom guard plate
NL-3 01/2016
JLE-4G18TDB Engine Control System - Knock Sensor ES-369
Knock sensor
Component
ES
Protective plate assembly on bottom

of engine
NL-3 01/2016
ES-370 JLE-4G18TDB Engine Control System - Knock Sensor
ES
sealing ring of
water pump
Water pump
assembly
Water pump belt
Water pump drive

pulley
Fixing bolt of the water pump

drive wheel
Water pump belt cover
RNon-reusable parts
NL-3 01/2016
ES
Carbon canister control Intake manifold assembly and fuel

valve injector harness
Oil filter
Knock sensor
NL-3 01/2016
Warning!
compartment”.
engine compartment”
compartment”
compartment”
7. Remove the carbon canister solenoid valve. Please
refer to “Carbon canister control valve”
8. Remove the electronic throttle. Please refer to
“Electronic throttle body”
Please refer to the section about intake pressure
temperature sensor
10. Remove the engine oil filter. Please refer to “Engine
oil and engine oil filter”.
11. Remove intake manifold assembly and fuel injector
harness
12. Discharge the engine coolant. Please refer to
Discharge and Filling for Engine Coolant.
refer to the section about left and right guard plate on
bottom of engine.
14. Remove the water pump belt pulley. Please refer to
“Water pump component”.
15. Remove the thermostat housing assembly. Please
refer to “Thermostat assembly.
16. Remove the knock sensor

1) Disconnect knock sensor harness connector.
NL-3 01/2016
2) Remove the knock sensor fixing bolts.

3) Remove the knock sensor.
ES
Check
1) At the normal temperature, connect the pins of ohm
gauge with pins 1 and 2 of sensor respectively,and
then measure the resistance
Standard parameters: (4.9±20%) MΩ
Notice
If the resistance is not within the specified range,
please replace knock sensor.
1. Install knock sensor
1) Install the knock sensor into installation hole of the
cylinder block and tighten up fixing bolts of the knock
sensor.
Torque: 20N·m (metric) 14.76lb-ft(English)
NL-3 01/2016
2) Connect knock sensor cable connector.

2. Install the thermostat housing assembly
3. Install water pump pulley
harness
ES 5. Install engine oil filter
7. Install the intake pressure temperature sensor
8. Install the electronic throttle valve body
NL-3 01/2016
JLE-4G18TDB Engine Control System - Engine ECU ES-375
Engine ECU
Component
ES
Engine ECU(4G18TD)
Engine ECU bracket assembly (4G18TD)
NL-3 01/2016
ES-376 JLE-4G18TDB Engine Control System - Engine ECU
Removal
Warning!
compartment”.
compartment”
cover of engine”
7. Remove the engine ECU
1) Disconnect the engine ECU harness connector.
2) Remove 4 fixing bolts of engine ECU and remove

engine ECU.
NL-3 01/2016
JLE-4G18TDB Engine Control System - Engine ECU Bracket ES-377
Installation
1) Put engine ECU on engine ECU mounting bracket

and tighten up 4 fixing bolts of engine ECU.
ES
2) Connect the engine ECU harness connector.

6. Install the connecting plate of upper trim panel of
fender.
Engine ECU bracket

Removal
Warning!
NL-3 01/2016
ES-378 JLE-4G18TDB Engine Control System - Engine ECU Bracket

compartment”.
ES engine compartment”.
compartment”.
6. Remove the trim cover of engine. Please refer to Trim
cover of engine
7. Remove the engine ECU. Please refer to “Engine ECU
8. Remove engine ECU bracket
1) Remove 3 fixing bolts of engine ECU bracket

assembly.
2) Remove engine ECU bracket assembly.
Installation
1. Install the engine ECU bracket assembly
1) Install the engine ECU bracket assembly.

2) Install and tighten up 3 fixing bolts.
NL-3 01/2016
JLE-4G18TDB Engine Control System - Electronic Accelerator Pedal ES-379
Electronic accelerator pedal

Component
ES
Electronic accelerator
pedal
NL-3 01/2016
ES-380 JLE-4G18TDB Engine Control System - Electronic Accelerator Pedal
On-board Check
1. Check electronic accelerator pedal

2) Read the voltage indicated on electronic accelerator
pedal potentiometer, and confirm whether it is normal.
ES
Removal
Warning!
3. Remove electronic accelerator pedal
1) Disconnect the accelerator pedal harness

connector.
NL-3 01/2016
JLE-4G18TDB Engine Control System - Electronic Accelerator Pedal ES-381
2) Remove 3 fixing nuts of electronic accelerator pedal.

3) Take out the accelerator pedal assembly.
ES
Check
between pins 1 and 5 or between pins 2 and 3 of
accelerator pedal sensor
Standard value: (1.7±0.8)KΩ
Installation
1. Install the electronic accelerator pedal
1) Install the electronic accelerator pedal onto the

bracket and tighten up 3 fixing nuts of the electronic
accelerator pedal.
Torque: 9N·m (metric) or 6.6lb-ft (English)
NL-3 01/2016
ES-382 JLE-4G18TDB Engine Control System - Electronic Accelerator Pedal
2) Connect harness connector of the electronic

accelerator pedal.
ES
NL-3 01/2016
2016 Geely NL-3 Repair Manual
This Repair Manual provides the information about specification, diagnosis and repair of NL-3 model (2016 version).

All Rights Reserved
The deadline of information is January, 2016
Foreword

Geely NL-3 Repair Manual

whole or part.
Warning
- Carefully read through this manual. It is especially important to fully understand all “Warnings” and “Notes” in Section
“General” relating to fault diagnostic interface.
- Repair methods described in this manual are helpful for the repair work. When following the repair procedures in this
- When replacing parts, please use parts approved by Geely Automobile Co., Ltd. with the same part numbers. Do not use
inferior parts.
- In order to reduce the risk of personal injury in the course of repair, or reduce the likelihood that the vehicle becomes
damaged or unsafe owing to incorrect repair, please strictly comply with all “Warnings” and “Notes” relating to fault
diagnostic interface in this Manual. Just as important, please be noted that the “Warnings” and “Notes” relating to fault
- Before carrying out any repair on or near any component or circuit of airbag system, please refer to the Position Diagram
of Components of Airbag System in Section “Safety Protection Devices” relating to fault diagnostic interface in this
General Contents
Overview IN-1
Preparatory work PP-1
JLD-4G20/24 Engine control system ES-1
JLD-4G18TDB Engine control system ES-1
JLE-4G18TDB Cooling system CO-2
JLD-4G20/24 Intake system AI-2
JLE-4G18TDB Intake system AI-2
JLD-4G20/24 Fuel system FU-2
JLE-4G18TDB Fuel system FU-2
JLD-4G20/24 Mechanical system EM-2
JLE-4G18TDB Mechanical system EM-2
JLD-4G20/24 Ignition system IG-3
JLE-4G18TDB Ignition system IG-3
JLD-4G20/24 Starter System ST-3
JLE-4G18TDB Starter System ST-3
Clutch System CL-3
Brake System BR-3

Brake control BC-4
Constant-velocity drive shaft DS-4
Power takeoff system TP-4
TPMS system TP-4
Tire and Wheel TW-4
A/C system AC-4
Active safety system AS-5
Emergency power supply BP-5
Intelligent entry & start system TD-5
Rearview mirror MI-5
Combination instrument ME-5
Horn System HO-5
Door lock DL-5
Defrosting system DF-5
Wiper and washer WW-5
Windshield & window glass WS-6
Sunroof system RF-6
Parking assist system RR-6
Safety control system SC-6
Seat Belt SB-6
Electrical control system of vehicle body BE-6
On-board network CA-6
Door CD-6
Instrument panel IP-6
Seats SE-6
Interior Trim IR-6
Appearance of vehicle ET-6

JLD-4G20/24 Cooling System - Contents CO-1
CO JLD-4G20/24 Cooling System
Cooling System ................................................................................................................ CO-3

On-board Check ...................................................................................................................... CO-3 CO
Cooling Fan System ........................................................................................................ CO-4
Component Position ................................................................................................................ CO-4
System Diagram...................................................................................................................... CO-5
Cooling Fan Circuit Diagnosis ................................................................................................. CO-6
Fault Symptoms Table ............................................................................................................. CO-7
High-speed Cooling Fan Is Not Running ................................................................................. CO-8
Cooling Fan Does Not Run at Low Speed ............................................................................. CO-11
Cooling Fan Always Runs at Low Speed ............................................................................... CO-17
Cooling Fan Always Runs at High Speed .............................................................................. CO-21
Diagnosis of Thermostat ....................................................................................................... CO-25
Engine Overheat ................................................................................................................... CO-26
Engine Does not Reach Normal Operating Temperature ....................................................... CO-27
Excessive Engine Coolant Loss ............................................................................................ CO-28
Cooling Fan Assembly .................................................................................................. CO-30
Component ........................................................................................................................... CO-30
Removal ................................................................................................................................ CO-33
Installation ............................................................................................................................. CO-34
Coolant ........................................................................................................................... CO-36
Drainage and Filling of Coolant ............................................................................................. CO-36
Water pump .................................................................................................................... CO-38
Component ........................................................................................................................... CO-38
Removal ................................................................................................................................ CO-40
Check .................................................................................................................................... CO-41
Installation ............................................................................................................................. CO-41
Thermostat component ................................................................................................. CO-44
Component ........................................................................................................................... CO-44
Removal ................................................................................................................................ CO-46
Check .................................................................................................................................... CO-47
Installation ............................................................................................................................. CO-48
Radiator assembly ......................................................................................................... CO-50
NL-3 01/2016
CO-2 JLD-4G20/24 Cooling System - Contents
Component ........................................................................................................................... CO-50

Removal ................................................................................................................................ CO-53
Installation ............................................................................................................................. CO-56
Expansion tank assembly ............................................................................................. CO-59
CO
Component ........................................................................................................................... CO-59
Removal ................................................................................................................................ CO-60
Installation ............................................................................................................................. CO-61
Oil cooler (AT) ................................................................................................................ CO-62
Component ........................................................................................................................... CO-62
Removal ................................................................................................................................ CO-66
Check .................................................................................................................................... CO-67
Installation ............................................................................................................................. CO-67
NL-3 01/2016
JLD-4G20/24 Cooling System - Cooling System CO-3
Cooling System
On-board Check
Notice
CO
Before carrying out any check, turn the A/C switch to
position OFF.
When the engine and radiator are hot, please don’t
dismantle the cover of expansion tank; otherwise the
high-temperature & high-pressure (up to about
2.2bar) Coolant or hot steam may be jetted out and
cause scalding.
1. Check the coolant for leakage.
1) Start the engine, and make the temperature of
engine coolant reach the normal temperature,
which means heating up the engine until the
large circulation is initiated.
2) Check the parts of cooling system such as
water pipes, expansion tank, radiator, water
pump, cylinder block and cylinder head as well
as every connection for leakage. If any leakage
is found, please re-install, connect or replace
the leaking part.
2. Check the level of coolant

1) When the engine is in cold state, check whether
the level of engine coolant is between the lines
MIN and Max on expansion tank. If the level of
engine coolant is lower than or close to the line
MIN, under the circumstance that the cooling
system does not leak, fill the coolant specified
by Geely until the level reaches the line MAX.
Warning!
Don’t use pure water instead of engine coolant.
3. Check the quality of coolant
1) Remove expansion tank cover.
2) Check whether there is excessive rust or scale
deposit in areas surrounding the filling port of
expansion tank, and make sure that the coolant
does not contain any engine oil. If there is too
much dirt, please clean up the expansion tank
and cooling pipeline, and replace the coolant.
3) Install expansion tank cover.
NL-3 01/2016
CO-4 JLD-4G20/24 Cooling System - Cooling Fan System
Cooling Fan System

Component Position
CO
Cooling fan assembly
NL-3 01/2016
JLD-4G20/24 Cooling System - Cooling Fan System CO-5
System Diagram
CO
High speed position of

Cooling fan high speed relay
cooling fan
Coolant temperature sensor A/C relay A/C compressor clutch
Low speed position of

Cooling fan low speed relay
cooling fan
NL-3 01/2016
Cooling Fan Circuit Diagnosis

Diagnosis tips:
- If a user reports the overheating fault, please firstly confirm whether the level of coolant is normal, and then confirm
whether the engine coolant is overheated. If the engine is overheated, but the cooling fan still runs normally, inspect the
engine cooling system.
- If the fuse EF10 in the engine fuse box immediately blows off after installation, inspect whether the circuit between the
cooling fan high or low-speed relay and EMS is short to ground, or there is short circuit in the EMS. If the fuse EF07 or
CO EF08 in the engine fuse box blows out just at the pull-in of the relay under the control of the EMS, the circuit between fan
relay and fan motor grounding is short to ground, and there is fault in cooling fan motor.
- When the A/C system is switched on, the engine control module controls the cooling fan to run at low speed. When the
A/C high pressure reaches 1,520 Pa (220.5 psiI), the engine control module will switch cooling fan from low speed to
high speed. When the A/C high pressure drops back to 1,450 kPa (210.3 psi), the cooling fan will return to low speed.
- Use the “function test" of fault diagnostic scanner to drive high or low speed cooling fan relay pull-in to confirm whether
the fan works normally , and then quickly determine the fault.
Diagnostic procedures:
Notice
Before performing this diagnostic procedure, inspect whether fuse EF10 of the engine compartment works normally, and
whether main relay works normally. When using the "action test" of fault diagnostic scanner, make sure the fault diagnostic
scanner communicates with EMS properly.
Step 1 Confirm the fault symptoms.
Next Step
Step 2 Confirm whether the low-speed cooling fan is running.

to OFF state.
(b) Connect the fault diagnostic scanner to the diagnostic test
interface.
(c) Start engine to normal operation temperature.
(d) Turn off the A/C switch.
(e) Select in sequence: Engine/data list/ engine coolant
temperature.
(f) When the indicated temperature of engine coolant is 98℃
(210.1℉), the cooling fan shall run at low speed.
(g) Does the cooling fan run at low speed?
No Refer to “Cooling fan does not run at low

speed"
Yes
Step 3 Confirm whether the high-speed cooling fan is running.
(a) Turn off the A/C switch.

(b) When the engine coolant temperature displays 103 ℃
(218.7 ℉) the cooling fan should be running at high speed.
(c) Is cooling fan running at high speed?
No
Refer to "Cooling fan does not run at low
speed"
Yes
Step 4 Turn on the A/C switch, and confirm whether the cooling fan is running at low-speed.
NL-3 01/2016
to OFF state.
(b) Connect the fault diagnostic scanner to the diagnosis test
interface.
(c) Select in sequence: engine / data list / engine coolant
temperature.
(d) When the engine coolant temperature is at 98 ℃ (210.1 CO
ºF), start the engine, turn on the A/C switch, cooling fan
should be running at low speed.
(e) Is cooling fan running at high speed?
No There is fault in A/C system, refer to "A/C

system"
Yes
Step 5 Intermittent fault, refer to “Intermittent fault inspection for intermittent faults”.
Fault Symptoms Table

Fault symptom Possible causes Solution
- The fuse EF07 has blown out
- The fan relay ER03 fails Refer to "Cooling fan does not run at
Cooling fan does not run at high speed
- Relay ER03 coil circuit open fault high speed"
- EMS fault
- The fuse EF08 has blown out
- The fan relay ER04 fails
- Relay ER04 coil circuit open fault
- EMS fault
Refer to "Cooling fan does not run at
Cooling fan does not run at low speed - Fan motor internal coil circuit open low speed"
fault
- There is electrical contact fault in
relay ER04
- The circuit is open
- Fan relay ER04 coil circuit and
control circuit short fault
- Short circuit between motor and fan Please refer to "Cooling fan always runs
Cooling fan always runs at low speed
relay ER04 at low speed"
- Fault on contact of cooling fan relay
ER04
- EMS fault
- Fan relay ER03 coil circuit and
control circuit short fault
- Short circuit between motor and fan Please refer to "Cooling fan at high
Cooling fan always runs at high speed
relay ER03 speed"
ER03
- EMS fault
NL-3 01/2016
High-Speed Cooling Fan Is Not Running

Circuit schematic:
CO
Main relay
Cooling fan Cooling fan low

high speed speed relay
relay ER03 ER03
Cooling
fan
Notice
Before performing this diagnosis procedures, refer to "Cooling fan circuit diagnosis", which will facilitate the quick elimination
of diagnosis.
Step 1 Check the high-speed fuse EF07 of cooling fan.
(b) Remove the high-speed fuse EF07 of cooling fan.
(c) Confirm whether fuse is blown out.
Yes Carry out repair for short circuit fault in fuse

harness, and if necessary, replace the
harness and fuse.
No
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CO
to ON state.

No There is fault in circuit. If necessary, replace

the harness.
Yes
Check the conductivity between terminal 31 of EMS harness connector CA45 and terminal 86 of
Step 3
relay ER03.
to OFF state.
connector


the harness.
Yes
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Step 4 Check the power wire of EMS.
to OFF state.
connector
(c) Measure the resistance between the fuse EF09 and the
CO terminal 15/16 of EMS harness connector CA45.
(d) Ensure that the system is normal.
Yes
Step 5 Check the grounding wire of EMS.
to OFF state.
connector
(c) Measure the resistance between terminal 63/64 of EMS

harness connector CA45 and reliable grounding point.
Yes
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(a) Replace the EMS , refer to "Engine ECU".

CO
Next Step
Cooling Fan Does Not Run at Low Speed

Circuit schematic:
Main relay

relay ER03 ER04
Cooling
fan
Notice
Before performing this diagnosis procedures, please refer to "Cooling fan circuit diagnosis", which will facilitate the quick
elimination of diagnosis.
Step 1 Check the low-speed fuse EF08 of cooling fan.
NL-3 01/2016
to OFF state.
Carry out repair for short circuit fault in fuse

Yes harness, and if necessary, replace the
CO harness and fuse.
No
Step 2 Check the low-speed power supply of cooling fan motor.
to OFF state.
CA28 Cooling fan harness connector (b) Disconnect the cooling fan harness connector CA28.
to ON state.
(d) Connect fault diagnostic scanner to the diagnostic
interface.
(e) Select in sequence: Engine/action test/low-speed fan.
(f) Make the low speed relay ER04 of cooling fan work.
(g) Measure the voltage between terminal 1 of the cooling fan
(h) Confirm whether the voltage conforms to the standard

value.
No Go to step 4
Yes
Step 3 Check the cooling fan grounding circuit.
to OFF state.
(b) Disconnect the cooling fan harness connector CA28.
(c) Measure the resistance value between terminal 3 of the
cooling fan harness connector CA28 and reliable grounding.
(d) Confirm whether the resistance value meets the standard

value.

the harness.
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Yes

the low-speed fan.
CO
No Go to step 7
Yes
Step 5 Check the input power of port 30 of relay ER04.
(d) Remove the cooling fan relay ER04.
(e) Measure the voltage value between port 30 of cooling fan
relay ER04 and reliable grounding.
No There is broken circuit fault. Please repair or

replace the harness
Yes
Check the harness between cooling fan relay ER04 and cooling fan motor harness connector
Step 6
CA28.
to OFF state.
(b) Remove the cooling fan relay ER04.
(c) Disconnect the cooling fan harness connector CA28.
(d) Measure the resistance between port 87 of cooling fan
relay ER04 and terminal 1 of cooling fan harness connector
CA28.

(e) Measure the resistance between terminal 1 of cooling fan
harness connector CA28 and reliable grounding point, and
check whether there is any short circuit.
Standard resistance value: Less than 10KΩ or

higher
Yes There is broken circuit fault. Please repair or

replace the harness.
NL-3 01/2016
CO
No
to ON state.
There is fault in circuit. If necessary, replace

No
the harness.
Yes
Step 8
relay ER04.
to OFF state.
connector

the harness.
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CO
Yes
(a) Replace the ER04 relay.
No
to OFF state.
connector
terminal 15/16 of EMS harness connector CA45.
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CO
Yes
to OFF state.
connector
Yes
Next Step
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Cooling Fan Always Runs at Low Speed

Circuit schematic:
CO
Main relay

relay ER03 ER04
Cooling
fan
Notice
Before performing this diagnostic procedures, please refer to "Cooling fan circuit diagnosis", which will facilitate the quick
Check the harness between terminal 56 of EMS harness connector CA45 and low-speed relay ER04 of cooling
Step 1
fan.
to OFF state.
CA45 Engine management system harness (b) Remove cooling fan low-speed relay ER04.
connector

harness connector CA45 and grounding on vehicle body.
Standard Resistance value: 10 kΩ or higher
No There is short circuit between control circuit

and earth. repair or replace the harness.
Yes
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Step 2 Check the output circuit of low-speed relay ER04 of cooling fan.
(b) Remove cooling fan low-speed relay ER04.
to ON state.
CO (d) Confirm whether the fan stops.
Circuit fault. If necessary, please replace the

No
harness. -Harness
Yes
Step 3 Replace the low-speed relay of fan.
(b) Replace the low-speed relay of fan with a new one of the
same specification.
(c) Confirm whether the fan stops.
No
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to OFF state.
manager
Standard resistance value: Less than 1Ω CO
Yes
to OFF state.
manager

Yes
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Next Step

CO
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Cooling Fan Always Runs at High Speed

Circuit schematic:
CO
Main relay

relay ER03 ER04
Cooling
fan
Notice
Before performing this diagnosis procedures, please refer to “Cooling fan circuit diagnosis”, which will facilitate the quick
Check the harness between terminal 56 of EMS harness connector CA45 and high-speed relay
Step 1
ER03 of cooling fan.
to OFF state.
CA45 Engine management system harness (b) Remove cooling fan high-speed relay ER03.
manager

harness connector CA45 and grounding on vehicle body.

Yes
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Step 2 Check the output circuit of high-speed relay ER03 of cooling fan.

CO (c) Operate the starter switch to turn the power supply mode
to ON state.
(d) Confirm whether the fan stops.
No
There is fault in circuit. If necessary, replace
the harness.
Yes
Step 3 Replace the high-speed relay of fan.
(b) Replace the high-speed relay of fan with a new one of the
same specification.
(c) Confirm whether the fan stops.
Yes
The system is normal.
No
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to OFF state.
CA45 engine management system harness (b) Disconnect and measure the fuse EF09.
manager
Standard resistance: less than 1Ω CO
Yes
to OFF state.
manager
Yes
NL-3 01/2016
Next Step

CO
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Diagnosis of Thermostat
Step 1 Remove the thermostat.
Next Step
CO
Step 2 Soak the thermostat in water and heat the water.
(a) Check the thermostat opening temperature.
Standard value: 82 ℃
(b) Confirm whether the opening temperature of thermostat is

normal.
No Replace the thermostat.
Yes
Step 3 Check thermostat valve lift range
Standard lift of valve: 8 mm (0.31 in) or above at

105℃
(a) Determine whether the valve lift is normal
Yes
Step 4 Check whether the thermostat is completely switched off at low temperature.
(a) When the thermostat is lower than 90 ℃, check whether

the valve is fully closed.
Next Step
NL-3 01/2016
Step 5 The thermostat is in normal conditions.
Engine Overheat
Warning!
If pressure cap is removed while the engine is still hot and under pressure during repair, the engine coolant will boil
immediately and spray into the operator's body, causing serious burns.
CO
Step 1 Check whether the engine coolant is drained off?
Yes Fill engine coolant
Next Step
Step 2 Check whether the engine coolant concentration is sufficient?
Use "Geely Genuine ultra-long-acting

engine coolant"" or the same level of
Yes high-quality ethylene glycol base engine
coolant, model or standard number: comply
with SH0521.
Next Step
Step 3 Check whether the front radiator has dust, leaves, insects or several other impurities?
Yes
Clear the radiator's front part
No
Check coolant pipes, water pumps, engine coolant inlet components and radiator and cylinder lid
Step 4
gasket for leakage?
Yes Replace any damaged component
No
Connect fault diagnostic scanner, when the data flow shows the engine coolant temperature
Step 5 reaches 97 ℃ (203 ℉ ), check the radiator inlet and outlet hoses temperature. There should be
no temperature difference. Is the temperature difference large?
1. Check whether the operation of the

Yes thermostat is normal. 2. Check whether the
radiator is blocked.
No
Step 6 Use the ignition timing gun to check whether the ignition timing is over delayed?
Check the ignition timing of engine, and

Yes implement the diagnosis for EMS
No
Step 7 Check whether the electric cooling fan works normally?
Check the cooling fan circuit. Refer to

"Cooling Fan Circuit Diagnosis"
NL-3 01/2016
No
Step 8 Check whether the water pump has fault.
Replace the water pump, refer to "Water

Yes
pump". CO
No
Step 9 Check whether the radiator cover has fault.
Yes Replace the faulty radiator cap.
No
Check whether the cylinder lid and engine body have rupture or blockage, whether the cylinder
Step 10
seal gasket is not well sealed?
Yes Repair broken cylinder lid and engine body.
Next Step
Step 11 Confirm that the fault has been excluded.
Engine Does Not Reach Normal Operating Temperature

Warning!
Step 1 Check whether coolant level in expansion tank is abnormal?
Fill the engine coolant to the specified level

Yes
height
No
Step 2 Check the cooling system temperature.
to OFF state.
interface.
to ON state.
(d) Select in sequence: Engine,data sheet, engine coolant
temperature.
(e) Sustain the engine speed at 2,000rpm and observe the
engine coolant temperature in the data stream.
(f) Does the engine coolant temperature rise?
There is fault in instrument. Refer to

Yes
"Combination instrument"
No
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Step 3 Check whether the cooling fan runs normally.
Refer to "Cooling fan always runs at high

Yes speed"
No
CO Step 4 Check whether the thermostat operation is reliable?
(a) Check whether the type of the installed thermostat is

correct.
(b) Check whether the thermostat is stuck at the open
position.
Yes Replace correct type of thermostat
No
Step 5 Check whether engine coolant pipes are blocked.
Yes Flush the cooling system or inspect the

radiator flow.
No
The vehicle road test confirms the fault has

Yes
been cleared.
Excessive Engine Coolant Loss

Warning!
Step 1 Check whether the radiator has leakage?
Yes Replace the damaged radiator
No
Step 2 Check for leakage at the following positions: expansion tank assembly, water pipes.
If necessary, replace the following

Yes components: expansion tank assembly,
water pipes.
No
Step 3 Check whether the radiator pipes and joints are loose or damaged?
Yes Reinstall and replace the water pipes or the

clamp.
No
Step 4 Check whether the water pump seal has leakage.
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Yes Replace the water pump seal
No
Step 5 Check whether the cylinder lid torque is suitable.

CO
Tighten the cylinder lid bolts to the specified
Yes torque. If necessary, replace the cylinder lid
gasket
No
Step 6 Check for leakage at the following positions:
(a) Intake manifold

(b) Cylinder head lining
(c) Cylinder block plug screw
(d) Heater core
(e)Radiator discharge plug
Yes If necessary, repair or replace component

and remove leakage fault
No
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CO-30 JLD-4G20/24 Cooling System - Cooling fan assembly
Cooling Fan Assembly

Component
CO
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JLD-4G20/24 Cooling System - Cooling fan assembly CO-31
CO
Air filter
Air filter intake pipe
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Vent hose of
radiator
Radiator outlet
pipe
Cooling fan
CO Radiator
assembly
Radiator water
inlet pipe.
Rubber
pad
Rubber
Air-air gasket
intercooler
Radiator cover
assembly
NL-3 01/2016
Removal
1. Open the engine hood.
2. Remove the left/right connecting plate bracket. Refer to
"Decorative covering parts of engine compartment".
3. Remove the upper trim panel of front bumper. Refer to
"Decorative covering parts of engine compartment". CO
4. Disconnect the negative battery cable.
5. Remove the engine trim cover. Refer to "Engine trim
cover"
6. Remove the intake pipe of air filter. Refer to “Intake pipe
of air filter”
7. Lift the vehicle
8. Remove the engine bottom guard plate
9. Lower the vehicle
10. Remove cooling fan assembly
1) Remove the two fixing screws on upper and lower

portions of cooling fan.
Notice: The fixing bolt on lower portion shall be dismantled

after the vehicle is lifted up and before the vehicle is lowered
down; otherwise it can’t be dismantled.
2) Disconnect the vent hose of radiator from cooling

fan assembly.
NL-3 01/2016
3) Disconnect the cooling fan assembly harness

connector.
CO
4) Disconnect the connection between cooling fan

assembly and radiator, and then pull out the
cooling fan assembly from radiator.
Installation
1. Install cooling fan assembly
1) Install the cooling fan assembly onto radiator, and

insert the buckle of cooling fan into clamp on
radiator until the sound “click” is heard.
NL-3 01/2016
2) Connect the cooling fan harness connector.
CO
3) Install the vent hose of radiator onto cooling fan

assembly.
4) Install the two fixing screws on upper and lower

Notice: Before installing the fixing screw on lower portion of

fan, be sure to lift up the vehicle; otherwise they can’t be
installed.
3. Connect the negative battery cable.
4. Lift the vehicle
7. Install the engine trim cover
NL-3 01/2016
CO-36 JLD-4G20/24 Cooling System - Coolant
Coolant
Drainage and Filling of Coolant
2. Screw off the cover of expansion tank

Notice
CO When the engine coolant is still hot, don’t dismantle the
cover of expansion tank; otherwise the hot engine
coolant or vapor may be released suddenly and cause
scalding.
3. Lift the vehicle
4. Remove the engine bottom guard plate. Refer to

“Left/right engine bottom guard plate”
5. Exhaust coolant
1) Loosen the water drain valve of radiator, and use a

container to receive the engine coolant drained.
Notice
Collect the used engine coolant in a centralized manner,
and then get such coolant scraped or recycled. Don’t
pour the used engine coolant into sewage!
2) After the coolant is fully drained, manually tighten
up the water drain valve of radiator.
8. Fill coolant.
1) Fill coolant into the expansion tank, until the level

of coolant reaches the line MAX on expansion
tank.
2) Press the water inlet/outlet pipes of radiator with

hand for several times, and then check the coolant
level.
Notice
If the coolant level is lower than or close to the line MIN
on expansion tank, please fill the coolant.
9. Empty the air of the cooling system
1) Start the engine, and keep the engine speed at

about 2500rpm until the thermostat is opened and
the large circulation is initiated.
2) Press the water inlet/outlet pipes of radiator with

hand for several times, until there is no bubble
coming out from coolant in expansion tank.
Notice
When pressing the radiator hose, please wear the
protective gloves. When the radiator hose is hot, please
be careful to avoid scalding!
Warning! Keep away from radiator fan.
Notice
Please make sure that there is always coolant in
expansion tank.
3) Shut down the engine, lift up the vehicle, and
confirm that there is no leakage on water drain
valve of radiator and cooling system.
NL-3 01/2016
JLD-4G20/24 Cooling System - Coolant CO-37
4) Install the engine bottom guard plate.
5) Lower down the vehicle, and fill the engine coolant

until the level of engine coolant reaches the line
MAX on expansion tank.
6) Mount and tighten up the cover of expansion tank.

CO
NL-3 01/2016
CO-38 JLD-4G20/24 Cooling System - Water pump
Water Pump
Component
CO
Engine right guard

plate assembly
NL-3 01/2016
JLD-4G20/24 Cooling System - Water pump CO-39
CO
Water pump belt

pulley
Water pump casing
Water pump Water inlet seat of

engine
NL-3 01/2016
Removal
Warning!
When there is pressure in cooling system, even if the coolant
in radiator does not boil, the temperature of coolant may
become very high. If the reservoir cover is opened when the
engine has not cooled down and the pressure is still very
high, the engine coolant may immediately boil, be splashed
CO onto operator, and then cause serious scalding!

“Decorative covering parts of engine compartment”.
fender. Refer to "Decorative covering parts of engine
compartment".
4. Remove the upper trim panel of right fender. Refer to
"Decorative & covering parts of engine compartment"

cover"
7. Remove the right front wheel. Refer to "Wheel and tire"
8. Lift the vehicle
9. Drain the coolant. Refer to "Drainage and filling of

coolant".
10. Remove the engine right guard plate Refer to “Engine
bottom left right protective plate”
11. Remove the drive belt. Refer to Drive belt
12. Remove the alternator. Refer to Alternator
13. Remove water pump pulley
1) Remove the fixing bolts of water pump belt pulley.

2) Take off water pump belt pulley
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14. Remove the water pump component

1) Remove 4 fixing bolts of water pump.
CO
2) Remove 2 short fixing bolts of water pump.

3) Take out the water pump and sealing gasket.
Check
1. Check the water pump component
1) Check whether the water pump bearing has a gap

or abnormal sound.
2) Turn the belt pulley flange, check and confirm that
the bearing of water pump component works
smoothly and makes no noise.
Notice
If necessary, please replace the water pump
component.
Installation
1. Install the water pump component
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1) Clean water pump sealing ring mounting groove

and contact surface.
2) Install new water pump seal ring.

Notice
The sealing ring of water pump is a disposable part.
Whenever water pump is dismantled and installed,
please replace the sealing ring of water pump with a
CO new one.
3) Preliminarily tighten up the 2 fixing nuts of water
pump.
4) Preliminarily tighten up the 4 fixing bolts of water

pump component.
5) Tighten fixing bolts of water pump to the specified

torque according to the sequence as shown in the
diagram.
Torque:
Water pump fixing bolt: 9N·m (metric system) or

6.64lb-ft (imperial system)
Water pump fixing nut: 9N·m (metric system) or

6.64lb-ft (imperial system)
2. Install the water pump pulley.
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1) Install the water pump belt pulley and 4 fixing bolts.
2) Tighten up the fixing bolt.
Tightening torque: 22 N·m (metric system) or 16.2

lb-ft (imperial system)
CO
3. Install the drive belt
4. Install the engine right guard plate
5. Install the right front wheel.
9. Fill the engine coolant.
12. Install the connecting plate of trim panel of fender.
NL-3 01/2016
CO-44 JLD-4G20/24 Cooling System - Thermostat Component
Thermostat Component
Component
CO

assembly
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JLD-4G20/24 Cooling System - Thermostat Component CO-45
CO
Cylinder block
Water pump
casing Thermostat
Water inlet seat of

engine
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Removal
Warning!
When there is pressure in cooling system, even if the coolant
in radiator does not boil, the temperature of coolant may
become very high. If the reservoir cover is opened when the
engine has not cooled down and the pressure is still very
CO high, the engine coolant may immediately boil, and splash on
operator's body, and then cause serious scalding!
2. Lift the vehicle

4. Discharge the engine coolant. Refer to “Drainage and

filling of coolant”.
6. Remove the thermostat
1) Loosen the hoop on water outlet pipe of radiator

from water inlet seat.
2) Disconnect the radiator outlet pipe from the engine

water inlet seat.
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3) Remove the engine inlet seat fixing nuts.
4) Remove the water inlet seat from water pump

casing.
CO
5) Remove the thermostat from the casing of water

pump.
Notice
Thermostat and seal ring are integrated.
6) Clean up the bonding face between water inlet
seat of engine and water pump casing.
Check
1. Check the thermostat.
1) Immerse the thermostat into water, and gradually

heat up the water.
2) Check the opening temperature of valve on

thermostat.
Standard opening temperature: 83℃

Notice
If the opening temperature of thermostat does not meet
the standard value, replace the thermostat.
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3) Check the opening lift of thermostat valve.
Fully-opened lift of thermostat: ≥ 10mm

Notice
If the lift of thermostat valve does not meet the standard
value, replace the thermostat.
4) Check whether the throttle is fully closed when the
CO thermostat is at low temperature.
Notice
If the throttle is not fully closed, replace the thermostat.
Installation
1. Install the thermostat
1) Replace the sealing ring of thermostat, and install

the thermostat into the installation hole.
2) Install the water inlet seat of engine onto water

pump casing.
3) Install and tighten up the fixing nut of water inlet

seat of engine.
Torque: 9 N.m (Metric) 6.64lb-ft(English)
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4) Install the water outlet pipe of radiator onto water

inlet seat of engine.
CO
5) Install the hop on water pipe of radiator.
3. Lift the vehicle
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CO-50 JLD-4G20/24 Cooling System - Radiator Assembly
Radiator Assembly
Component
CO
Air filter exhaust pipe
Air filter upper housing
Air filter element
Air filter lower housing
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JLD-4G20/24 Cooling System - Radiator Assembly CO-51
CO
Engine bottom guard

plate assembly
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Vent hose of radiator
Radiator outlet
pipe
Cooling fan
CO Radiator
assembly
Radiator water
inlet pipe.
Rubber pad
Rubber gasket
Air-air
intercooler
Radiator cover
assembly
NL-3 01/2016
Removal

3. Disconnect the negative battery cable. CO

4. Remove the engine trim cover. Rfer to "Engine trim
cover"
5. Collect the refrigerant. Refer to “Drainage and filling of

coolant”
6. Remove the air filter intake pipe. Refer to “Air filter

intake pipe”
7. Lift the vehicle
8. Remove the engine bottom guard plate. Refer to "Left

and right engine bottom guard plate".

11. Remove the wheel trim plate of front fender.
12. Remove the cover of radiator. Refer to "Front bumper

assembly".
13. Remove the front bumper. Refer to "Front bumper

assembly".
14. Remove the A/C pipe. Refer to "A/C pipe (4G20)"
15. Remove the frame of front-end module. Refer to

"Front-end module".
16. Remove the cooling module.
1) Disconnect the cooling fan assembly harness

connector.
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2) Remove fixing bolts of left radiator
CO
3) Remove the fixing bolt of right radiator , and

remove the radiator assembly and condenser
assembly component.
4) Loosen the hoop, and disconnect the connection

between water filling hose and radiator assembly.
5) Remove the hoop, and disconnect the connection

between water outlet pipe of radiator and radiator
assembly.
6) Take out the cooling module.
Disassembling
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17. Remove the radiator
1) Remove the fixing bolt between left portion of

condenser and radiator, and disconnect the
radiator assembly from condenser.
CO
2) Remove the 2 fixing bolts of fan.
3) Remove the fixing clamp between cooling fan

assembly and radiator, and separate the radiator
from cooling fan assembly.
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Assembling
1. Install the radiator
1) Mount the condenser into groove on radiator, and

tighten up the fixing bolt for radiator and
condenser.
CO Torque: 9N·m (Metric) or 6.64lb-ft (English)
2) Install the 2 fixing bolts of fan.

Installation
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2. Install the cooling module.
1) Connect the water outlet pipe of radiator.
2) Connect the water filling pipe of radiator.
CO
3) Mount the radiator and condenser assembly onto

vehicle, and install the right fixing bolt of radiator.
Torque: 9 N·m (Metric) 6.64 lb-ft (English)
NL-3 01/2016
4) Install the left fixing bolt of radiator.
3. Install the frame of front-end module.
4. Install the A/C pipe.
CO 5. Install the front bumper
6. Install the cover of radiator.
7. Install the wheel trim panel of front fender.
10. Fill coolant.
11. Fill the refrigerant
12. Lift the vehicle
NL-3 01/2016
JLD-4G20/24 Cooling System - Expansion Tank Assembly CO-59
Expansion Tank Assembly

Component
CO
Expansion tank

Water filling
hose
Radiator
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CO-60 JLD-4G20/24 Cooling System - Expansion Tank Assembly
Removal
2. Remove the upper trim panel of front bumper.Refer to

"Decorative covering parts of engine compartment".
3. Remove the connecting plate of upper trim panel. Refer

CO to "Decorative covering parts of engine compartment"

"Decorative covering parts of engine compartment"
5. Remove expansion tank.
1) Disconnect the connection between vent hose of

radiator and expansion tank assembly.
Notice
Use a container to receive the coolant leaking out from
expansion tank.
between water filling hose and expansion tank
assembly.
3) Pull out the expansion tank assembly from

supporting seat of expansion tank.
NL-3 01/2016
JLD-4G20/24 Cooling System - Expansion Tank Assembly CO-61
Installation
1. Install the expansion tank assembly.
1) Install the expansion tank assembly onto

CO
2) Connect the water filling hose to expansion tank

assembly.
3) Connect the vent hose of radiator to expansion

tank assembly, and fix the hoop.
4) Add the engine coolant
NL-3 01/2016
CO-62 JLD-4G20/24 Cooling System - Oil Cooler (AT)
Oil Cooler (AT)

Component
CO
Vehicle wheel nut
Wheel assembly
N·m (Ib-ft) Specified torque
NL-3 01/2016
JLD-4G20/24 Cooling System - Oil Cooler (AT) CO-63
CO
Engine right guard

plate assembly
Engine left guard plate

assembly
Engine bottom guard

plate assembly
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Buffer block of front

bumper
CO
Front bumper right
mounting bracket
Upper body of front

Trim strip of front bumper bumper
(right 2)
Trim cover of right Front bumper left

front fog light mounting bracket
Protective beam of small lower

leg of front bumper
Trim strip of front bumper

(right 1)
Trim cover of left

front fog light
(left 2)

(left 1)
Lower body of front

Front bumper lower trim bumper
panel
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Cooling fan assembly
CO
Radiator assembly
Condenser
Oil cooler
Thermostat
Oil inlet pipe of

oil cooler
Oil outlet pipe of

oil cooler
Radiator cover
assembly
NL-3 01/2016
Removal


CO
4. Remove the wheel trim plate of front fender.
5. Remove the cover of radiator. Refer to "Front bumper

assembly".
6. Remove the front bumper. Refer to the section about

front bumper assembly.
7. Remove the oil cooler.
1) Loosen the connecting nut between thermostat

assembly and pipe of oil cooler.
2) Disconnect the oil inlet pipe of oil cooler.
3) Disconnect the oil outlet pipe of oil cooler.
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4) Remove 2 fixing bolts on right portion of oil cooler.
CO
5) Remove the left fixing bolt of oil cooler, and remove

the oil cooler from radiator.
Check
1. Check the oil cooler.
1) Check whether there is leakage on oil cooler.
Installation
1. Install the oil cooler.
1) Install the oil cooler into the installation hole on

radiator, and tighten up the left fixing bolt of oil
cooler.
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2) Tighten up the 2 fixing bolts of right oil cooler.
CO
3) Connect the oil inlet pipe of oil cooler.
4) Connect the oil outlet pipe of oil cooler.
5) Connect the oil/inlet/outlet pipes of automatic

transmission and thermostat assembly.
2. Install the front bumper
4. Install the wheel trim panel of front fender.
NL-3 01/2016
JLE-4G18TDB Cooling System - Contents CO-1
CO JLE-4G18TDB cooling system
Cooling System ................................................................................................................ CO-3

On-board Check ...................................................................................................................... CO-3
Component Position ................................................................................................................ CO-4
Cooling Fan Assembly .................................................................................................. CO-29 CO
Component ........................................................................................................................... CO-29
Removal ................................................................................................................................ CO-31
Installation ............................................................................................................................. CO-32
Coolant ........................................................................................................................... CO-34
Drainage and Filling of Coolant ............................................................................................. CO-34
Water Pump Component ............................................................................................... CO-36
Component ........................................................................................................................... CO-36
Removal ................................................................................................................................ CO-38
Check .................................................................................................................................... CO-39
Installation ............................................................................................................................. CO-40
Thermostat Assembly ................................................................................................... CO-42
Component ........................................................................................................................... CO-42
Removal ................................................................................................................................ CO-44
Check .................................................................................................................................... CO-45
Installation ............................................................................................................................. CO-45
Radiator Assembly ........................................................................................................ CO-47
Component ........................................................................................................................... CO-47
Removal ................................................................................................................................ CO-50
Disassembling ....................................................................................................................... CO-51
Assembling ........................................................................................................................... CO-52
Installation ............................................................................................................................. CO-53
Expansion Tank Assembly ............................................................................................ CO-55
Component ........................................................................................................................... CO-55
Removal ................................................................................................................................ CO-56
Installation ............................................................................................................................. CO-57
Oil Cooler (AT) ................................................................................................................ CO-58
Component ........................................................................................................................... CO-58
Removal ................................................................................................................................ CO-60
Check .................................................................................................................................... CO-61
Installation ............................................................................................................................. CO-61
NL-3 01/2016
CO-2 JLE-4G18TDB Cooling System - Contents
Gas Outlet Pipe of Supercharger ................................................................................. CO-63

Component ........................................................................................................................... CO-63
Removal ................................................................................................................................ CO-65
Installation ............................................................................................................................. CO-66
CO
Intercooler Intake Pipe .................................................................................................. CO-67
Component ........................................................................................................................... CO-67
Removal ................................................................................................................................ CO-69
Installation ............................................................................................................................. CO-70
Intercooler Exhaust Hose.............................................................................................. CO-71
Component ........................................................................................................................... CO-71
Removal ................................................................................................................................ CO-73
Installation ............................................................................................................................. CO-74
Air-air Intercooler Assembly ......................................................................................... CO-75
Component ........................................................................................................................... CO-75
Removal ................................................................................................................................ CO-78
Installation ............................................................................................................................. CO-80
NL-3 01/2016
JLE-4G18TDB Cooling System - Cooling System CO-3
Cooling System
On-board Check
Notice
Before carrying out any check, turn the A/C switch to
position OFF.
When the engine and radiator are hot, please don’t
dismantle the cover of expansion tank; otherwise the CO
high-temperature & high-pressure (up to about 2.2bar)
Coolant or hot steam may be jetted out and cause
scalding.
1. Check the coolant leakage.
1) Start the engine, and make the temperature of

engine coolant reach the normal temperature,
which means heating up the engine until the large
circulation is initiated.
2) Check the parts of cooling system such as water

pipes, expansion tank, radiator, water pump,
cylinder block and cylinder head as well as every
connection for leakage. If any leakage is found,
please re-install, connect or replace the leaking
part.
2. Check the level of coolant
1) When the engine is in cold state, check whether

the level of engine coolant is between the lines
MIN and Max on expansion tank. If the level of
engine coolant is lower than or close to the line
MIN, under the circumstance that the cooling
system does not leak, fill the coolant specified by
Geely until the level reaches the line MAX.
Warning!
Don’t use pure water instead of engine coolant.
3. Check the quality of coolant
1) Remove expansion tank cover.
2) Check whether there is excessive rust or scale

deposit in areas surrounding the filling port of
expansion tank, and make sure that the coolant
does not contain any engine oil. If there is too
much dirt, please clean up the expansion tank and
cooling pipeline, and replace the coolant.
3) Install the cover of expansion tank.
NL-3 01/2016
CO-4 JLE-4G18TDB Cooling System - Cooling System
Component Position
CO
Expansion tank
Radiator
Electronic
water pump
Thermostat
assembly
NL-3 01/2016
Cooling Fan Circuit Diagnosis

Diagnosis tips:
- If a user reports the overheating fault, please firstly confirm whether the level of coolant is normal, and then confirm whether
the engine coolant is overheated. If the engine is overheated, but the cooling fan still runs normally, inspect the engine
cooling system.
- If the fuse EF10 in the engine fuse box immediately blows off after installation, inspect whether the circuit between the
cooling fan high or low-speed relay and EMS is short to ground, or there is short circuit in the EMS. If the fuse EF07 or
EF08 in the engine fuse box blows out just at the pull-in of the relay under the control of the EMS, the circuit between fan CO
relay and fan motor grounding is short to ground, and there is fault in cooling fan motor.
- When the A/C system is switched on, the engine control module controls the cooling fan to run at low speed. When the A/C
high pressure reaches 1,520 Pa (220.5 psiI), the engine control module will switch cooling fan from low speed to high speed.
When the A/C high pressure drops back to 1,450 kPa (210.3 psi), the cooling fan will return to low speed.
- Use the “function test" of fault diagnostic scanner to drive high or low speed cooling fan relay pull-in to confirm whether the
fan works normally, and then quickly determine the fault.
Notice
whether main relay works normally. When using the "action test" of fault diagnostic scanner, make sure the fault diagnostic
scanner communicates with EMS properly.
Next Step
Step 2 Confirm whether the low-speed cooling fan is running.
to OFF state.
interface.
(e) Select in sequence: Engine/data list/ engine coolant
temperature.
(f) When the engine coolant temperature displays 103 ℃
(217.4 ºF), cooling fan should be running at low speed.
(g) Does the cooling fan run at low speed?
No Refer to "Cooling fan does not run at low

speed"
Yes
Step 3 Confirm whether the high-speed cooling fan is running.
(a) Turn off the A/C switch.

(b) When the engine coolant temperature displays 106 ℃
(228.7 ℉) the cooling fan should be running at high speed.
(c) Does the cooling fan run at high speed?
No Refer to "Cooling fan does not run at high

speed"
Yes
Step 4 Turn on the A/C switch, and confirm whether the cooling fan is running at low-speed.
NL-3 01/2016
to OFF state.
interface.
(c) Select in sequence: Engine / data list / engine coolant
temperature.
(d) When the engine coolant temperature is at 93 ℃ (199.4
CO ºF), start the engine, turn on the A/C switch, cooling fan
should be running at low speed.
(e) Does the cooling fan run at low speed?
No There is fault in A/C system, refer to "A/C

system"
Yes
Step 5 Intermittent fault, refer to "Intermittent fault inspection for intermittent faults".
Fault symptoms table
Fault symptom Possible causes Solution
High-speed cooling fan is not running - The fuse EF07 has blown out Refer to "Cooling fan does not run at
- The fan relay ER03 fails high speed"
- EMS fault
- Water temperature sensor signal
errors
Cooling fan does not run at low speed - The fuse EF08 has blown out Refer to "Cooling fan does not run at
- The fan relay ER04 fails low speed"
- EMS fault
- Fan motor internal coil circuit open
fault
- There is electrical contact fault in
relay ER04
- The circuit is open
- Water temperature sensor signal
errors
Cooling fan always runs at low speed - The fuse EF08 has blown out Please refer to "Cooling fan always runs
- The fan relay ER04 fails at low speed"
- Control circuit of fan relay ER04
- Open circuit fault
– Motor internal coil circuit is open
- Short circuit between motor and fan
relay ER04
ER04
- Open circuit in EMS
Cooling fan always runs at high speed - Water temperature sensor signal Please refer to "Cooling fan always runs
errors at high speed"
- Short circuit in EMS
- The circuit from high-speed relay box
to engine is short to the ground
NL-3 01/2016
High-speed Cooling Fan is Not Running

Circuit schematic:
CO
Main relay

relay ER03 ER04
Cooling
fan
Notice
Before performing this diagnosis procedures, please refer to “Cooling fan circuit diagnosis”, which will facilitate the quick

harness and fuse.
No
NL-3 01/2016

Engine compartment fuse, relay box mode to OFF state.

CO mode to ON state.


No
harness
Yes
Step 3
relay ER03.

mode to OFF state.
connector 2 (b) Disconnect the EMS harness connector CA01.

No Circuit fault. If necessary, please replace the

harness
Yes
NL-3 01/2016

mode to OFF state.
CA01 Engine management system (plug-in part K) harness (b) Measure the resistance value between B＋ of battery
connector 2 and fuse EF09.
(c) Measure the resistance between fuse EF09 and CO

terminal 3/5/6 of EMS harness connector CA01.
Yes

mode to OFF state.
CA01 Engine management system (plug-in part K) harness (b) Measure the resistance between terminal 1, 2, 4 of EMS
connector 2 harness connector CA01 and reliable grounding point.
(c) Ensure that the system is normal.
Yes
NL-3 01/2016
Next Step
CO
Cooling Fan Does Not Run at Low Speed

Circuit schematic:
Main relay

relay ER03 ER04
Cooling
fan
Notice
Before performing this diagnostic procedures, please refer to "Cooling fan circuit diagnosis", which will facilitate the quick
NL-3 01/2016

Carry out repair for short circuit fault in fuse

Yes
CO
harness and fuse.
No
Step 2 Check the low-speed power supply of cooling fan motor.

mode to OFF state.
(b) Disconnect the cooling fan harness connector CA28.
mode to ON state.
(d) Connect fault diagnostic scanner to the diagnostic
interface.
(e) Select in sequence: Engine/action test/low-speed fan.
(f) Make the low speed relay ER04 of cooling fan work.
(g) Measure the voltage value between terminal 1 of the
cooling fan harness connector CA28 and reliable
grounding.
(h) Confirm whether the voltage value meets the standard
value.
No Go to step 4
Yes
Step 3 Check the cooling fan grounding circuit.

mode to OFF state.
CA28 Cooling fan harness connector (b) Disconnect the cooling fan harness connector CA28.
(c) Measure the resistance value between terminal 3 of the

grounding.
(d) Confirm whether the resistance value meets the

standard value.

harness
NL-3 01/2016
Yes
Step 4 Use the “Action test” of fault diagnostic scanner to drive the low-speed fan.

the low-speed fan.

CO
No Go to step 7. 7
Yes
Step 5 Check the input power of port 30 of relay ER04.

(d) Remove the cooling fan relay ER04.
(e) Measure the voltage value between port 30 of cooling

fan relay ER04 and reliable grounding.
(f) Confirm whether the voltage value meets the standard

value.

replace the harness
Yes
Check the harness between cooling fan relay ER04 and cooling fan motor harness connector
Step 6
CA28.

(b) Remove the cooling fan relay ER04.
(c) Disconnect the cooling fan harness connector CA28.
(d) Measure the resistance between port 87 of cooling fan

relay ER04 and terminal 1 of cooling fan harness
connector CA28.

grounding, and check whether there is any short circuit.
Standard resistance value: Less than 10KΩ or higher

replace the harness
NL-3 01/2016
CO
No


mode to ON state.


harness
Yes
Step 8
relay ER04.

mode to OFF state.
CA01 Engine management system (plug-in part K) harness (b) Disconnect the EMS harness connector CA01.
connector 2


harness
NL-3 01/2016
CO
Yes
(a) Replace the ER04 relay.
No

mode to OFF state.
CA01 Engine management system (plug-in part K) harness
connector 2 (b) Measure the resistance value between B＋ of battery
and fuse EF09.
(c) Measure the resistance between fuse EF09 and

NL-3 01/2016
CO
Yes

mode to OFF state.
Yes
Next Step
NL-3 01/2016
Cooling Fan Always Runs at Low Speed

Circuit schematic:
CO
Main relay

high-speed low-speed relay
relay ER03 ER04
Cooling
fan
Notice
Before performing this diagnosis procedures, please refer to cooling fan circuit diagnosis, which will facilitate the quick

harness and fuse.
No
NL-3 01/2016
Check the harness between terminal 26 of EMS harness connector CA01 and low-speed relay
Step 2

mode to OFF state.
connector 2
(c) Disconnect the EMS harness connector CA01. CO

harness connector CA01 and grounding point on vehicle
body.

Yes
Step 3 Use the “Action Test” of fault diagnostic scanner to drive the fan high-speed.
No Go to step 8
Yes
Step 4 Check the power supply circuit of the cooling fan high-speed relay ER03 coil.


mode to ON state.


No
harness
Yes
Step 5
relay ER03.
NL-3 01/2016

mode to OFF state.
connector 2 (b) Disconnect the EMS harness connector CA01.
(d) Resistance of terminal 85 of ER03.

CO Standard resistance value: Less than 1Ω

harness
Yes

mode to OFF state.
and fuse EF09.

NL-3 01/2016
CO
Yes

mode to OFF state.
CA01 Engine management system (plug-in part K) harness (b) Measure the resistance between terminal 1/2/4 of EMS
Yes
Step 8 Replace the high-speed relay ER03 of cooling fan.
(a) Replace the high-speed relay ER03 of cooling fan.
No
Next Step
NL-3 01/2016
Cooling Fan Always Runs at High Speed

Circuit schematic:
CO
Main relay

high speed low-speed relay
relay ER03 ER04
Cooling
fan
Notice
Before performing this diagnosis procedures, please refer to cooling fan circuit diagnosis, which will facilitate the quick

(b) Remove the low-speed fuse EF08 of cooling fan.

harness and fuse.
No
NL-3 01/2016
Check the harness between terminal 27 of EMS harness connector CA01 and low-speed relay
Step 2

mode to OFF state.
connector 2 (b) Remove cooling fan low-speed relay ER03.
(c) Disconnect the EMS harness connector CA01. CO

harness connector CA01 and grounding on vehicle
body.
There is short circuit between control circuit

No
and earth. Repair or replace the harness.
Yes
Step 3 Use the “Action test” of fault diagnostic scanner to drive the low-speed fan.
(a) Check whether the fan relay ER04 is working.
No Go to step 8
Yes


mode to ON state.


No
harness
Yes
Step 5
relay ER04.
NL-3 01/2016

mode to OFF state.
CA01 Engine management system (plug-in part K) harness (b) Disconnect the EMS harness connector CA01.
connector 2

CO

harness
Yes

mode to OFF state.
and fuse EF09.

NL-3 01/2016
CO
Yes

mode to OFF state.
connector 2
Yes
Step 8 Replace the low-speed relay ER04 of cooling fan.
(a) Replace the low-speed relay ER04 of cooling fan.
No
Next Step
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Diagnosis of Thermostat
Step 1 Remove the thermostat. Refer to "Thermostat assembly".
Next Step
CO Step 2 Soak the thermostat in water and heat the water.
(a) Check the thermostat opening temperature.
Standard value: (95±2) ℃
(b) Confirm whether the opening temperature of thermostat

is normal.
No Replace the thermostat. Please refer to

"Thermostat assembly".
Yes
Step 3 Check thermostat valve lift range
Standard lift of valve: 8 mm (0.31 in) or above at 105℃
(a) Determine whether the valve lift is normal
No Replace the thermostat. Please refer to

Yes
Step 4 Check whether the thermostat is completely switched off at low temperature.
(a) When the thermostat is lower than 91℃, check whether

the valve is fully closed.
Replace the thermostat. Refer to

No
Next Step
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Step 5 The thermostat is in normal conditions.
Engine Overheat
Warning!
CO
Step 1 Check whether the engine coolant is drained off?
Yes Fill engine coolant
Next Step
Step 2 Check whether the engine coolant concentration is sufficient?
Use "Geely Genuine ultra-long-acting

engine coolant"" or the same level of
Yes
high-quality ethylene glycol base engine
coolant, model or standard number: comply
with SH0521.
Next Step
Step 3 Check whether the front radiator has dust, leaves, insects or several other impurities?
Yes Clear the radiator's front part
Next Step
Check coolant pipes, water pumps, engine water inlet, outlet joint components, radiator, core
Step 4
plugging and cylinder head gasket for leakage.
Yes Replace any damaged component
Next Step
Connect fault diagnostic scanner, when the data flow shows the engine coolant temperature
Step 5 reaches 97 ℃ (203 oF ), check the radiator inlet and outlet hoses temperature. There should be
no temperature difference. Is the temperature difference large?
1. Check whether the operation of the

Yes thermostat is normal. 2. Check whether the
radiator is blocked.
Next Step
Step 6 Use the ignition timing gun to check whether the ignition timing is over delayed?
Yes Check the ignition timing of engine, and

implement the diagnosis for EMS
Next Step
Step 7 Check whether the electric cooling fan works normally?
Yes Check the cooling fan circuit. Refer to

"Cooling Fan Circuit Diagnosis"
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No
Step 8 Check whether the water pump has fault.
Yes Replace the water pump. Refer to "Water

pump component".
No
CO
Step 9 Check whether there is any fault in cover of expansion tank.
Replace the cover of expansion tank which

Yes has fault.
No
Step 9 Check whether there is any fault in cover of expansion tank.
Yes Replace the cover of expansion tank which

has fault.
No
Check whether the cylinder lid and engine body have rupture or blockage, whether the cylinder
Step 10
seal gasket is not well sealed?
Yes Repair broken cylinder lid and engine body.
Next Step
Engine Does Not Reach Normal Operating Temperature

Warning!
Step 1 Check whether coolant level in expansion tank is abnormal?
Yes Fill the engine coolant to the specified level

height
No
Step 2 Check the cooling system temperature.

mode to OFF state.
(b) Connect the fault diagnostic scanner to the diagnosis
test interface.
mode to ON state.
(d) Select in sequence: Engine,data sheet, engine coolant
temperature.
(e) Sustain the engine speed at 2000rpm and observe the
engine coolant temperature in the data stream.
(f) Does the engine coolant temperature rise normal?
There is fault in instrument. Refer to

"Combination instrument"
No
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Step 3 Check whether the cooling fan runs normally.
Yes Please refer to "Cooling fan always runs at

high speed"
No
CO
Step 4 Check whether the thermostat operation is reliable?
(a) Check whether the type of the installed thermostat is

correct.
(b) Check whether the thermostat is stuck at the open
position.
No Yes Replace correct type of thermostat
Yes Flush the cooling system or inspect the

radiator flow.
No
Step 6 The vehicle road test confirms the fault has been cleared.
Excessive Engine Coolant Loss

Warning!
Step 1 Check whether the radiator has leakage?
Yes Replace the damaged radiator
No
Step 2 Check for leakage at the following positions: expansion tank assembly, water pipes.
If necessary, replace the following

Yes components: expansion tank assembly,
water pipes.
No
Step 3 Check whether the radiator pipes and joints are loose or damaged?
Yes Reinstall and change the water pipes or the

clamp.
No
Step 4 Check whether the water pump seal has leakage.
NL-3 01/2016
Yes Replace the water pump component
No
Step 5 Check whether the cylinder lid torque is suitable.
CO
Tighten the cylinder lid bolts to the specified
Yes torque. If necessary, replace the cylinder lid
gasket
No
Step 6 Check for leakage at the following positions:
(a) Intake manifold
(b) Cylinder head lining
(c) Cylinder block plug screw
(d) Heater core
(e) Radiator discharge plug
If necessary, repair or replace component

Yes
and remove leakage fault
No
NL-3 01/2016
JLE-4G18TDB Cooling System - Cooling Fan Assembly CO-29
Cooling Fan Assembly

Component
Air flowmeter
CO
Engine intake hose Upper cover of air filter
Air filter element
Lower cover of air

filter
Engine bottom guard

plate assembly
NL-3 01/2016
CO-30 JLE-4G18TDB Cooling System - Cooling Fan Assembly
CO Radiator outlet Cooling fan

pipe
Radiator water
inlet pipe.
Rubber
pad
Radiator
assembly
Rubber
gasket
Air-air
intercooler
Radiator cover
assembly
NL-3 01/2016
Removal

Decorative covering parts of engine compartment.

“Decorative covering parts of engine compartment”. CO

cover"
6. Remove the air filter intake pipe. Refer to "Air filter

intake pipe"
7. Lift the vehicle
8. Remove the engine bottom guard plate
10. Remove cooling fan assembly
1) Remove the two fixing screws on upper and lower

Notice: The fixing bolt on lower portion shall be dismantled

after the vehicle is lifted up and before the vehicle is lowered
down; otherwise it can’t be dismantled.
2) Disconnect the vent hose of radiator from cooling

fan assembly.
NL-3 01/2016
CO-32 JLE-4G18TDB Cooling System - Cooling Fan Assembly
3) Loosen the fixing clamp between cooling fan

assembly and radiator.
4) Move the radiator towards engine, and pull out the

cooling fan assembly from radiator.
Notice
The cooling fan assembly can be taken out only after the
CO radiator has been moved towards engine compartment for
certain distance.
Installation
1. Install cooling fan assembly
1) Install the cooling fan assembly into the installation

hole.
2) Install the vent hose of radiator onto cooling fan

assembly.
3) Install the two fixing screws on upper and lower

Notice: Before installing the fixing screw on lower portion of

fan, be sure to lift up the vehicle; otherwise they can’t be
installed.
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3. Lift the vehicle

CO
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CO-34 JLE-4G18TDB Cooling System - Coolant
Coolant
Drainage and Filling of Coolant
2. Screw off the cover of expansion tank
1) Screw off the cover of expansion tank.
Notice
CO When the engine coolant is still hot, don’t dismantle the
expansion tank cover. The hot engine coolant and vapor
may be released and cause serious scalding.
3. Lift the vehicle
fender. Refer to “Decorative covering parts of engine
compartment”.
7. Remove the upper trim panel of left fender. Refer to
9. Exhaust coolant
1) Screw off the cover of expansion tank.

Notice
When the engine coolant is still hot, don’t dismantle the
expansion tank cover. The hot engine coolant and vapor
may be released and cause serious scalding.
2) Loosen the water drain valve of radiator, and use a

container to receive the engine coolant drained.
Notice
Handle the recycled old engine coolant, waiting for
scrap or recycling. Do not dispose the old engine
coolant into the water sewage for protecting the
environmen.
NL-3 01/2016
JLE-4G18TDB Cooling System - Coolant CO-35
12. Fill coolant.
1) Tighten up the water drain valve of radiator with

hand.
CO
2) Fill the coolant into expansion tank, until the level
reaches the mark line MAX on expansion tank.
3) Press the water inlet/outlet hoses of radiator with

hand for several times, and then check the level of
coolant.
Notice
If the coolant level is lower than or close to the line MIN
on expansion tank, please fill the coolant.
13. Empty the air of the cooling system
1) Start the engine, until the thermostat assembly has

been fully opened and the coolant has been
circulated for several minutes.
Hint: Press the water inlet/outlet hoses of radiator

with hand. When you feel that the coolant is flowing
into the radiator, you may confirm that the
thermostat assembly is fully opened.
2) Keep the engine speed between 2,500 and 3,000

rpm.
3) Press the water inlet/outlet hoses of radiator with

hand for several times, until there is no bubble in
liquid flowing out.
Notice
When pressing the radiator hose, please wear the
protective gloves. When the radiator hose is hot, please
be careful, so as to avoid scalding!
Warning! Keep away from radiator fan.
Notice
Please make sure that there is always coolant in
expansion tank.
4) Shut down the engine, lift up the vehicle, and
confirm that there is no leakage on water drain
valve of radiator.
5) Install the engine bottom guard plate.
6) Lower down the vehicle, and fill the engine coolant

until the level of engine coolant reaches the line
MAX on expansion tank assembly.
7) Tighten up the cover of expansion tank.
NL-3 01/2016
CO-36 JLE-4G18TDB Cooling System - Water Pump Component
Water Pump Component

Component
CO
Water inlet
pipe for warm
wind
Water outlet
pipe for warm
wind
Engine bottom guard

plate assembly
NL-3 01/2016
JLE-4G18TDB Cooling System - Water Pump Component CO-37
CO
Sealing ring of
thermostat casing
Thermostat casing
component
Water pump
component
Water pump
belt
Water pump
drive pulley
Fixing bolt of the water

pump drive wheel Water pump
belt cover
Non-reusable parts
NL-3 01/2016
Removal
Warning!
though the solution in the radiator is not boiled, the solution
temperature will be much higher than the water boiling point.
If the expansion tank cap is removed while the engine is still
hot and under high pressure during maintenance, the engine
coolant will boil immediately and may spray into the
CO operator's body, causing serious burns.
cover"
7. Remove the water outlet pipe component for warm
wind. Refer to "Water pipe for warm wind".
8. Remove water pump pulley cover
1) Remove the 2 fixing bolts of water pump belt cover.
2) Remove the belt cover.
9. Remove the water pump belt

1) Remove the fixing bolt of water pump driving
pulley.
2) Remove the driving pulley and driving belt.

Notice
Remove the fixing bolt of water pump driving pulley
clockwise. (viewed forwards from rear end of engine)
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3) Remove the 5 fixing bolts of thermostat casing

assembly.
CO
4) Remove the 5 bolts of water pump component,

and remove the water pump component from
thermostat casing assembly.
Notice: Remove the sealing ring of thermostat casing.
Check
1. Check the water pump component
1) Check whether the water pump bearing has a gap

or abnormal sound.
2) Turn the belt pulley, check and make sure that the
bearing of water pump component works smoothly
and makes no noise.
Notice
If necessary, please replace the water pump
component.
NL-3 01/2016
Installation
1. Install the water pump component
1) Install the water pump component.
2) Install and tighten up the 5 fixing bolts.
Torque: 10.5 N.m (Metric) 7.75 lb-ft (English)

CO
3) Install the thermostat casing assembly.
Torque: 10.5 N.m (Metric) 7.75 lb-ft (English)

Notice: Install the new sealing ring for thermostat casing.
4) Install the driving pulley and driving belt.
5) Tighten up the water pump driving pulley fixing

bolt.
Torque: 13 N·m (metric system) or 9.59 lb-ft(imperial

system) (left-hand turning)
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2. Install belt pulley cover of water pump.
1) Install 2 fixing bolts of water pump belt cover.
3. Install the water outlet components from heater

CO
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CO-42 JLE-4G18TDB Cooling System - Thermostat Assembly
Thermostat Assembly
Component
Trim cover of
CO engine
Engine bottom guard

plate assembly
NL-3 01/2016
JLE-4G18TDB Cooling System - Thermostat Assembly CO-43
CO
Cylinder block
Sealing ring of
thermostat casing
Thermostat casing
component
Water pump
component
Thermostat
assembly
Engine thermostatcover
assembly
Non-reusable parts
NL-3 01/2016
Removal
Warning!
though the solution in the radiator is not boiled, the solution
temperature will be much higher than the water boiling point.
If the expansion tank cap is removed while the engine is still
hot and under high pressure during maintenance, the engine
coolant will boil immediately and may spray into the
CO operator's body, causing serious burns.
cover"
2. Lift the vehicle


6. Remove the thermostat assembly
1) Loosen the elastic hoop.
2) Disconnect the oil outlet pipe of radiator from

engine thermostat cover assembly.
3) Remove the 2 fixing bolts of engine thermostat

cover assembly.
4) Remove the engine thermostat cover assembly

from thermostat casing assembly.
NL-3 01/2016
JLE-4G18TDB Cooling System - Thermostat Assembly CO-45
5) Remove the thermostat assembly from thermostat

casing assembly.
CO
Check
1. Check the thermostat assembly
1) Immerse the thermostat assembly into water, and

gradually heat up the water.
2) Check the opening temperature of valve of

thermostat assembly.
Standard opening temperature: 95±2℃
Notice
If the opening temperature of thermostat assembly is

not identical with the standard value, replace the
thermostat assembly.
Installation
1. Install the thermostat assembly
1) Install the thermostat assembly into the installation

hole on thermostat casing assembly.
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2) Install the thermostat cover assembly onto

thermostat casing assembly.
3) Install and tighten up the 2 fixing nuts of thermostat

cover assembly.
Torque: 10.5 N.m (Metric) 7.75 lb-ft(English)
CO
4) Install the water outlet pipe of radiator onto engine

thermostat cover assembly.
5) Install the hoop of water outlet pipe of radiator.
3. Lift the vehicle
NL-3 01/2016
JLE-4G18TDB Cooling System - Radiator Assembly CO-47
Radiator Assembly
Component
Air flowmeter
CO
Engine intake hose Upper cover of air

filter
Air filter element
Lower cover of air

filter

assembly
NL-3 01/2016
CO-48 JLE-4G18TDB Cooling System - Radiator Assembly
CO
Right front combination lamp
mounting crossbeam assembly
Left front combination

lamp mounting
crossbeam
Radiator frame assembly (including

front-end module)
Radiator central support

assembly
Front reinforcing beam

assembly of radiator
Front cross beam

assembly
Radiator cover
assembly
Front bumper
assembly
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Cooling fan CO
Radiator outlet
pipe
Radiator water
inlet pipe.
Rubber pad
Radiator
assembly
Rubber
Air-air
gasket
intercooler
Radiator cover
assembly
NL-3 01/2016
Removal

CO
5. Drain the refrigerant. Refer to "Drainage and filling of

A/C refrigerant".
6. 6. Remove the air filter intake pipe. Refer to “Air filter

intake pipe”
7. Remove the cover of radiator. Refer to "Radiator

assembly".
8. Remove front bumper assembly. Refer to "Front bumper

assembly".
9. Remove the frame of front-end module (only for

JLE-4G18TDB engine). Refer to Front-end module.
10. Remove the cooling module.
1) Separate the elastic hoop, and disconnect the

connection between water outlet pipe of radiator
and radiator assembly.
2) Disconnect the connection between intake/exhaust

hose of compressor and condenser.
NL-3 01/2016
3) Remove the fixing bolts on left and right portions of

radiator.
4) Take out the cooling module.
CO
Disassembling
11. Remove the radiator
1) Remove the fixing bolt between left portion of

condenser and radiator.
2) Separate the radiator from condenser.
NL-3 01/2016
3) Remove the 2 fixing bolts of fan.
CO
4) Remove the fixing clamp between cooling fan

assembly and radiator, and separate the radiator
from cooling fan assembly.
Assembling
1. Install the cooling module.
1) Mount the condenser into groove on radiator, and

tighten up the fixing bolt for radiator and
condenser.
NL-3 01/2016

CO
3) Install the 2 fixing bolts of fan.
Installation
2. Install the radiator
1) Mount the cooling module onto vehicle, and install 2

radiator fixing bolts.
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2) Install the intake/exhaust pipe of compressor onto

condenser, and then tighten up the connecting bolts.
CO
3) Connect the intake pipe of radiator.
4) Connect the water filling pipe of radiator.
5. Install the radiator cover assembly
6. Install the front bumper assembly
8. Fill coolant.
NL-3 01/2016
JLE-4G18TDB Cooling System - Expansion Tank Assembly CO-55
Expansion Tank Assembly

Component
CO
Vent hose of
radiator
Expansion
tank
Water filling
hose
Radiator
assembly
NL-3 01/2016
CO-56 JLE-4G18TDB Cooling System - Expansion Tank Assembly
Removal

refer to "Decorative covering parts of engine
compartment"
CO 3. Remove the connecting plate of upper trim panel.

Please refer to "Decorative covering parts of engine
compartment"

compartment"
5. Remove expansion tank.
1) Disconnect the connection between vent hose of

radiator and expansion tank assembly.
Notice
Use a container to receive the coolant leaking out from
expansion tank.
between water filling hose and expansion tank
assembly.
3) Pull out the expansion tank assembly from

NL-3 01/2016
JLE-4G18TDB Cooling System - Expansion Tank Assembly CO-57
Installation
1. Install the expension tank assembly.
1) Install the expansion tank assembly onto

CO
2) Connect the water filling hose to expansion tank

assembly.
3) Connect the vent hose of radiator to expansion

tank assembly, and fix the hoop.
4) Add the engine coolant
NL-3 01/2016
CO-58 JLE-4G18TDB Cooling System - Oil cooler (AT)
Oil cooler (AT)

Component
CO Decorative plate assembly of right

front fender
Radiator cover
assembly
Decorative plate assembly of left

front fender
Front bumper
assembly
Engine bottom guard

plate assembly
NL-3 01/2016
JLE-4G18TDB Cooling System - Oil cooler (AT) CO-59
Cooling fan
assembly
Radiator assembly CO
Condenser
Oil cooler
Thermostat
Oil inlet pipe of

oil cooler
Oil outlet pipe of

oil cooler
Radiator cover
assembly
NL-3 01/2016
Removal

CO
4. Remove the trim panel of front fender. Refer to Trim
panel of front fender.

assembly".

assembly".
7. Remove the oil cooler.
1) Loosen the connecting nut between thermostat

assembly and pipe of oil cooler.
1) Disconnect the oil inlet pipe of oil cooler.
2) Disconnect the oil outlet pipe of oil cooler.
NL-3 01/2016
JLE-4G18TDB Cooling System - Oil cooler (AT) CO-61
3) Remove the right fixing bolt of oil cooler.
CO
4) Remove the left fixing bolt of oil cooler, and remove

the oil cooler from radiator.
Check
1. Check the oil cooler.
1) Check the oil cooler for leakage.
Installation
1) Install the oil cooler into the installation hole on

radiator, and tighten up the left fixing bolt of oil
cooler.
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2) Tighten up the right oil cooler fixing bolt.
CO
3) Connect the oil inlet pipe of oil cooler.
4) Connect the oil outlet pipe of oil cooler.
5) Connect the oil/inlet/outlet pipes of automatic

transmission and thermostat assembly.
4. Install the trim panel of front fender.
NL-3 01/2016
JLE-4G18TDB Cooling System - Gas Outlet Pipe of Supercharger CO-63
Gas Outlet Pipe of Supercharger

Component
CO
Engine bottom guard

plate assembly
NL-3 01/2016
CO-64 JLE-4G18TDB Cooling System - Gas Outlet Pipe of Supercharger
CO Gas outlet pipe of

supercharger
Radiator
assembly
Intercooler
intake pipe Intake pipe of
engine
Air-air Intercooler exhaust

intercooler hose
NL-3 01/2016
JLE-4G18TDB Cooling System - Gas Outlet Pipe of Supercharger CO-65
Removal
1. Lift the vehicle

and right engine bottom guard plate"
3. Remove the engine right guard plate Refer to "Left and

right engine bottom guard plate"
CO
4. Remove the gas outlet pipe of supercharger.
1) Loosen the type-A worm-driven hose hoop.
2) Separate the gas outlet pipe of supercharger from

intake pipe of intercooler.
3) Loosen the quick-type elastic circlip.
4) Remove two connecting bolts of gas outlet pipe of

supercharger and cylinder block, and remove the
gas outlet pipe of supercharger from turbocharger.
NL-3 01/2016
CO-66 JLE-4G18TDB Cooling System - Gas Outlet Pipe of Supercharger
Installation
1. Install the gas outlet pipe of supercharger.
1) Install 2 connecting bolts of gas outlet pipe of

supercharger and cylinder block.
Torque:9 N (Metric) 6.64 lb-ft (English)

CO
2) Connect the gas outlet pipe of supercharger to

turbocharger, and fix the quick-type elastic circlip.

4) Install the type-A worm-driven hose hoop.
Torque:4 N·m (Metric) 6.64 lb-ft (English)
NL-3 01/2016
JLE-4G18TDB Cooling System - Intercooler Intake Pipe CO-67
Intercooler Intake Pipe

Component
CO

assembly
NL-3 01/2016
CO-68 JLE-4G18TDB Cooling System - Intercooler Intake Pipe
Gas outlet pipe of

CO supercharger
Radiator
assembly
Intercooler Intake pipe of

intake pipe engine
Air-air
Intercooler exhaust
intercooler
hose
NL-3 01/2016
JLE-4G18TDB Cooling System - Intercooler Intake Pipe CO-69
Removal
1. Lift the vehicle
2. Remove the engine bottom guard plate. Please refer to

"Left and right engine bottom guard plate"
3. Remove the engine right guard plate. Please refer to

CO
4. Remove the intake pipe of intercooler.
1) Loosen the hoop on connection between gas outlet

pipe of supercharger and intake pipe of intercooler.
Remove the gas outlet pipe of supercharger from

separate the intake pipe of intercooler from air-air
intercooler assembly.
NL-3 01/2016
CO-70 JLE-4G18TDB Cooling System - Intercooler Intake Pipe
Installation
1. Install the intake pipe of intercooler.
1) Connect the intake hose of intercooler to air-air

intercooler assembly, and fix the type-A
worm-driven hose hoop.
CO

intake pipe of intercooler, and fix the type-A
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JLE-4G18TDB Cooling System - Intercooler Exhaust Hose CO-71
Intercooler Exhaust Hose

Component
CO

assembly
NL-3 01/2016
CO-72 JLE-4G18TDB Cooling System - Intercooler Exhaust Hose
Gas outlet pipe of

supercharger
CO
Radiator
assembly
Intercooler intake
pipe Intake pipe of
engine

intercooler hose
NL-3 01/2016
JLE-4G18TDB Cooling System - Intercooler Exhaust Hose CO-73
Removal
1. Lift the vehicle
2. Remove the engine right guard plate Refer to “Left/right

engine bottom guard plate”

CO
4. Remove the gas outlet hose of intercooler.

separate the gas outlet hose of intercooler from
intake pipe of engine.

air-air intercooler assembly.
NL-3 01/2016
CO-74 JLE-4G18TDB Cooling System - Intercooler Exhaust Hose
Installation
1. Install the gas outlet hose of intercooler.
1) Connect the gas outlet hose of intercooler to air-air

CO
2) Connect the gas outlet hose of intercooler connect

to intake pipe of engine, and fix the type-A
NL-3 01/2016
JLE-4G18TDB Cooling System - Air-air Intercooler Assembly CO-75
Air-air Intercooler Assembly

Component
CO
Right front combination lamp

mounting crossbeam assembly
Left front combination lamp

mounting crossbeam
Radiator frame assembly (including

front-end module)
Radiator central support

assembly
Front reinforcing beam

assembly of radiator
Front cross beam

assembly
Radiator cover
assembly
Front bumper
assembly
NL-3 01/2016
CO-76 JLE-4G18TDB Cooling System - Air-air Intercooler Assembly
CO Radiator outlet Cooling fan

pipe
Radiator water
inlet pipe.
Rubber
pad
Radiator
assembly
Rubber
gasket
Air-air
intercooler
Radiator cover
assembly
NL-3 01/2016
Gas outlet pipe of

supercharger
CO
Radiator
assembly
Intercooler intake
pipe Intake pipe of
engine

intercooler hose
NL-3 01/2016
Removal
1. Lift the vehicle


CO and right engine bottom guard plate"
4. Remove the front wheel trim. Refer to Front fender.

assembly".

assembly".
7. Remove the intake pressure temperature sensor. Refer

to "Intake pressure temperature sensor"
8. Remove the frame of front-end module. Refer to

"Front-end module".
9. Remove the air-air intercooler assembly

separate the intake hose of intercooler from air-air
intercooler assembly.

air-air intercooler assembly.
NL-3 01/2016
3) Remove the hexagonal head bolt & flat gasket

component between air-air intercooler and left
portion of radiator assembly.
CO
4) Remove the hexagonal head bolt & flat gasket

component between air-air intercooler and right
portion of radiator assembly.
5) Remove the air-air intercooler assembly from

radiator.
NL-3 01/2016
Installation
1. Install the air-air intercooler assembly
1) Install the air-air intercooler assembly onto radiator

assembly.
CO
2) Install and tighten up the hexagonal head bolt &

flat gasket component between air-air intercooler
and left portion of radiator assembly.
3) Install and tighten up the hexagonal head bolt &

flat gasket component between air-air intercooler
and right portion of radiator assembly.
NL-3 01/2016
4) Connect the gas outlet hose of intercooler to air-air

CO
5) Connect the intake hose of intercooler to air-air

3. Install the intake pressure temperature sensor.
4. Install the front bumper.
6. Install the front wheel trim.
NL-3 01/2016
CO
NL-3 01/2016
JLD-4G20/24 Intake System - Contents AI-1
AI JLD-4G20/24 Intake System
Air Intake System ............................................................................................................... AI-2

Component Position .................................................................................................................. AI-2
On-board Check ........................................................................................................................ AI-3
Air Filter Intake Pipe .......................................................................................................... AI-4
CO
Component ............................................................................................................................... AI-4
Removal .................................................................................................................................... AI-5
Installation ................................................................................................................................. AI-6
Engine Intake Hose ............................................................................................................ AI-7
Component ............................................................................................................................... AI-7
Removal .................................................................................................................................... AI-8
Installation ................................................................................................................................. AI-9
Air Filter ............................................................................................................................ AI-10
Component ............................................................................................................................. AI-10
Removal .................................................................................................................................. AI-11
Disassembling ......................................................................................................................... AI-12
Check ...................................................................................................................................... AI-12
Assembling ............................................................................................................................. AI-12
Installation ............................................................................................................................... AI-13
Intake Manifold Component ............................................................................................ AI-14
Component ............................................................................................................................. AI-14
On-board dismantlement ......................................................................................................... AI-20
Disassembling ......................................................................................................................... AI-21
Assembling ............................................................................................................................. AI-22
On-board installation ............................................................................................................... AI-23
NL-3 01/2016
AI-2 JLD-4G20/24 Intake System - Air Intake System
Air Intake System

Component Position
CO
Intake manifold
Air filter
NL-3 01/2016
JLD-4G20/24 Intake System - Air Intake System AI-3
On-board Check
1. Check whether there is leakage on sealing face of

intake system
1) Check whether there is leakage on connecting
face of air outlet of air filter.
face between electronic throttle and intake
manifold. CO
face between intake manifold and cylinder head.
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AI-4 JLD-4G20/24 Intake System - Air Filter Intake Pipe
Air Filter Intake Pipe

Component
CO
Air filter
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JLD-4G20/24 Intake System - Air Filter Intake Pipe AI-5
Removal

2. Remove the engine trim cover
fender. Refer to "Decorative covering parts of engine CO
compartment"
5. Remove the upper trim panel assembly of left fender.
Refer to "Decorative covering parts of engine
compartment"
1) Remove the 2 fixing clamps of intake pipe of air
filter.
2) Separate the intake pipe of air filter from air filter,

and remove the intake pipe of air filter.
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AI-6 JLD-4G20/24 Intake System - Air Filter Intake Pipe
Installation

1) Install the intake pipe of air filter onto air filter.
CO
2) Use the clamp to fix the intake pipe of air filter.

4. Install the connecting plate of upper trim panel of fender.
NL-3 01/2016
JLD-4G20/24 Intake System - Engine Intake Hose AI-7
Engine Intake Hose

Component
B type worm drive flexible pipe

ring clamp
Engine intake hose CO
Exhaust hose of
crankcase
Air filter assembly
B type worm drive flexible pipe

ring clamp
4G24 Engine
NL-3 01/2016
AI-8 JLD-4G20/24 Intake System - Engine Intake Hose
Removal

cover"
CO 4. Remove the connecting plate of upper trim panel of
compartment"
compartment"
6. Remove the intake hose of engine. Refer to Intake hose
of engine.
separate the intake hose of engine from gas outlet
flange.
2) Loosen the elastic hoop, and separate the exhaust

hose of crankcase from intake hose of engine.
remove the intake hose of engine from electronic
throttle body.
NL-3 01/2016
JLD-4G20/24 Intake System - Engine Intake Hose AI-9
Installation
1. Install the intake hose of engine

1) Install the intake hose of engine onto electronic
throttle body, and tighten up the type-B
2) Install the exhaust hose of crankcase onto intake
hose of engine, and use the elastic hoop to fix it.
CO
3) Connect the intake hose of engine to gas outlet

flange, and tighten up the type-B worm-driven
hose hoop.
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AI-10 JLD-4G20/24 Intake System - Air Filter
Air Filter
Component
CO
Air filter element
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JLD-4G20/24 Intake System - Air Filter AI-11
Removal

2. Remove the upper trim panel of front bumper.Refer to
compartment"
CO
compartment"
cover"
intake pipe"
7. Remove the air vent flange of upper housing
disconnect the connection between intake hose of
engine and upper gas outlet flange pipe.
2) Remove 2 fixing bolts of upper gas outlet flange,
and remove the upper gas outlet flange.
8. Remove air filter

1) Remove the fixing bolt of air filter assembly, and
remove the air filter assembly.
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AI-12 JLD-4G20/24 Intake System - Air Filter
Disassembling
1. Disassemble the air filter assembly

1) Remove connecting screws between upper and
lower housings of air filter, and take out air filter
element.
CO
Check
1. Check the air filter element

1) Check visually whether air intake side of air filter
element is too dirty; clean filter element from air
vent side with compressed air or replace filter
element if it is too dirty.
Assembling
1. Install air filter assembly.

1) Install the air filter element, use screw to connect
the upper and lower casings of air filter, and tighten
up such screw.
NL-3 01/2016
JLD-4G20/24 Intake System - Air Filter AI-13
Installation

1) Mount the air filter assembly into installation hole
for air filter, and tighten up the air filter fixing bolt.
CO
2. Install the air vent flange of upper housing

1) Connect the intake hose of engine and pipe of
upper gas outlet flange.
2) Install the 2 fixing bolts of upper gas outlet flange.
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AI-14 JLD-4G20/24 Intake System - Intake manifold component
Intake manifold component

Component
CO
Trim cover of
engine
Engine assembly
4G20/24
NL-3 01/2016
JLD-4G20/24 Intake System - Intake manifold component AI-15
Air filter assembly
CO
Clamp
Electronic
throttle
Intake
manifold
Throttle valve body

seal gasket
NL-3 01/2016
CO
Vehicle wheel nut
Wheel
assembly
Specified torque
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CO

assembly
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Carbon canister
control valve Vent hose of
carbon canister
Protective sleeve of solenoid
valve of carbon canister
CO
Carbon canister
hose
Intake
manifold
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Intake
manifold
CO
Intake pressure
temperature sensor
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CO 5. Remove the connecting plate of upper trim panel of
compartment"
compartment"
7. Remove the upper trim panel assembly of right fender.
compartment"
cover"
9. Remove the intake hose of engine assembly. Refer to
"Intake hose of engine"
10. Remove the electronic throttle. Refer to "Electronic
throttle body"
11. Remove the intake manifold component and intake
pressure/temperature sensor. Refer to "Intake manifold
component"
1) Install the positive crankcase ventilation vacuum

tube
2) Disconnect the vacuum booster hose.
3) In the sequence as indicated in the figure,

dismantle the 2 nuts and 3 bolts on upper end.
NL-3 01/2016
4) Remove the 2 bolts on lower end.
CO
5) Disconnect intake pressure temperature sensor

cable connector
6) Install the intake manifold component and intake
pressure temperature sensor
Disassembling

1) Remove the intake pressure temperature sensor
fixing bolt from intake manifold, and then remove
the intake pressure temperature sensor.
NL-3 01/2016
2. Remove the lower cover component of intake manifold

1) Remove the upper cover component of intake
manifold and the connecting bolt of intake
manifold.
2) Remove the lower cover component intake
manifold.
CO
3. Remove the upper cover component of intake manifold

manifold.
manifold from intake manifold.
Assembling
1. Install the upper cover component of intake manifold

1) Install the upper cover component of intake
manifold.
2) Tighten up the 4 connect bolts between the lower
cover component of intake manifold and the intake
manifold.
2. Install the lower cover component of intake manifold
1) Install the lower cover component of intake
manifold
2) Tighten up the lower cover component of intake
manifold.
NL-3 01/2016

1) Install the intake pressure temperature sensor onto
intake manifold, and then tighten up the fixing bolt.
Torque: 9 N.m (Metric) 6.64 lb-ft(English)
CO
1. Install the intake manifold and intake pressure

temperature sensor component
1) Connect the intake pressure temperature sensor
cable connector
2) Clean cylinder head intake manifold installation

end surface.
3) Clean intake manifold installation end surface.
4) Install intake manifold seal ring.
NL-3 01/2016
5) Install and tighten the intake manifold upper fixing

bolts and nuts in the sequence as shown in the
figure.
Notice
The bolts and nuts can not be tightened to the specified
torque at once; otherwise it will result in the intake
manifold leakage. They should be tightened at several
stages to the specified torques.
CO Torque: 25 N.m (Metric) 18.45 lb-ft(English)
6) Install and tighten lower fixing bolt of intake

manifold.
Notice
The bolts and nuts may not be tightened up to the
specified torque in one time; otherwise the intake
manifold will not be properly sealed and then air may
leak. Please tighten them up in several times, until the
specified torque is reached.
Torque: 25 N·m (Metric) 18.45lb-ft(English)
7) Connect crankcase ventilation tube.
8) Connect the vacuum booster hose of engine.

3. Install the engine intake manifold assembly
NL-3 01/2016
JLE-4G18TDB/24 Intake System - Contents AI-1
AI JLE-4G18TDB/24 Intake System
Air Intake System ............................................................................................................... AI-2

Component Position .................................................................................................................. AI-2
On-board Check ........................................................................................................................ AI-3
Air Filter Intake Pipe .......................................................................................................... AI-4 Al
Component ............................................................................................................................... AI-4
Removal .................................................................................................................................... AI-5
Installation ................................................................................................................................. AI-6
Air Filter .............................................................................................................................. AI-7
Component ............................................................................................................................... AI-7
Removal .................................................................................................................................... AI-8
Disassembling ........................................................................................................................... AI-9
Check ........................................................................................................................................ AI-9
Assembling ............................................................................................................................... AI-9
Installation ............................................................................................................................... AI-10
Engine Intake Hose .......................................................................................................... AI-11
Component ............................................................................................................................. AI-11
Removal .................................................................................................................................. AI-12
Installation ............................................................................................................................... AI-13
Intake Pipe of Engine....................................................................................................... AI-14
Component ............................................................................................................................. AI-14
Removal .................................................................................................................................. AI-16
Installation ............................................................................................................................... AI-17
Intake Manifold Component ............................................................................................ AI-18
Component ............................................................................................................................. AI-18
On-board dismantlement ......................................................................................................... AI-21
Disassembly ............................................................................................................................ AI-23
Re-install. ................................................................................................................................ AI-24
On-board installation ............................................................................................................... AI-25
NL-3 01/2016
AI-2 JLE-4G18TDB/24 Intake System- Air Intake System
Air Intake System

Component Position
Al
Air flow sensor
Intake Air filter intake pipe

manifold
Air filter
NL-3 01/2016
JLE-4G18TDB/24 Intake System - Air Intake System AI-3
On-board Check

intake system

face of air outlet of air filter.

face between electronic throttle and intake Al
manifold.

face between intake manifold and cylinder head.
NL-3 01/2016
AI-4 JLE-4G18TDB/24 Intake System - Air Filter Intake Pipe
Air Filter Intake Pipe

Component
Al
Air filter
NL-3 01/2016
JLE-4G18TDB/24 Intake System - Air Filter Intake Pipe AI-5
Removal


fender. Refer to Decorative covering parts of engine
compartment Al
compartment"
1) Remove the 2 fixing clamps of intake pipe of air

filter.
2) Separate the intake pipe from air filter, and then

remove the intake pipe from air filter.
NL-3 01/2016
AI-6 JLE-4G18TDB/24 Intake System - Air Filter Intake Pipe
Installation
1) Install the intake pipe of air filter onto air filter.
Al
2) Use the clamp to fix the intake pipe of air filter.
NL-3 01/2016
JLE-4G18TDB/24 Intake System - Air Filter AI-7
Air Filter
Component
Al
Air flowmeter
Engine intake hose
Air filter element
NL-3 01/2016
AI-8 JLE-4G18TDB/24 Intake System - Air Filter
Removal

cover"

Al
fender. Refer to Decorative covering parts of engine
compartment

compartment"

intake pipe"
7. Remove the air flowmeter. Refer to Intake hose of

engine
8. Remove air filter
1) Remove the fixing bolt of clamp of intake pipe of

engine, and separate the intake pipe of engine
from air filter assembly.
2) Remove the fixing bolt of air filter assembly, and

remove the air filter assembly.
NL-3 01/2016
JLE-4G18TDB/24 Intake System - Air Filter AI-9
Disassembling
1. Remove the air filter assembly.
1) Remove connecting screws between upper and

lower housings of air filter, and take out air filter
element.
Al
Check
1) Check visually whether air intake side of air filter

element is too dirty; clean filter element from air
vent side with compressed air or replace filter
element if it is too dirty.
Assembling
1. Install air filter assembly.
1) Install the air filter element, use screw to connect

the upper and lower casings of air filter, and tighten
up such screw.
NL-3 01/2016
AI-10 JLE-4G18TDB/24 Intake System - Air Filter
Installation
1) Place the air filter assembly in the installation hole

for air filter, and then tighten up the air filter fixing
bolt.

Al
2) Connect the intake pipe of engine to the air filter

assembly, and tighten up the fixing bolt of clamp.
3. Install the air flowmeter
NL-3 01/2016
JLE-4G18TDB/24 Intake System - Engine Intake Hose AI-11
Engine Intake Hose

Component
Al
Trim cover of
engine
NL-3 01/2016
AI-12 JLE-4G18TDB/24 Intake System - Engine Intake Hose
Removal


Al compartment"

compartment"

cover"
6. Remove the engine intake hoses
1) Loosen the type-B worm-driven hose hoop,

separate the intake hose of engine from air
flowmeter, and then remove the air flowmeter.
2) Loosen the elastic hoop, and separate the vent

pipe assembly 2 of crankcase from intake hose of
engine.
3) Loosen the elastic hoop, and separate the

connecting hose of one-way valve turbocharger
from intake hose of engine.

remove the intake hose of engine from
turbocharger.
NL-3 01/2016
JLE-4G18TDB/24 Intake System - Engine Intake Hose AI-13
Installation
1) Install the intake hose of engine onto turbocharger,

and tighten up the type-B worm-driven hose hoop.
Al
2) Install the vent pipe component 2 of crankcase

onto the intake hose of engine, and then fix it with
elastic hoop.
3) Install the connecting hose of one-way valve

turbocharger onto the intake hose of engine, and
then fix it with elastic hoop.
4) Install the air flowmeter, connect the intake pipe of

engine to air flowmeter, and tighten up the type-B
NL-3 01/2016
AI-14 JLE-4G18TDB/24 Intake System - Intake Pipe of Engine
Intake Pipe of Engine

Component
Al
Trim cover of
engine
NL-3 01/2016
JLE-4G18TDB/24 Intake System - Intake Pipe of Engine AI-15
Gas outlet pipe of

supercharger
Al
Radiator
assembly
Intercooler intake
pipe Intake pipe of
engine

intercooler hose
NL-3 01/2016
AI-16 JLE-4G18TDB/24 Intake System - Intake Pipe of Engine
Removal
3. Remove the engine intake hoses

Al separate the gas outlet hose of intercooler from
intake pipe of engine.

separate the intake hose of engine from the
electronic throttle body.
NL-3 01/2016
JLE-4G18TDB/24 Intake System - Intake Pipe of Engine AI-17
Installation
1. Install the engine intake hoses
1) Connect the intake pipe of engine to the electronic

throttle body, and then fix the type-A worm-driven
hose hoop.
Al
2) Connect the gas outlet hose of intercooler connect

to intake pipe of engine, and fix the type-A
NL-3 01/2016
AI-18 JLE-4G18TDB/24 Intake System - Intake Manifold Component
Intake Manifold Component

Component
Al
Trim cover of
engine
NL-3 01/2016
JLE-4G18TDB/24 Intake System - Intake Manifold Component AI-19
Al
Intake pressure
temperature sensor
Carbon canister Intake manifold assembly and fuel

control valve injector harness
Electronic throttle
body
Oil filter
Engine assembly
(4G18TD)
NL-3 01/2016
Al
Cylinder
block
Intake
Intake manifold seal manifold
gasket
Fuel
rail
Intake manifold
bracket
NL-3 01/2016

3. Remove the left/right connect bracket. Refer to

Al

cover"
6. Remove the solenoid valve of carbon canister. Refer to

“Control valve of carbon canister”
7. Remove the electronic throttle. Refer to "Electronic

throttle body"
8. Remove the intake pressure temperature sensor. Refer

to "Intake pressure temperature sensor"

harness
1) Disconnect the connection between the vent pipe

component 1 of crankcase and the intake manifold.
2) Remove engine hood fixing bolt and harness

bracket.
3) Remove the hexagonal flange bolt.
4) Remove the intake pipe component of control

valve of carbon canister from the bracket.
5) Remove the engine hood fixing bolt.
6) Remove the tee joint & pipeline component of

carbon canister from the bracket.
NL-3 01/2016
7) Disconnect the fuel pressure sensor harness

connector.
Al
8) Remove the fixing bolt and nut of intake manifold

bracket, and then remove the intake manifold
bracket.
9) In accordance with the sequence as indicated in

the figure, connect the 4 fixing bolts on lower
portion of fuel rail with the 5 fixing nuts on upper
portion of intake manifold.
NL-3 01/2016
10) Remove the intake manifold assembly and fuel

injector harness.
Al
Disassembly
1. Remove the fuel injector harness
1) Disconnect the fuel pressure sensor harness

connector.
2) Disconnect 4 harness connectors of fuel injector.
NL-3 01/2016
3) Separate the fuel injector harness from fuel rail

bracket.
Al
4) Remove the fuel injector harness mounting bracket

fixing bolt.
2. Remove the fuel rail and fuel injector subassembly
1) Remove the 2 hexagonal-socket cylinder-head

screws.
2) Remove the intake manifold component from the

fuel rail fuel injector component.
Re-install.
NL-3 01/2016
1. Install intake manifold assembly
1) Install the fuel rail fuel injector component onto

intake manifold component.
2) Install and tighten up the 2 hexagonal-socket

cylinder-head screws.

Al
1. 6Install intake manifold assembly and fuel injector

harness
1) Connect the intake pressure temperature sensor

cable connector
2) Install intake manifold assembly.
3) Diagonally install and tighten up the 5 fixing nuts

on upper portion of intake manifold and the 4 fixing
bolts on lower portion of fuel rail.

Notice
The bolts and nuts can not be tightened to the specified
torque at once; otherwise it will result in the intake
manifold leakage. They should be tightened at several
stages to the specified torques.
NL-3 01/2016
4) Install intake manifold bracket.
5) Install and tighten up the fixing bolt and nut of

intake manifold bracket.
Tightening torque for nut: 22.5 N·m (Metric) or 16.6

lb-ft (English)
Tightening torque for nut: 10.5N·m (Metric) or 7.75

lb-ft (English)
Al
6) Install the fuel injector harness mounting bracket

fixing bolt.
Torque:10.5 N (Metric) 7.75 lb-ft (English)
7) Fix the fuel injector harness.
NL-3 01/2016
8) Connect fuel pressure sensor harness connector.
6. Connect the negative battery cable Al

NL-3 01/2016
Al
NL-3 01/2016
JLD-4G20/24 Exhaust System - Contents EX-1
EX JLD-4G20/24 Exhaust System
Exhaust System ................................................................................................................ EX-2

Component Position .................................................................................................................EX-2
Exhaust System Blocked..........................................................................................................EX-3
Exhaust System Leakage .........................................................................................................EX-3
EX
Exhaust System Noise .............................................................................................................EX-3
On-board Check .......................................................................................................................EX-4
Exhaust pipe ..................................................................................................................... EX-5
Component ..............................................................................................................................EX-5
Removal ...................................................................................................................................EX-6
Installation ................................................................................................................................EX-7
Muffler ................................................................................................................................ EX-8
Component ..............................................................................................................................EX-8
Removal ...................................................................................................................................EX-9
Installation .............................................................................................................................. EX-11
Exhaust manifold ............................................................................................................ EX-13
Component ............................................................................................................................EX-13
Removal .................................................................................................................................EX-17
Installation ..............................................................................................................................EX-18
NL-3 01/2016
EX-2 JLD-4G20/24 Exhaust System - Exhaust System
Exhaust System
Component Position
EX Muffler
Exhaust
manifold
Exhaust
pipe
NL-3 01/2016
JLD-4G20/24 Exhaust System - Exhaust System EX-3
Exhaust System Blocked

If the power of engine is lost, the fuel economy reduces or the acceleration performance becomes poor, please check whether
there is the fault “the exhaust system is blocked up”. You may use the exhaust backpressure gauge to monitor whether the
backpressure of system exceeds 50kPa, so as to confirm the fault. The possible causes for fault include:
- Damage of exhaust pipe.
- The exhaust pipe has debris.
- Internal fault of muffler.
- The exhaust pipe is blocked due to interior erosion of the exhaust pipe.
EX
Exhaust System Leakage
If the engine makes "hissing" or burst sound during operation, check whether there is "exhaust system leakage" fault, as
shown in the table below:
Exhaust system component malposition or installation error - Locate the components of exhaust system and tighten
them up with the specified torque. Refer to the
specification for fixture given in “Specifications for Repair”.
- Make sure that the exhaust pipe hook is in the right
position and is not loose.
Seals or gaskets leakage: Replace the leaking seals or gaskets.

- Exhaust manifold and cylinder head
- Exhaust manifold and front exhaust pipe assembly
- Front exhaust pipe assembly and middle muffler assembly
- Middle muffler assembly and rear muffler assembly
Irregular flange joint surface If necessary, repair or replace the associated components.
Exhaust manifold cracked or broken Replace the exhaust manifold. Please refer to "Exhaust
manifold".
Exhaust system component welding joint leakage Replace leakage component.
Exhaust system noise

When the engine is running, if exhaust has noise or unusual sound, it is necessary to check whether there is “exhaust system
noise" fault, as shown in the following table:
Crackle or hiss noise Exhaust system leakage, refer to "Exhaust system blockage
for the exhaust system leakage".
Big exhaust noise 1. Compare with a vehicle known in good conditions.

2. Check the muffler assembly for damage or fault.
Replace muffler assembly with fault.
3. Please refer to "Muffler".
Exterior noise or vibration noise 1. Check whether the hook is bent or loose or whether
thermal shroud fasteners are loose.
2. Check whether the exhaust pipe is interfered.
Interior noise 1. Use a rubber hammer to knock these components so as

to confirm the noise.
2. Replace the faulty three-way catalytic purifier assembly
or muffler assembly.
NL-3 01/2016
EX-4 JLD-4G20/24 Exhaust System - Exhaust System
On-board Check

exhaust system
1) Check whether there is leakage on installation face

between exhaust manifold and cylinder head.
2) Check whether there is leakage on the installation

between exhaust manifold and front exhaust pipe
EX assembly.
3) Check whether there is leakage between the

connecting face between front exhaust pipe
assembly and middle muffler.
4) Check whether there is leakage on the connecting

face between middle muffler and rear muffler.
2. Check whether the components of exhaust system are

cracked or fall off from welded position
3. Check whether the rubber supporter is aged.
NL-3 01/2016
JLD-4G20/24 Exhaust System - Exhaust Pipe EX-5
Exhaust Pipe
Component
EX
Rear rubber
seat
20/24 Front exhaust pipe
assembly
Sealing gasket
of exhaust pipe Rear muffler
assembly
Middle muffler
assembly
Sealing gasket of
exhaust pipe
Front rubber supporter
(front section)
Sealing gasket
of exhaust pipe
NL-3 01/2016
EX-6 JLD-4G20/24 Exhaust System - Exhaust Pipe
Removal
1. Lift the vehicle

”
3. Remove front exhaust pipe
1) Remove 2 fixing nuts between exhaust manifold

EX and front exhaust pipe, and disconnect the
connection between front exhaust pipe and
exhaust manifold.
2) Remove 2 fixing nuts between front exhaust pipe

and middle muffler.
3) Remove the rubber supporter between front

exhaust pipe and vehicle body.
NL-3 01/2016
JLD-4G20/24 Exhaust System - Exhaust Pipe EX-7
Installation
1. Install the front exhaust pipe
1) Install the front exhaust pipe onto rubber supporter

of vehicle body.
2) Install 2 fixing nuts between front exhaust pipe and

middle muffler.
Notice
Replace the sealing gasket between front exhaust pipe
EX
and exhaust manifold
3) Install the 2 fixing nuts between front exhaust pipe

and exhaust manifold.
NL-3 01/2016
EX-8 JLD-4G20/24 Exhaust System - Muffler
Muffler
Component
EX
Rear rubber
seat
Front Exhaust
Pipe Assembly
Sealing gasket of
exhaust pipe Rear muffler
assembly
Middle muffler
assembly
Sealing gasket of
Front rubber supporter exhaust pipe
(front section)
Sealing gasket of
exhaust pipe
NL-3 01/2016
JLD-4G20/24 Exhaust System - Muffler EX-9
Removal
1. Lift the vehicle
2. Remove the rear muffler
1) Remove 2 rubber supporters between the rear

muffler and the right side of vehicle body.
EX
2) Remove the rubber supporter between the rear

muffler and the left side of vehicle body.
Notice
The rear muffler is relatively heavy, so support shall be
used when dismantling it.
3) Remove the 2 nuts between rear muffler and

middle muffler, and remove the rear muffler.
NL-3 01/2016
3. Remove the middle muffler
1) Remove 2 rubber supporters between the middle

muffler and the middle portion of vehicle body.
EX
2) Remove the rubber supporter between the middle

muffler and the rear portion of vehicle body.
3) Remove 2 fixing nuts between middle muffler and

front exhaust pipe, and remove the middle muffler.
Notice
The rear muffler is very heavy, so that support shall be
used when dismantling it.
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JLD-4G20/24 Exhaust System - Muffler EX-11
Installation
1. Install middle muffler
1) Install the rubber supporter between the middle

EX
2) Install 2 rubber supporters between the middle

3) Install the 2 nuts between middle muffler and front

exhaust pipe.
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2. Install the rear muffler
1) Install the rear muffler the rubber supporter of left

side of vehicle body.
EX
2) Install the rear muffler 2 rubber supporters of right

3) Install and tighten up 2 nuts between rear muffler

and middle muffler.
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JLD-4G20/24 Exhaust System - Exhaust Manifold EX-13
Exhaust Manifold
Component
EX
Engine bottom guard

plate assembly
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EX-14 JLD-4G20/24 Exhaust System - Exhaust Manifold
EX
Trim cover of
engine
Engine assembly
4G24
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EX
Front Exhaust Pipe

4G24 front oxygen Assembly
sensor
Sealing gasket of 4G24 rear oxygen

exhaust pipe sensor
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Engine assembly
EX
Front oxygen
sensor
Exhaust manifold
gasket
Lower thermal
shroud
Exhaust manifold
Heat shield
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Removal

cover"
4. Lift the vehicle

EX
6. Remove front oxygen sensor Please refer to "Front

oxygen sensor"
7. Remove drain manifold heat insulation shield.
1) Remove 4 fixing bolts of thermal shroud of exhaust

manifold, and remove the thermal shroud of
exhaust manifold.
8. Remove drain manifold.
1) Remove the 2 fixing nuts between exhaust

manifold and front exhaust pipe, and disconnect
the connection between front exhaust pipe and
exhaust manifold.
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2) Remove 2 fixing bolts between exhaust manifold

and its bracket.
EX
3) Remove 5 fixing nuts between exhaust manifold

and cylinder head, and remove the exhaust
manifold and its sealing gasket.
Notice
If the bolt of exhaust manifold is removed when it is hot,
the bolt or cylinder head may get damaged. Be sure to
remove it after the engine cools down!
Installation
1. Install exhaust manifold
1) Replace the new sealing of gasket exhaust

manifold and the new exhaust manifold, and
tighten up the 5 fixing nuts between exhaust
manifold and cylinder head.
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2) Install the 2 fixing bolts between exhaust manifold

and exhaust manifold bracket.
EX
3) Replace the sealing gasket between exhaust pipe

and exhaust manifold, and install and tighten up
the 2 fixing nuts between front exhaust pipe and
exhaust manifold.
2. Install the exhaust manifold heat shield
1) Install and tighten up 4 fixing bolts of thermal shroud of

exhaust manifold.
Torque: 10.5 N·m (Metric) 7.75 lb-ft (English)
4. Install the front oxygen sensor.
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EX
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JLE-4G18TDB /24 Exhaust System - Contents EX-1
EX JLE-4G18TDB/24 Exhaust System
Exhaust System; ............................................................................................................... EX-2

Component Position .................................................................................................................EX-2
On-board Check .......................................................................................................................EX-3
Exhaust System Blocked..........................................................................................................EX-4
Exhaust System Leakage .........................................................................................................EX-4 EX
Exhaust System Noise .............................................................................................................EX-4
Three-Way Catalytic Converter Assembly ...................................................................... EX-5
Component ..............................................................................................................................EX-5
Removal ...................................................................................................................................EX-6
Installation ................................................................................................................................EX-7
Muffler ................................................................................................................................ EX-8
Component ..............................................................................................................................EX-8
Removal ...................................................................................................................................EX-9
Installation .............................................................................................................................. EX-11
Exhaust manifold ............................................................................................................ EX-13
Component ............................................................................................................................EX-13
On-board dismantlement ........................................................................................................EX-16
Assembling ............................................................................................................................EX-19
Installation ..............................................................................................................................EX-19
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EX-2 JLE-4G18TDB /24 Exhaust System- Exhaust System;
Exhaust System;
Component Position
Exhaust
manifold
EX
Turbocharger
Three-way
catalytic Exhaust
converter pipe
Muffler
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JLE-4G18TDB /24 Exhaust System - Exhaust System; EX-3
On-board Check

exhaust system
1) Check whether there is leakage on installation face

between exhaust manifold and cylinder head.

face between exhaust manifold and three-way
catalytic converter.
EX
face between three-way catalytic converter and
middle muffler.
4) Check whether there is leakage on the connecting

face between middle muffler and rear muffler.
2. Check whether the components of exhaust system are

cracked or fall off from welded position
3. Check whether the rubber supporter is aged.
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EX-4 JLE-4G18TDB /24 Exhaust System- Exhaust System;
Exhaust System Blocked

In case of engine power loss, poor fuel economy or bad acceleration performance, check whether there is "exhaust system
blockage" fault. Use the emission back pressure gauge to detect whether the system back pressure has exceeded 50kpa to
determine fault; the possible reasons may include:
- Damage of exhaust pipe.
- The exhaust pipe has debris.
- Internal fault of muffler.
- The exhaust pipe is blocked due to interior erosion of the exhaust pipe.
EX Exhaust System Leakage

If the engine makes "hissing" or burst sound during operation, check whether there is "exhaust system leakage" fault, as
shown in the table below:
Exhaust system component malposition or installation error - Locate the components of exhaust system and tighten
them up with the specified torque. Refer to the
specification for fixture given in “Specifications for Repair”.
- Make sure that the exhaust pipe hook is in the right
position and is not loose.
Whether there is exhaust leakage in the following joints: Replace leakage component.
- Exhaust manifold and three-way catalytic purifier
assembly
- Exhaust manifold and cylinder head
- Exhaust manifold and three-way catalytic purifier
assembly
- Three-way catalytic purifier assembly and middle muffler
assembly
- Middle muffler assembly and rear muffler assembly
Irregular flange joint surface If necessary, repair or replace the associated components.
Exhaust manifold cracked or broken Replace the exhaust manifold. Please refer to "Exhaust
manifold".
Exhaust system component welding joint leakage Replace leakage component.
Exhaust system noise

When the engine is running, if exhaust has noise or unusual sound, it is necessary to check whether there is “exhaust system
noise" fault, as shown in the following table:
Crackle or hiss noise Exhaust system leakage, refer to "Exhaust system blockage
for the exhaust system leakage".
Big exhaust noise 1. Compare with a vehicle known in good conditions.

2. Check the muffler assembly for damage or fault.
Replace muffler assembly with fault.
Exterior noise or vibration noise 1. Check whether the hook is bent or loose or whether
thermal shroud fasteners are loose.
2. Check whether the exhaust pipe is interfered.
Interior noise 1. Use a rubber hammer to knock these components so as

to confirm the noise.
2. Replace the faulty three-way catalytic purifier assembly
or muffler assembly.
3. Refer to "Three-way catalytic converter assembly".
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JLE-4G18TDB /24 Exhaust System - Three-Way Catalytic Converter Assembly EX-5
Three-Way Catalytic Converter Assembly

Component
Front oxygen
sensor
Rear oxygen
sensor EX
Three-Way Catalytic
Converter Assembly
Rear rubber seat

Catalytic
converter bracket
Rear muffler
assembly
Front rubber
supporter
Middle muffler
assembly
Sealing gasket of
Front rubber exhaust pipe
supporter
Sealing gasket of
exhaust pipe

(front section)
Specified torque
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EX-6 JLE-4G18TDB /24 Exhaust System- Three-Way Catalytic Converter Assembly
Removal
1. Lift the vehicle
2. Remove the thermal baffle of exhaust pipe
3. Remove the three-way catalytic converter assembly
1) Screw off the bracket bolts
2) Remove 3 fixing bolts between the three-way

EX catalytic converter assembly and the exhaust
manifold assembly.
3) Remove 2 fixing bolts between the three-way

catalytic converter assembly and the three-way
catalytic converter bracket.
4) Remove 2 fixing nuts between the three-way

catalytic converter assembly and the middle
muffler.
5) Remove the rubber supporter between the

three-way catalytic converter assembly and the
vehicle body.
6) Take out the three-way catalytic purifier assembly.
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JLE-4G18TDB /24 Exhaust System - Three-Way Catalytic Converter Assembly EX-7
Installation
1. Install the thermal baffle on bottom of vehicle
2. Install the three-way catalytic purifier assembly.
1) Install 3 fixing bolts between the three-way

catalytic converter assembly and the exhaust
manifold assembly.

EX
2) Install the 2 fixing bolts between the three-way

catalytic converter assembly and the three-way
catalytic converter bracket.
3) Install the rubber lifting lug.
4) Install 2 fixing nuts between the three-way catalytic

converter assembly and the middle muffler.
Notice
Replace the sealing gasket between the three-way
catalytic converter and the exhaust manifold.
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EX-8 JLE-4G18TDB /24 Exhaust System- Muffler
Muffler
Component
Front oxygen
sensor
EX Rear oxygen
sensor
Three-Way Catalytic
Converter Assembly
Rear rubber
Catalytic converter seat
bracket
Rear muffler
assembly
Front rubber
supporter
Middle muffler
assembly
Sealing gasket of
Front rubber exhaust pipe
supporter
Sealing gasket
of exhaust pipe
(front section)
Specified torque
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JLE-4G18TDB /24 Exhaust System - Muffler EX-9
Removal
1. Lift the vehicle
2. Remove the rear muffler
1) Remove 2 rubber supporters between the rear

muffler and the right side of vehicle body.
EX
2) Remove the rubber supporter between the rear

muffler and the left side of vehicle body.
Notice
The rear muffler is relatively heavy, so that support shall
be used when dismantling it.
3) Remove 2 nuts between rear muffler and middle

muffler, and remove the rear muffler.
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3. Remove the middle muffler
1) Remove 2 rubber supporters between the middle

EX
2) Remove the rubber supporter between the middle

3) Remove 2 fixing nuts between the middle muffler

and the three-way catalytic converter, and remove
the middle muffler.
Notice
The rear muffler is relatively heavy, so that support shall
be used when dismantling it.
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JLE-4G18TDB /24 Exhaust System - Muffler EX-11
Installation
1. Install middle muffler
1) Install the rubber supporter between the middle

EX
2) Install 2 rubber supporters between the middle

3) Install 2 nuts between middle muffler and front

exhaust pipe.
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1) Install the rear muffler the rubber supporter of left

EX
2) Install the rear muffler the 2 rubber supporters of

right side of vehicle body.
3) Install and tighten up 2 nuts between rear muffler

and middle muffler.
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JLE-4G18TDB /24 Exhaust System - Exhaust Manifold EX-13
Exhaust Manifold
Component
Trim cover of
engine
EX
Engine bottom guard

plate assembly
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EX-14 JLE-4G18TDB /24 Exhaust System- Exhaust Manifold
A/C high & lowpressure

A/C high-pressure pipe assembly
pipe
EX
Compressor exhaust hose

assembly
Condenser
assembly
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EX
Supercharger
heat shield
Supercharger
heat shield
Cylinder
head
Holder block of Exhaust manifold

exhaust manifold gasket
Exhaust
manifold
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compartment"
compartment"
EX 5. Remove the upper trim panel assembly of right fender.
compartment"
cover"
7. Remove the water guide plate assembly of engine
compartment
8. Collect the A/C refrigerant
9. Remove the A/C high/low-pressure pipe assembly.
Refer to "A/C pipe (4G18TD)"
10. Remove the intake hose of engine. Refer to "Intake
hose of engine"
11. Remove the thermal shroud of turbocharger
1) Remove the mounting brackets of air inlet hoses of
2 air filters for the vehicle.
2) Remove 4 fixing bolt of thermal shroud of exhaust

manifold, and remove the thermal shroud of
turbocharger.
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12. Remove the exhaust manifold assembly and

turbocharger
1) Disconnect the exhaust control valve harness

connector.
2) Disconnect the intake relief valve harness

connector.
EX
3) Remove the fixing bolt between the water inlet pipe

component of turbocharger and the turbocharger.
4) Remove the bolt of water pipe of turbocharger, and

disconnect the connection between the water inlet
pipe component of turbocharger and the
turbocharger.
5) Loosen the elastic hoop, and disconnect the

connection between the water outlet pipe of
turbocharger and the water return pipe component
of turbocharger.
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6) Remove 1 hexagonal flange fixing bolts between

the oil inlet pipe component of turbocharger and
the turbocharger.
7) Remove the oil inlet bolt of turbocharger.
8) Disconnect the connection between oil inlet pipe

component of turbocharger and the turbocharger.
EX
9) Remove 2 hexagonal flange fixing bolts between

the oil return pipe component of turbocharger and
the turbocharger.
10) Remove the gasket on oil drain port of

turbocharger.
11) Disconnect the connection between the oil return

pipe component of turbocharger and the
turbocharger.
12) Remove the fixing bolt between turbocharger and

its bracket.
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13) Remove 5 heat-resistant nuts and double-end bolt

on upper portion of exhaust manifold.
14) Pull out the exhaust manifold and turbocharger

forwards.
EX
Assembling
1. Replace the turbocharger
Installation
1. Install the exhaust manifold assembly and turbocharger
1) Install the water return pipe component of

turbocharger.
2) Install and tighten up the bolt of water pipe of

turbocharger.
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3) Install the gasket of oil drain port of

turbocharger and the oil return pipe
component of turbocharger
4) Install and tighten up 2 hexagonal flange

fixing bolts between the oil return pipe
component of turbocharger and the
turbocharger.
EX
5) Insert the exhaust manifold assembly and

turbocharger under the holder block of exhaust
manifold.
6) Install and tighten up the 5 heat-resistant nuts and

double-end studs on upper portion of exhaust
manifold.
Tightening torque for double-end stud: 20 N·m

(Metric) or 14.8 lb-ft (English)
Tightening torque for double-end stud: 28 N·m

(Metric) or 20.66 lb-ft (English)
7) Install and tighten up the fixing bolt between

turbocharger and its bracket.
Torque:28 N·m(Metric) 20.66 lb-ft (English)
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8) Connect the water inlet pipe component of

turbocharger to the turbocharger.
9) Install and tighten up the bolt of water pipe of

turbocharger.
10) Install and tighten up the fixing bolts between

water inlet pipe component of turbocharger and
turbocharger.
Torque: 45 N·m(Metric) 33.21 lb-ft (English)
Notice EX
All removed gaskets, such as gasket of exhaust pipe,
gasket of oil inlet/return pipe and gasket of water
inlet/return pipe, shall be replaced with new ones.
11) Connect the oil inlet pipe component of

turbocharger to turbocharger
12) Install and tighten up the oil-inlet bolt of

turbocharger.
13) Install and tighten up the fixing bolt of hexagonal

flange on oil inlet pipe component of turbocharger.
14) Connect the water outlet hose of turbocharger and

the of water return pipe component of
turbocharger.
15) Fix the elastic hoop.
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2. Install the thermal shroud of turbocharger.
1) Install the thermal shroud of turbocharger.
2) Install and tighten up the 4 fixing bolt of thermal

shroud of exhaust manifold.
EX
3) Remove the mounting brackets of air inlet hoses of

2 air filters for the vehicle.
4. Install the A/C high/low-pressure pipe assembly
5. Install the water guide plate assembly of engine

compartment
6. Fill the A/C refrigerant.
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JLD-4G20 /24 Fuel System - Contents FU-1
FU JLD-4G20/24 Fuel System
Fuel System ....................................................................................................................... FU-2

Precautions ..............................................................................................................................FU-2
Component Position .................................................................................................................FU-3
Fault of fuel Pump ....................................................................................................................FU-4
All Fuel Injectors Are Not Working ..........................................................................................FU-12
FU
Surge Diagnosis During Driving .............................................................................................FU-16
Fuel Pressure Testing Procedure ...........................................................................................FU-20
On-board Check .....................................................................................................................FU-22
Fuel Distribution Pipe Assembly ................................................................................... FU-24
Component ............................................................................................................................FU-24
Removal .................................................................................................................................FU-26
Disassembling ........................................................................................................................FU-27
Check .....................................................................................................................................FU-28
Assembling ............................................................................................................................FU-28
Installation ..............................................................................................................................FU-29
Fuel Pump with The Fuel Sensor Assembly ................................................................. FU-31
Component ............................................................................................................................FU-31
Removal .................................................................................................................................FU-32
Check .....................................................................................................................................FU-33
Installation ..............................................................................................................................FU-34
Fuel Filter......................................................................................................................... FU-35
Component ............................................................................................................................FU-35
Removal .................................................................................................................................FU-36
Installation ..............................................................................................................................FU-37
Fuel Tank ......................................................................................................................... FU-38
Component ............................................................................................................................FU-38
Removal .................................................................................................................................FU-40
Installation ..............................................................................................................................FU-42
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FU-2 JLD-4G20 /24 Fuel System -
Fuel System
Precautions
1. Before inspecting or repairing the fuel system, please

disconnect the negative battery cable.
2. When inspecting or repairing the fuel system, don’t

smoke or work near any ignition source.
3. Don’t drop gasoline on any decorative part made of

FU rubber or leather. If gasoline has been dropped on such
part, please wipe it away immediately.
4. When disconnecting the high-pressure fuel pipeline, a

lot of fuel may be sprayed out. Therefore, please comply
with the following operating steps:
1) Release fuel system pressure
Plastic bag 2) Disconnect fuel pump pipeline.
3) Drin the residual fuel in pipe of fuel pump.
4) In order to prevent the disconnected fuel pump and

pipeline from being damaged or contaminated by
foreign matter, please put a plastic bag over them.
5) When dismantling the connection of pipeline,

please place a container under the connection, so
as to receive the fuel drained from pipeline.
5. Release fuel system pressure

Notice
Before dismantling any component of fuel system, in
order to prevent the fuel from being sprayed out, please
implement the following steps.
1) Open the fuel tank cover.
2) Pull out the fuse for fuel pump in fuse box of

engine compartment.
3) Start the engine until the engine flameout

automatically.
4) Start the engine again and make it run for 10s.

Notice
After the above steps are implemented, the pressure in
fuel pipeline may still exist. When disconnecting the fuel
pipeline, please cover it with wiping cloth or other cloth,
so as to prevent the fuel from being sprayed out.
Notice
If you want to remove any fuel system components,
wrap pipe fittings with plastic bags to prevent fuel
leakage and prevent the entry of foreign matter. Check
and make sure that no oil leaks from fuel system after it
is maintained or repaired. If there is any leakage of oil,
please replace the relevant component.
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JLD-4G20 /24 Fuel System - Fuel System FU-3
Component Position
FU
Fuel injector
Fuel tank
Carbon assembly
canister
Fuel supply
pipeline
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FU-4 JLD-4G20 /24 Fuel System -Fuel System
Fault of Fuel Pump

Circuit schematic:
Main relay
FU
Fuel pump
relay ER09
Fuel Pump
Notice
whether main relay works normally. When using the function “action test” of fault diagnosis instrument, make sure that the
communication between fault diagnosis instrument and EMS is normal.

No
Go to step 3
Yes
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Step 2 Overhaul fuel pump fuse EF20 circuit.
(a) Check fuel pump fuse EF20 circuit fault.

(b) Repair fuel pump power supply circuit short to ground
fault.
Rated value of the fuse: 15 A
Yes FU
No
(a) Use the diagnosis instrument to drive the fuel pump relay
Engine compartment fuse, relay box ER09.
(a) Check the voltage between the terminal 87 of fuel pump

relay and the reliable grounding point.
Yes
Go to step 7
No
Step 4 Overhaul open circuit fault between terminal 30 of fuel pump relay ER09 and fuel pump fuse EF20.
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Engine compartment fuse, relay box the state OFF.
(b) Remove the fuel pump relay ER09.

pump relay ER09 and the fuse EF20.
No
FU Repair or replace the harness
No

Engine compartment fuse, relay box the state OFF.
(c) Measure the voltage between the terminal 85 of fuel pump

relay ER09 and the reliable grounding point.
(d) Confirm whether the voltage meets standard value.
No Go to step 7
No
Step 6 Check fuel pump relay fuse EF10 circuit.
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(a) Check whether the fuel pump fuse EF10 has blown out.
Yes Replace the fuse, and repair the circuit of

fuse.
FU
No
Step 7 Check the fuel pump relay ER09.
(b) Replace the fuel pump relay ER09 with a new part in good
condition.
to ON state.
(d) Confirm whether the fuel pump is working properly.
Yes
Replace the fuel pump relay ER09.
No
to OFF state.

(c) Measure the resistance between fuel pump harness

connector SO26 terminal4 and the body grounding.
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Yes
Check the conductivity of the circuit between terminal 87 of fuel pump harness connector ER09
Step 9
and terminal 1 of fuel pump harness connector SO26.
(a) Remove the fuel pump relay ER09.
(b) Measure the resistance between terminal 87 of fuel pump

harness connector ER09 and terminal 1 of fuel pump harness
connector SO26.

FU (c) Confirm whether the voltage meets standard value.
Yes
Check conductivity between terminal 49 of harness connector CA45 of EMS control module and
Step 10
terminal 86 of relay.
(a) Disconnect the EMS harness connector CA45.

(b) measure the resistance between the terminal 49 of EMS
harness connector CA45 and the terminal 86 of fuel pump
relay
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connector
FU
Yes
(d) Install the fuel pump relay ER09.
(e) Connect the EMS control module harness connector

CA45.
(f) Connect fault diagnostic scanner to vehicle diagnostic

interface.
(g) Connect fuel pump harness connector SO26 terminal 1

and body grounding with test lamp.
(h) Operate the starter switch to turn the power supply mode
to ON state.
(i) Use a diagnostic scanner to carry out "Action test" on

pump relay.
(j) Does test lamp light up?
Yes Go to step 13
Yes
(a) Replace the fuel pump. Refer to "Fuel pump & fuel sensor
assembly".
(b) Confirm the repair is completed.
Yes
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(b) Remove the EMS harness connector CA45.
FU No Repair or replace the harness.

connector
Yes
to OFF state.
CA45 engine management system harness (b) Remove the EMS harness connector CA45.
connector
Yes
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Next Step
FU
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All Fuel Injectors Are Not Working

Circuit schematic:
Main relay Fuel injector 3 Fuel injector 4

Fuel injector 1 Fuel injector 2
ER05
FU
Step 1 Check whether the engine anti-theft system is activated.
(a) Whether the engine malfunction indicator lamp flashes?
No Go to step 3
Yes
Step 2 Repair engine anti-theft system fault.
(a) Repair engine anti-theft system fault
(b) Whether fuel injector is working properly.
Yes
No
Step 3 Check the fuses IF17 and EF09 of engine management system (EMS).
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(a) Check whether the fuses IF17 and EF09 of engine

management system (EMS) have blown out.
No Go to step 6
FU
Yes
Engine compartment fuse, relay to OFF state.
box
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connector
FU
No
to OFF state.
CA45 engine management system harness (b) Remove the EMS harness connector CA45.
connector
(c) Measure the resistance between terminal 64, 63 of EMS
Yes
No
Check the circuit between the fuel injector and engine management system (taking the cylinder 1
Step 6
as an example).
to OFF state.
(b) Disconnect cylinder No.1 fuel injector harness connector

EG01.
(c) Disconnect the engine management system harness

connector EG24.

injector harness connector EG01 of cylinder No. 1 and the
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(e) Confirm whether the resistance meets standard value?

connector 2
FU
Yes

connector
Yes
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to OFF state.
CA45 engine management system harness (b) Measure the resistance between terminal 63/64 of EMS
connector
harness connector CA45 and the reliable grounding point.
FU
Yes

Next Step
Surge Diagnosis During Driving

Fault definition: When the accelerator pedal position remains unchanged, the engine power changes causing speed increase
or decrease.
Notice
Before performing this diagnostic test, make sure the engine control system has no DTC.
Step 1 Perform the preliminary check.
(a) Check vacuum pipe for whether there is cracking, twist

and so on.
(b) Check engine EMS grounding point for oxidation, loose,
incorrect position and so on.
(c) Check whether each sensor harness connector is
correctly connected, and the existence of loose, poor
connection and so on.
Next Step
Step 2 Check whether the intake pressure sensor is normal.
(a) Refer to” table of fault symptoms”.
Yes
Step 3 Is the engine coolant temperature sensor working properly?
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(b) Refer to “Table of fault symptoms”.
Yes
Step 4 Test the fuel pressure, is it normal?
(a) Refer to "Testing procedure of fuel oil pressure"
No
Check whether the pipeline is blocked, if FU
necessary, replace the faulty component.
Yes
Use the common tool "Fuel injector cleaning and testing machine" to test the performance of each
Step 5
cylinder fuel injector. Check whether the fuel injectors are normal.
No Replace damaged fuel injectors.
Yes
Step 6 Check whether fuel quality is normal and the fuel is contaminated.
No
Replace with good quality fuel.
Yes
Step 7 Check whether fuel quality is normal, is the fuel contaminated.

(b) Start engine and turn on the fault diagnostic scanner.
(c) Make the engine run at the speed of about 2,500 rpm for
more than 2 minutes, and measure the oxygen sensor under
idle speed, so as to ensure that its operating temperature
reaches 350℃.
(e) Select on the fault diagnostic scanner: Engine/Read data
stream/Front oxygen sensor voltage.
(f) Observe the front oxygen sensor output voltage and the
data stream display shall fluctuate within the 0.1- 0.9V scope.
(g) If the data stream shows the voltage is constantly lower
 Proper amount of propane gas will be injected in the inlet.
 Check whether the front oxygen sensor data stream

voltage has a significant change, in which case the signal
(h) If the data stream shows the voltage is constantly higher
 Place the gear shift lever at neutral position or parking
position.
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 Pull tightly the hand brake.
 Depress the acceleration pedal so that the engine speed

 Repeat more than three times as per the above procedure.
 Observe whether there is a significant change in the front

oxygen sensor data stream voltage, in which case the
signal voltage will decrease rapidly.
(i) When executing the above test, the oxygen sensor signal
voltage shall significantly vary with the test.
FU
(j) Significant voltage change?
Signal voltage no response A
Signal voltage remains high B
Signal voltage remains low C
Signal voltage is normal D
A Replace the front oxygen sensor
B Go to step 13
C Go to step 14
Step 8 Check whether the spark plug is normal?
(a) Refer to "Diagnosis for spark plug".
No Replace with the correct type of spark plug.
Yes
Step 9 Check the ignition coil to confirm whether the arcing capacity of ignition coil is normal.
(a) Check whether the high voltage resistance cable

connection is firm, no damage and such like shall occur.
No Replace with the correct type of ignition coil.
Yes
Step 10 Check whether the speed sensor signal tooth is correctly installed.
(a) Check whether the crankshaft position sensor signal tooth

installation is firm. The signal tooth can not be missing, worn
and torn and so on.
No Handle the fault position. If necessary,

replace the faulty components.
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Yes
Step 11 Check whether A/C system is working correctly?
(a) Check whether the exhaust system is blocked up.
Yes Go to step 15
Yes
FU
Step 12 Check whether the exhaust system is normal?
(a) Check whether the compressor clutch engagement is

rough. The A/C system pressure should not be too high.
Check whether the A/C compressor is working properly.
No Handle the faulty position. If necessary,

Next Step
Step 13 Check the cause for the mixture too rich.
(a) Check whether the carbon canister solenoid valve is

normally turned on.
(b) Check whether there is any leakage of fuel injector.
(c) Check whether the air filter element is blocked.
(d) Check whether there is intake pipe bloackage or
deformation.
(e) Check whether the engine lubricating oil is contaminated
by fuel.
(f) Check whether the fuel pressure is too high.
(g) Check whether the intake manifold absolute pressure
sensor is normal.
(h) Check whether the temperature sensor of engine coolant
is abnormal.
(i) Are the above faults available?
No Go to step 15
Yes Handle the faulty position. If necessary,

Next Step
Step 14 Check the cause for the mixture too thin.
(a) Check whether there is a vacuum leakage in the intake

pipe.
(b) Check the existence of damaged vacuum pipes.
(c) Check whether the fuel injector is blocked.
(d) Check whether intake manifold absolute pressure sensor
is abnormal.
(e) Check whether the temperature sensor of engine coolant
is abnormal.
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(f) Check whether the fuel is contaminated.

(g) Are the above faults available?
No
Step 15 The vehicle road test confirms the fault has been cleared.
Fuel Pressure Testing Procedure

FU
Warning!
Gasoline and gasoline vapor is highly flammable. In order to avoid fire or explosion, please keep away from a fire source. It is
prohibited to use mobile phones during this procedure.
Do not use open container to exhaust or store exhausted gasoline, and please prepare a dry chemical fire extinguisher nearby
in advance.
Warning!
Wrap a duster cloth around the fuel pressure gauge and fuel distribution pipe joints to absorb leaked fuel when you connect
the fuel pressure gauge, in order to reduce the risk of fire and injury. After completion of the test, place the cloth into the
designated containers. Clean the fuel pipe fitting before removing the fuel pipe.
Warning!
It is prohibited to drain or store fuel in an open container, otherwise it will cause a fire.
Operation steps
Step 1 Install fuel pressure gauge to the fuel distribution pipe inlet.
Next Step
Step 2 Place the fuel pressure gauge exhaust hose into a specified gasoline container.
Next Step
Step 3 Open the exhaust valve on the fuel pressure gauge to drain the air out from the gauge.
Next Step
Step 4 Operate the starter switch to turn the power supply mode to ON state.
Next Step
Use fault diagnostic scanner "Function test" to drive fuel pump relay to make fuel pump work, until
Step 5
all the air drained out from the pressure gauge.
Next Step
Step 6 Turn off the exhaust valve on the fuel pressure gauge.
Next Step
Use fault diagnostic scanner to connect the fuel pump to check whether there is fuel leakage and
Step 7
handle the leakage position.
Next Step
When there is no leakage in the pipeline, start the engine and the fuel pressure should be 350 kPa
Step 8
(50.75psi).
Next Step
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Operate the ignition switch so as to set the power mode in the state OFF. Under normal
circumstances, the system should maintain the pressure higher than 80% of rated pressure, and
Step 9
should maintain the pressure higher than 70% of rated pressure 20 minutes later. If the fuel
pressure in system continuously drops, please check the fuel pump.
Next Step
Step 10 End.
FU
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On-board Check
1. Check the operation of fuel pump.

2) Power on the engine.
3) Fuel pump working control
4) Check whether the flowing noise of fuel in fuel tank

can be heard. If the noise can’t be heard, check
relay, fuel pump, ECU and harness connector.
FU 5) Turn off the ignition switch.
6) Disconnect fault diagnosis instrument.
2. Inspection of fuel pressure
2) Measure the voltage between two ends of battery.
3) Disconnect the negative battery cable
4) Disconnect the fuel supply pipe of engine at the

connector of fuel distributor assembly.
Notice
leakage and prevent the entry of foreign matter.
5) Connect the pressure gauge to fuel pipeline, and

then connect it with fuel distributor assembly.
6) Wipe away all splashed gasoline.
7) Connect the negative battery cable.
8) Connect the fault diagnosis instrument to OBD

9) Start the engine.
10) Measure the fuel pressure when the engine is

running at idle speed.
Fuel pressure:
340 - 360 kPa （3.5 - 3.7 kgf*cm2， 49.3 - 52.2 psi）
If the fuel pressure is higher than the standard

value, replace the fuel pump.
If the fuel pressure is lower than the standard value,
check fuel hose, connector, fuel filter and fuel
pump.
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11) Disconnect the fault diagnosis instrument from
OBD diagnostic interface.
12) Close the engine
13) Check and confirm that: after the engine stops, the
system should maintain the pressure higher than
80% of rated pressure; 20 minutes later, the
70% of rated pressure.
If the fuel pressure fails to meet the specified value,
please check the fuel pump or fuel injector.
FU
15) Remove the pressure gauge, and re-connect the
fuel pipe to fuel distributor assembly.
Notice: Prevent the gasoline from being splashed out. If
any gasoline is splashed out, please wipe it away.
16) Start the engine, and check the fuel system for
leakage. If there is any leakage, please re-connect
or replace the relevant component.
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FU-24 JLD-4G20 /24 Fuel System -Fuel Distribution Pipe Assembly
Fuel Distribution Pipe Assembly

Component
FU
Engine trim cover
Engine assembly
4G24
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JLD-4G20 /24 Fuel System - Fuel Distribution Pipe Assembly FU-25
Fuel distribution pipe

assembly FU
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Removal
2. Release the pressure in fuel system. Refer to "Check

procedure for fuel pressure".

cover"
5. Remove the fuel distributor assembly

FU
1) Disconnect the vent pipe of crankcase.
2) Disconnect 4 fuel injector harness connectors.
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3) Disconnect the fuel inlet pipe on fuel distributor

assembly.
Notice
Press safety device of oil inlet pipe opening downward,
and press and hold the device to pull out oil inlet pipe.
FU
4) Remove 2 fixing bolt, and remove the fuel

distributor assembly.
Disassembling
1. Remove the fuel injectors retaining spring clip.
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2. Pull out the fuel injector.
FU
Check
1. Check the fuel injector assembly

Ohmmeter
1) Measure the resistance between the two terminals
of fuel injector.
Standard resistance: 12Ω
Assembling
1. Install injector assembly
1. Replace the new O ring, apply a layer of gasoline

onto the new O ring, and install the O ring onto fuel
injector.
New O-ring
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2. Install fuel injector to ensure that the fuel injector

harness connector terminal and the fuel distribution pipe
mounting hole are in the same direction.
FU
3. Install the fuel injectors retaining snap spring.
Installation
1. Fuel distributor assembly
1) Mount the fuel distributor assembly and fixing bolt,

and tighten up the bolt.
Tightening torque: 9N·m (metric system) or 6.64 lb-ft

(imperial system)
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2) Connect fuel ejector harness connector.
FU
3) Connect the fuel supply pipe of fuel distributor

assembly.
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JLD-4G20 /24 Fuel System - Fuel Pump with the Fuel Sensor Assembly FU-31
Fuel Pump with the Fuel Sensor Assembly

Component
Fuel tank
cover
Sealing
FU
ring
Fuel pump with the fuel sensor

assembly
Fuel tank assembly
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FU-32 JLD-4G20 /24 Fuel System -Fuel Pump with the Fuel Sensor Assembly
Removal

4. Remove the rear seat. Refer to "Rear seat assembly"
5. Remove the fuel pump & fuel sensor assembly

FU 1) Remove fuel tank from reserved hole on blanket,
and then check and repair the cover plate.
2) Disconnect the harness connector of fuel pump &

fuel sensor assembly.
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JLD-4G20 /24 Fuel System - Fuel Pump with the Fuel Sensor Assembly FU-33
3) Disconnect the fuel inlet/outlet hose on fuel pump

& fuel sensor assembly.
FU
4) Use the special tool to remove the fuel tank cover,

remove the sealing ring, and take out the fuel
pump & fuel sensor assembly from fuel tank.
Check
1. Check the operation of fuel pump & fuel sensor

assembly.
Connect the fuel pump with battery, and check the

operation of pump.
Notice
The power-on test of fuel pump shall be completed

within 10 seconds, so as to prevent the fuel pump being
from damaged.
Keep the fuel pump away from battery as far as

possible.
Don’t set up the power switch on the side of battery or

the side of fuel pump.
If the fuel pump can’t work or makes abnormal noise or

abnormal vibration, please replace the fuel pump and its
sealing ring.
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FU-34 JLD-4G20 /24 Fuel System -Fuel Pump with the Fuel Sensor Assembly
Installation
1. Install the fuel pump & fuel sensor assembly
1) Replace and install the new sealing ring of fuel

pump, and mount the fuel pump & fuel sensor
assembly.
2) Tighten up the fuel tank cover, and fix the fuel

pump & fuel sensor assembly.
FU
3) Connect the fuel inlet/outlet hose of fuel pump &

fuel sensor assembly.
4) Connect the harness connector of fuel pump & fuel

sensor assembly.
2. Install the rear seat.
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JLD-4G20 /24 Fuel System - Fuel Filter FU-35
Fuel Filter
Component
FU
Fuel tank
Fuel filter
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FU-36 JLD-4G20 /24 Fuel System -Fuel Filter
Removal
2. Release the pressure in fuel system. Please refer to the

section about "Check procedure for fuel pressure".
5. Remove the oil filter assembly.

FU 1) Remove the grounding bolt of fuel filter.
2) Disconnect the fuel pipe on both sides of fuel filter.
3) Remove the fuel filter bracket.
4) Remove the fuel filter.
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JLD-4G20 /24 Fuel System - Fuel Filter FU-37
Installation
1. Install the oil filter assembly.
1) Install the fuel filter onto bracket, and tighten up the

fuel filter fixing screw.
2) Connect the pipes on both sides of fuel filter.
FU
3) Connect the fuel filter grounding wire.
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FU-38 JLD-4G20 /24 Fuel System -Fuel Tank
Fuel Tank
Component
FU
Fuel tank
Carbon
canister
Rear hanging strip

assembly of fuel tank
Protective plate
on bottom of
carbon canister
Front hanging strip

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JLD-4G20 /24 Fuel System - Fuel Tank FU-39
Fuel tank cap
Seal ring
Fill cap assembly

Fuel pump with fuel sensor assembly
FU
Fuel tank device
Filler pipe
assembly
Inlet filter fuel assembly
Outlet filter fuel hose Fuel filter
Hose to carbon canister

control valve
Rear hanging strip

Front hanging strip assembly of fuel tank
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Removal

3. Disconnect the negative battery cable. Refer to

"Battery".
4. Lift the vehicle
5. Remove the fuel filter. Refer to "Fuel filter".

FU
6. Remove the fuel tank assembly and fuel pump
component
1) Disconnect the connection between the oil inlet

pipe of carbon canister and the carbon canister.
2) Remove the vent hose of carbon canister and its

clamp.
3) Disconnect the connection between the fuel outlet

pipe of fuel filter and fuel supply pipe of engine.
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4) Disconnect the connection between the fuel tank

and the fuel filling pipe assembly.
FU
5) Disconnect the connection between the front

fuel-filling vent hose and fuel filling pipe assembly.
6) Remove the fixing bolts of front/rear hanging strip

of fuel tank.
7) Slowly lower down the fuel tank assembly.
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8) Remove the vent hose of carbon canister and the

fuel inlet/outlet hose assembly of filter.
9) Remove the fuel pump & fuel sensor assembly.

Refer to “Fuel pump & fuel sensor assembly”
FU
Installation
1. Install the fuel pump & fuel sensor assembly
1) Install the vent hose of carbon canister onto fuel

tank assembly.
2) Install the fuel inlet/outlet hose assembly of filter

onto fuel tank assembly.
3) Install the front/rear hanging strip assembly of fuel

tank, and fix the fuel tank.
Tightening torque of bolt: 45N·m (Metric) or 33.21

lb-ft (English)
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4) Connect the front fuel-filling vent hose and fuel

filling pipe assembly.
FU
5) Connect the pipeline between fuel tank and fuel

6) Connect the fuel outlet pipe of fuel filter with the

fuel supply pipe of engine.
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7) Install the vent hose of carbon canister and its

clamp.
8) Connect the oil outlet pipe of carbon canister with

carbon canister.
2. Install the engine oil filter.

FU
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JLE-4G18TDB Fuel system - Contents FU-1
FU JLE-4G18TDB Fuel system
Fuel System ....................................................................................................................... FU-2

Precautions ..............................................................................................................................FU-2
Component Position .................................................................................................................FU-3
On-board Check .......................................................................................................................FU-4
Fault of Fuel Pump ...................................................................................................................FU-6
All Fuel Injectors Are Not Working ..........................................................................................FU-14 FU
Surge Diagnosis During Driving ..............................................................................................FU-18
Testing Procedure of Fuel Oil Pressure ..................................................................................FU-22
Injector sub-assembly of Fuel Rail ................................................................................ FU-24
Component .............................................................................................................................FU-24
On-board removal...................................................................................................................FU-26
Check .....................................................................................................................................FU-26
Installation ..............................................................................................................................FU-27
Fuel Pump With The Fuel Sensor Assembly ................................................................ FU-28
Component .............................................................................................................................FU-28
Removal .................................................................................................................................FU-30
Check .....................................................................................................................................FU-31
Installation ..............................................................................................................................FU-32
Fuel Filter......................................................................................................................... FU-33
Component .............................................................................................................................FU-33
Removal .................................................................................................................................FU-34
Installation ..............................................................................................................................FU-35
Fuel Tank ......................................................................................................................... FU-36
Component .............................................................................................................................FU-36
Removal .................................................................................................................................FU-37
Installation ..............................................................................................................................FU-39
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FU-2 JLE-4G18TDB Fuel system - Fuel System
Fuel System
Precautions
1. Before inspecting or repairing the fuel system, please

disconnect the negative battery cable.
2. When inspecting or repairing the fuel system, don’t

smoke or work near any ignition source.
3. Don’t drop gasoline on any decorative part made of

FU rubber or leather. If gasoline has been dropped on such
part, please wipe it away immediately.
4. Fuel system
1) When disconnecting the high-pressure fuel

pipeline, a lot of fuel may be sprayed out.
Therefore, please comply with the following
operating steps:
Plastic bag
2) Disconnect fuel pump pipeline.
3) Drin the residual fuel in pipe of fuel pump.
4) In order to prevent the disconnected fuel pump and

pipeline from being damaged or contaminated by
foreign matter, please put a plastic bag over them.
5) When dismantling the connection of pipeline,

please place a container under the connection, so
as to receive the fuel drained from pipeline.
5. Release fuel system pressure

Notice
Before dismantling any component of fuel system, in
order to prevent the fuel from being sprayed out, please
implement the following steps.
1) Open the fuel tank cover.
2) Pull out the fuse for fuel pump in fuse box of engine
compartment.
3) Start the engine until the engine flameout

automatically.
4) Start the engine again and make it run for 10s.
Notice
After the above steps are implemented, the pressure in
fuel pipeline may still exist. When disconnecting the fuel
pipeline, please cover it with wiping cloth or other cloth,
so as to prevent the fuel from being sprayed out.
Notice
leakage and prevent the entry of foreign matter. Check
and make sure that no oil leaks from fuel system after it
is maintained or repaired. If there is any leakage of oil,
please replace the relevant component.
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JLE-4G18TDB Fuel system - Fuel System FU-3
Component Position
FU
Fuel injector
Fuel tank
assembly
Carbon
canister
Fuel supply
pipeline
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On-board Check
1. Check the operation of fuel pump.
2) Power on the engine.
3) Fuel pump working control
4) Check whether the flowing noise of fuel in fuel tank

can be heard. If the noise can’t be heard, check
FU relay, fuel pump, ECU and harness connector.
5) Turn off the ignition switch.
6) Disconnect fault diagnostic scanner.
2. Check fuel pressure
2) Measure the voltage between two ends of battery.
3) Disconnect the negative battery cable.
4) Disconnect the fuel supply pipe of engine at the

connector of fuel distributor assembly.
Notice
leakage and prevent the entry of foreign matter.
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5) Connect the pressure gauge to fuel pipeline, and

then connect it with fuel distributor assembly.
SST (clamp) SST (clamp)
6) Wipe away all splashed gasoline.
SST (T-shaped joint)
7) Connect the negative battery cable.
SST (pressure gauge)
8) Connect the fault diagnosis scanner to OBD
SST (hose)

SST (hose)
SST (clamp)
SST (pipe 10) Measure the fuel pressure when the engine is
connector) running at idle speed. FU
Fuel pipe
Fuel pressure:
304 to 343 kPa （3.1 to 3.5 kgf*cm2， 44.1 to49.7 psi）
If the fuel pressure is higher than the standard value,

replace the fuel pump.
If the fuel pressure is less than the standard value,

please check the fuel hose and pipe connectors, fuel
pump, fuel filter and oil pump.
11) Disconnect the fault diagnostic scanner from OBD

12) Close the engine
13) Check and confirm that: after the engine stops, the
80% of rated pressure; 20 minutes later, the system
should maintain the pressure higher than 70% of
rated pressure.
If the fuel pressure fails to meet the specified value,

please check the fuel pump or fuel injector.
15) Remove the pressure gauge, and re-connect the

fuel pipe to fuel distributor assembly.
Notice: Prevent the gasoline from being splashed out. If

any gasoline is splashed out, please wipe it away.
16) Start the engine, and check the fuel system for
leakage. If there is any leakage, please re-connect
or replace the relevant component.
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Fault of Fuel Pump

Circuit schematic:
Main relay
ER05
FU
Fuel pump relay
ER09
Fuel Pump
Notice
whether main relay works normally. When using the function “action test” of fault diagnostic scanner, make sure that the
communication between fault diagnostic scanner and EMS is normal.

No
Go to step 3
Yes
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Step 2 Overhaul fuel pump fuse EF20 circuit.
(a) Check fuel pump fuse EF20 circuit fault.

(b) Repair fuel pump power supply circuit short to ground
fault.

FU
Yes
No
(a) Use the diagnostic scanner to drive the fuel pump relay
Engine compartment fuse, relay box ER09.
(a) Check the voltage between the terminal 5 of fuel pump

relay and the reliable grounding point.
Yes
Go to step 7
No
Overhaul open circuit fault between terminal 3 of fuel pump relay ER09 and fuel pump fuse
Step 4
EF20.
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pump relay ER09 and the fuse EF20.

value.
FU No Repair or replace the harness
No

mode to OFF state.
(c) Measure the voltage between the terminal 1 of fuel

pump relay ER09 and the reliable grounding point.
(d) Confirm whether the voltage meets standard value?
Yes Go to step 7
No
Step 6 Check fuel pump relay fuse EF10 circuit.
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(a) Check the fuel pump fuse EF10 circuit.

(b) Repair the fuel pump fuse EF10 circuit fault.

(d) Confirm whether the fuel pump is working normally.
FU
No
Step 7 Check the fuel pump relay ER09.

(b) Replace the fuel pump relay ER09 with a new part in
good condition.

mode to ON state.
(d) Confirm whether the fuel pump is working properly.
Yes Replace the fuel pump relay ER09
No
Check the conductivity between terminal 4 of fuel pump harness connector SO26 and body
Step 8
grounding.

mode to OFF state.

(c) Measure the resistance between fuel pump harness
connector SO26 terminal4 and the body grounding.

value.
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Yes
Check the conductivity of the circuit between terminal 5 of fuel pump harness connector ER09
Step 9
and terminal 1 of fuel pump harness connector SO26.
(a) Remove the fuel pump relay ER09.
(b) Measure the resistance between terminal 5 of fuel
pump harness connector ER09 and terminal 1 of fuel
pump harness connector SO26.
FU
No
Repair or replace the harness
Yes
Check conductivity between terminal 28 of harness connector CA01 of EMS control module and
Step 10
terminal 2 of relay.
(a) Disconnect the EMS harness connector CA01.
(b) Measure the resistance between the terminal 28 of
EMS harness connector CA01 and the terminal 2 of
fuel pump relay
No
Repair or replace the harness
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connector 2
FU
Yes
(d) Install the fuel pump relay ER09.

(e) Connect the EMS control module harness connector
CA01.
(f) Connect fault diagnostic scanner to vehicle diagnostic
interface.
(g) Connect fuel pump harness connector SO26 terminal 1
and body grounding with test lamp.
(h) Operate the starter switch to turn the power supply
mode to ON state.
(i) Use a diagnostic scanner to carry out "Action test" on
pump relay.
(j) Does test lamp light up?
No
Go to Step 13.
Yes
(a) Replace the fuel pump. Refer to Fuel pump with fuel
sensor assembly.
(b) Confirm that the fault in the system has been

eliminated.

Yes
No
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FU No Repair or replace the harness
CA01 Engine management system (plug-in part K) harness connector 2
Yes

mode to OFF state.
CA01 Engine management system (plug-in part K) harness connector 2 (b) Disconnect the EMS harness connector CA01.
(c) Measure the resistance between the terminal 1/2/4 of
EMS harness connector CA01 and the reliable
grounding point.
Yes
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(b) Ensure whether the system is normal?
Next Step
FU
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All Fuel Injectors Are Not Working

Circuit schematic:
Main relay
ER05
FU
Step 1 Check whether the engine anti-theft system is activated.
(a) Whether the engine malfunction indicator lamp flashes?
No Go to Step 3.
Yes
Step 2 Repair engine anti-theft system fault.
(a) Repair engine anti-theft system fault
(b) Whether fuel injector is working properly.
No
Step 3 Check the fuses IF17 and EF09 of engine management system (EMS).
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(a) Check whether the fuses IF17 and EF09 of engine

Engine compartment fuse, relay box management system (EMS) have blown out.
No Go to Step 6.
FU
Yes


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connector 2
FU
No

mode to OFF state.
connector 2

grounding point.
No
Check the circuit between the fuel injector and the engine management system EMS (taking
Step 6
cylinder a as an example).

mode to OFF state.
connector 2
connector EN48.
(c) Disconnect the engine management system harness

connector EN35.

injector harness connector EN48 of cylinder No. 1
(e) Measure the resistance between the terminal2 of fuel

injector harness connector EN48 of cylinder No. 1
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value?
Fuel nozzle 1 harness connector EN48 Repair or replace the harness

Yes
FU
Yes



connector 2
Yes
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mode to OFF state.

CA01 Engine management system (plug-in part K) harness connector
2
grounding point.
FU
Yes

Next Step
Surge Diagnosis during Driving

Fault definition: When the accelerator pedal position remains unchanged, the engine power changes causing speed increase
or decrease.
Notice
Before performing this diagnostic test, make sure the engine control system has no DTC.
Step 1 Perform the preliminary check.
(a) Check vacuum pipe for whether there is cracking,

twist and so on.
(b) Check engine EMS grounding point for oxidation,
loose, incorrect position and so on.
(c) Check whether each sensor harness connector is
correctly connected, and the existence of loose, poor
connection and so on.
Next Step
Step 2 Check whether the intake pressure sensor is normal.
(a) Refer to “ Intake pressure temperature sensor”.
Yes
Step 3 Is the engine coolant temperature sensor working properly?
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(a) Refer to “Water temperature sensor”
Yes
Step 4 Test the fuel pressure, is it normal?
(a) Refer to "Testing procedure of fuel oil pressure"
Check whether the pipeline is blocked, if

No
necessary, replace the faulty FU
component.
Yes
Use the common tool "Fuel injector cleaning and testing machine" to test the performance of
Step 5
each cylinder fuel injector. Check whether the fuel injectors are normal.
No Replace damaged fuel injectors.
Yes
Step 6 Check whether fuel quality is normal and the fuel is contaminated.
No Replace with good quality fuel.
Yes
Step 7 Connect fault diagnostic scanner to check the front oxygen sensor signal.

(b) Start engine and turn on the fault diagnostic scanner.
(c) Make the engine run at the speed of about 2,500 rpm
for more than 2 minutes, so as to heat up the engine
(d) Under idle speed, measure the oxygen sensor, and
let its operating temperature reach 350℃.
(e) Select on the fault diagnostic scanner: Engine/Read
data stream/Front oxygen sensor voltage.
(f) Observe the front oxygen sensor output voltage and
the data stream display shall fluctuate within the 0.1-
0.9V scope.
(g) If the data stream shows the voltage is constantly
lower than 0.45V (mixture too thin), execute the
check procedure according to the following steps:
 Proper amount of propane gas will be injected in the
inlet.
 Check whether the front oxygen sensor data stream
voltage has a significant change, in which case the
signal voltage will increase rapidly.
(h) If the data stream shows the voltage is constantly
higher than 0.45V (mixture too rich), execute the
check procedure according to the following steps:
 Place the gear shift lever at neutral position or
parking position.
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 Pull tightly the hand brake.
 Depress the acceleration pedal so that the engine

speed suddenly increases to 4000rpm and then
suddenly release the acceleration pedal.
 Repeat more than three times as per the above
procedure.
 Observe whether there is a significant change in the
front oxygen sensor data stream voltage, in which
case the signal voltage will decrease rapidly.
(i) When executing the above test, the oxygen sensor
FU signal voltage shall significantly vary with the test.
(j) Is the voltage change obvious?
Signal voltage no response A
Signal voltage remains B

high
Signal voltage remains low C
Signal voltage is normal D
A Replace the front oxygen sensor
B Go to step 13
C Go to step 14
Step 8 Check whether the spark plug is normal.
(a) Refer to “Spark plug”.
Replace with the correct type of spark

No
plug.
Yes
Step 9 Check the ignition coil to confirm whether the arcing capacity of ignition coil is normal.

No Replace with the correct type of ignition

coil.
Yes
Step 10 Check whether the speed sensor signal tooth is correctly installed.

Handle the fault position. If necessary,

No replace the faulty components.
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Yes
Step 11 Check whether A/C system is working correctly?
(a) Check whether the exhaust system is blocked up.
Yes Go to step 15
Yes
FU
Step 12 Check whether the exhaust system is normal?
(a) Check whether the compressor clutch engagement is

rough. The A/C system pressure should not be too
high. Check whether the A/C compressor is working
properly.
No replace the faulty components.
Next Step
Step 13 Check the cause for the mixture too rich.
(a) Check whether the carbon canister solenoid valve is

normally turned on.
(b) Check whether there is any leakage of fuel injector.
(c) Check whether the air filter element is blocked.
(d) Check whether there is block or deformation for
intake pipe.
(e) Check whether the engine lubricating oil is
contaminated by fuel.
(f) Check whether the fuel pressure is too high.
(g) Check whether the intake manifold absolute pressure
sensor is normal.
(h) Check whether the temperature sensor of engine
coolant is abnormal.
(i) Are the above faults available?
No Go to step 15

Yes
Next Step
Step 14 Check the cause for the mixture too thin.
(a) Check whether there is a vacuum leakage in the

intake pipe.
(b) Check the existence of damaged vacuum pipes.
(c) Check whether the fuel injector is blocked.
(d) Check whether intake manifold absolute pressure
sensor is abnormal.
(e) Check whether the temperature sensor of engine
coolant is abnormal.
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(f) Check whether the fuel is contaminated.

(g) Are the above faults available?
No
Step 15 The vehicle road test confirms the fault has been eliminated.
Testing Procedure of Fuel Oil Pressure

FU
Warning!
Gasoline and gasoline vapor is highly flammable. In order to avoid fire or explosion, please keep away from a fire source. It is
prohibited to use mobile phones during this procedure. Do not use open container to exhaust or store exhausted gasoline, and
please prepare a dry chemical fire extinguisher nearby in advance.
Warning!
Wrap a duster cloth around the fuel pressure gauge and fuel distribution pipe joints to absorb leaked fuel when you connect
the fuel pressure gauge, in order to reduce the risk of fire and injury. After completion of the test, place the cloth into the
designated containers. Clean the fuel pipe fitting before removing the fuel pipe.
Warning!
Operation steps
Step 1 Install fuel pressure gauge to the fuel distribution pipe inlet.
Next Step
Step 2 Place the fuel pressure gauge exhaust hose into a specified gasoline container.
Next Step
Step 3 Open the exhaust valve on the fuel pressure gauge to drain the air out from the gauge.
Next Step
Step 4 Operate the starter switch to turn the power supply mode to ON state.
Next Step
Use fault diagnostic scanner "Function test" to drive fuel pump relay to make fuel pump work,
Step 5
until all the air drained out from the pressure gauge.
Next Step
Step 6 Turn off the exhaust valve on the fuel pressure gauge.
Next Step
Use fault diagnostic scanner to connect the fuel pump to check whether there is fuel leakage
Step 7
and handle the leakage position.
Next Step
When there is no leakage in the pipeline, start the engine and the fuel pressure should be 550
Step 8
kPa (50.75psi).
Next Step
NL-3 01/2016
Operate the starter switch to turn the power supply mode to OFF state. Under normal
circumstances, the system should maintain the pressure higher than 80% of rated pressure,
Step 9
and should maintain the pressure higher than 70% of rated pressure 20 minutes later. If the fuel
pressure in system continuously drops, please check the fuel pump.
Next Step
Step 10 End.
FU
NL-3 01/2016
FU-24 JLE-4G18TDB Fuel system - Injector Sub-assembly of Fuel Rail
Injector Sub-assembly of Fuel Rail

Component
FU
Engine trim cover
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JLE-4G18TDB Fuel system - Injector Sub-assembly of Fuel Rail FU-25
Intake pressure
temperature sensor
FU
Carbon canister control Intake manifold assembly and fuel

valve injector harness
Electronic throttle
body
Oil filter
Engine assembly（4G 18 TD）
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FU-26 JLE-4G18TDB Fuel system - Injector Sub-assembly of Fuel Rail
On-board Removal

cover"
4. Remove the carbon canister solenoid valve. Refer to

Carbon canister control valve.
FU 5. Remove electronic throttle. Refer to Electronic

throttle body.
6. Remove intake pressure and temperature sensor.

Refer to the section about intake pressure
temperature sensor

harness
8. Remove the fuel rail and fuel injector sub-assembly
1) Remove 2 hexagonal-socket cylinder-head

screws.
2) Remove the fuel rail fuel injector subassembly

from the intake manifold component.
Check
1. Check the fuel injector assembly
1) Measure the resistance value between the two

terminals of fuel injector.
Ohmmeter
Standard resistance: Ω
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JLE-4G18TDB Fuel system - Injector Sub-assembly of Fuel Rail FU-27
Installation
1. Install injector assembly
1) Install the fuel rail fuel injector component onto

intake manifold component.
2) Tighten up 2 hexagonal-socket cylindrical-head

screws.

harness
FU
6. Install the electronic throttle
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FU-28 JLE-4G18TDB Fuel system - Fuel Pump with The Fuel Sensor Assembly
Fuel Pump with the Fuel Sensor Assembly

Component
FU
Right rear seat

backrest
Left rear seat

backrest
Rear seat cushion

assembly
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JLE-4G18TDB Fuel system - Fuel Pump with The Fuel Sensor Assembly FU-29
Fuel tank cap
Sealing ring FU

assembly
Fuel tank assembly
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Removal
2. Release the pressure in fuel system. Refer to

“Engine oil pressure alarm”
4. Remove the rear seat. Refer to "Rear seat assembly"
5. Remove the fuel pump with fuel sensor assembly

FU
1) Remove fuel tank from reserved hole on
blanket, and then check and repair the cover
plate.
2) Disconnect the harness connector of fuel pump

with fuel sensor assembly.
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JLE-4G18TDB Fuel system - Fuel Pump with The Fuel Sensor Assembly FU-31
3) Disconnect the plastic fuel outlet/return hose on

fuel pump with fuel sensor assembly.
FU
4) Use the special tool to remove the fuel tank

cover, remove the sealing ring, and take out the
fuel pump with fuel sensor assembly from fuel
tank.
Check
1. Check the operation of fuel pump with fuel sensor

assembly.
Connect the fuel pump with battery, and check the

operation of pump.
Notice
The power-on test of fuel pump shall be completed
within 10 seconds, so as to prevent the fuel pump
from being damaged.
Keep the fuel pump away from battery as far as
possible.
Set the power switch on the side of battery, rather
than the side of fuel pump.
If the fuel pump can’t work or makes abnormal noise
or abnormal vibration, then replace the fuel pump and
its sealing ring
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Installation
1. Install the fuel pump with fuel sensor assembly
1) Install the fuel pump with fuel sensor assembly,

and install the new sealing ring.
2) Tighten up the fuel tank cover, and fix the fuel

pump with fuel sensor assembly.
FU
3) Connect the fuel inlet/outlet hose of fuel pump

4) Connect the harness connector of fuel pump

2. Install the rear seat.
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JLE-4G18TDB Fuel system - Fuel Filter FU-33
Fuel Filter
Component
Fuel tank cap
Sealing ring FU
Fuel pump with the fuel sensor assembly
Fuel tank
Fuel filter
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FU-34 JLE-4G18TDB Fuel system - Fuel Filter
Removal
2. Release the pressure in fuel system. Please refer to

"Check procedure for fuel pressure".
4. Lift the vehicle
5. Remove the oil filter assembly.

FU
1) Remove the grounding bolt of fuel filter.
2) Disconnect the fuel pipe on both sides of fuel

filter.
3) Remove the fuel filter bracket fixing screw and

take down the fuel filter.
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JLE-4G18TDB Fuel system - Fuel Filter FU-35
Installation
1. Install the oil filter assembly.
1) Install the fuel filter onto bracket, and tighten up

the fuel filter fixing screw.
2) Connect the pipes on both sides of fuel filter.
FU
3) Install the bolt of grounding wire of fuel filter.
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FU-36 JLE-4G18TDB Fuel system - Fuel Tank
Fuel Tank
Component
Fuel tank cap
Sealing ring
Filler cap assembly

assembly
FU
Fuel tank
Filler pipe assembly
Intake filter hose

assembly
Filter fuel hose outlet

Fuel filter
Carbon canister control

valve hose outlet
Rear hanging strip

assembly of fuel
tank
Front hanging strip

assembly of fuel
tank
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JLE-4G18TDB Fuel system - Fuel Tank FU-37
Removal

3. Disconnect the negative cable of battery. Refer to

Battery cable
4. Lift the vehicle
5. Remove the fuel filter. Refer to "Fuel filter". FU

6. Remove the fuel tank assembly and fuel pump
component
1) Disconnect the connection between the oil inlet

pipe 1 of carbon canister and the carbon
canister.
2) Disconnect the connection between the vent

hose 2 of carbon canister and the carbon
canister.
3) Disconnect the connection between the fuel

outlet pipe of fuel filter and fuel supply pipe of
engine.
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4) Disconnect the connection between the fuel

tank and the fuel filling pipe assembly.
FU
5) Disconnect the connection between the front

fuel-filling vent hose and fuel filling pipe
assembly.
6) Remove the fixing bolts of front/rear hanging

strip of fuel tank.
7) Slowly lower down the fuel tank assembly.
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8) Remove the vent hose of carbon canister and

the fuel inlet/outlet hose assembly of filter.
9) Remove the fuel pump with fuel sensor

assembly. Refer to Fuel pump with fuel sensor
assembly
FU
Installation
1. Install the fuel pump with fuel sensor assembly
1) Install the vent hose of carbon canister onto fuel

tank assembly.
2) Install the fuel inlet/outlet hose assembly of filter

onto fuel tank assembly.
3) Install the front/rear hanging strip assembly of

fuel tank, and fix the fuel tank.
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4) Connect the oil inlet pipe 1 of carbon canister

with the carbon canister
5) Connect the vent hose 2 of carbon canister with

the carbon canister.
FU
6) Connect the pipeline between fuel tank and fuel

7) Connect the fuel outlet pipe of fuel filter with the

fuel supply pipe of engine.
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8) Install the vent hose of carbon canister and its

clamp.
9) Connect the oil outlet pipe of carbon canister

with carbon canister.
2. Install fuel filter.

FU
NL-3 01/2016
FU
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JLD-4G20/24 mechanical System –Contents EM-1
EM JLD-4G20/24 Mechanical system
Engine ............................................................................................................................... EM-3

Comprehensive Check of Engine ............................................................................................ EM-3
Engine Noise Diagnosis........................................................................................................... EM-5
There Is Noise When The Engine Loaded ............................................................................... EM-5
Slight Vibration When Engine Is Warming Up .......................................................................... EM-5
Vibration at Idle and When Engine Is Warming Up .................................................................. EM-6
Engine Misfire with Abnormal Noise ........................................................................................ EM-7
Check on Drive Belt ................................................................................................................. EM-9
Drive Belt Chirp Diagnosis ..................................................................................................... EM-10 EM
Drive Belt Scream Diagnosis ................................................................................................. EM-11
Drive Belt Hum Sound Diagnosis........................................................................................... EM-12
Drive Belt Falling-off Diagnosis .............................................................................................. EM-13
Excessive Wear of Drive Belt................................................................................................. EM-13
On-board Check .................................................................................................................... EM-15
EngineTrim Cover .......................................................................................................... EM-16
Component ............................................................................................................................ EM-16
Removal ................................................................................................................................ EM-17
Installation ............................................................................................................................. EM-17
Cylinder Head Cover Assembly .................................................................................... EM-18
Component ............................................................................................................................ EM-18
Removal ................................................................................................................................ EM-22
Installation ............................................................................................................................. EM-23
Drive Belt ........................................................................................................................ EM-26
Component ............................................................................................................................ EM-26
Removal ................................................................................................................................ EM-27
Check .................................................................................................................................... EM-27
Installation ............................................................................................................................. EM-27
Belt Tensioning Mechanism Subassembly.................................................................. EM-29
Component ............................................................................................................................ EM-29
Removal ................................................................................................................................ EM-30
Installation ............................................................................................................................. EM-31
Damping Pulley .............................................................................................................. EM-33
Component ............................................................................................................................ EM-33
Removal ................................................................................................................................ EM-35
Installation ............................................................................................................................. EM-36
Crankshaft Front Oil Seal .............................................................................................. EM-37
Component ............................................................................................................................ EM-37
Removal ................................................................................................................................ EM-39
Installation ............................................................................................................................. EM-39
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EM-2 JLD-4G20/24 mechanical System –Contents
Engine Suspension........................................................................................................ EM-40

Component ............................................................................................................................ EM-40
Engine Front Vibration Isolator Assembly................................................................... EM-42
Removal ................................................................................................................................ EM-42
Installation ............................................................................................................................. EM-43
Rear Vibration Isolator Of Engine................................................................................. EM-44
Removal ................................................................................................................................ EM-44
Installation ............................................................................................................................. EM-45
Left Vibration Isolator of Engine ................................................................................... EM-46
Removal ................................................................................................................................ EM-46
EM Installation ............................................................................................................................. EM-47
Right Vibration Isolator of Engine ................................................................................ EM-49
Removal and Installation ....................................................................................................... EM-49
Installation ............................................................................................................................. EM-50
Engine Assembly ........................................................................................................... EM-51
Component ............................................................................................................................ EM-51
Removal ................................................................................................................................ EM-63
Installation ............................................................................................................................. EM-71
Crankshaft Rear Oil Seal ............................................................................................... EM-79
Removal ................................................................................................................................ EM-91
Installation ............................................................................................................................. EM-92
Timing Chain .................................................................................................................. EM-94
Component ............................................................................................................................ EM-94
Removal .............................................................................................................................. EM-101
Check .................................................................................................................................. EM-105
Installation ........................................................................................................................... EM-105
Camshaft .......................................................................................................................EM-111
Component ...........................................................................................................................EM-111
Removal .............................................................................................................................. EM-122
Installation ........................................................................................................................... EM-124
Cylinder Head Component .......................................................................................... EM-127
Component .......................................................................................................................... EM-127
Removal .............................................................................................................................. EM-139
Check .................................................................................................................................. EM-144
Installation ........................................................................................................................... EM-147
Cylinder Block .............................................................................................................. EM-168
Component .......................................................................................................................... EM-168
Removal .............................................................................................................................. EM-196
Check .................................................................................................................................. EM-203
Installation ........................................................................................................................... EM-208
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JLD-4G20/24 mechanical System - Engine EM-3
Engine
Comprehensive Check of Engine
1. Check of engine coolant
Refer to “On-board check”
2. Check engine oil
3. Check the battery
4. Check the spark plug.
Refer to On-board check
5. Check ignition timing
Prior to checking ignition timing, the following conditions shall be met:
- The engine shall reach the normal operation temperature.
• Test methods with fault diagnostic scanner: EM
Step 1 Connect fault diagnostic scanner

mode to OFF state.
(b) Connect the fault diagnostic scanner to the diagnostic
test interface.
(e) Select in sequence: Engine/Data list/cylinder No.1
ignition advance angle.
Standard timing: 1°~7°before TDC at standard idling
• Detection method using the timing lamp:
Step 1 Connect the clip of the timing lamp to the cylinder No.1 ignition coil harness.
Next Step
Step 2 Check the ignition timing when idling.
Next Step
Step 3 Check ignition timing during acceleration.
Next Step
Step 4 Remove the timing lamp and restore the mounting position of the ignition coil harness.
Next Step
Step 5 The test is finished.
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EM-4 JLD-4G20/24 mechanical System - Engine
6. Check on pressure of cylinder

The possible cause for reduced pressure of cylinder is that the valve is not properly closed or the piston ring is worn.
The pressure of cylinder may not be lower than 750kPa.
Prior to the compression, the following conditions shall be met:
1. The engine shall reach the normal operation temperature.
2. Throttle valve must be fully opening.
3. The battery shall be fully charged without power-lack.
Notice
During the start-up test, the starter switch can not remain at the "ST" position for more than 15s; otherwise it will damage the
starter.
After the test is completed, use the fault diagnostic scanner to clear the fault diagnosis code.
EM
Remove the fuse EF10, disconnect the fuel injector harness connector, and ensure that the fuel
Step 1
and ignition systems can’t work.
Next Step
Remove the spark plugs of 4 cylinders, and inject an appropriate amount of engine oil in every
Step 2
cylinder.
Next Step
Step 3 Install the tester for pressure of cylinder on installation hole for every spark plug.
Next Step
Turn the ignition switch to "ST" position and make each cylinder move 4~5 compression
Step 4
strokes.
Next Step
The lowest reading of each cylinder pressure shall not be lower than 75% of the highest reading
Step 5 of the single cylinder. The reading of any cylinder pressure gauge shall not be lower than
750kPa.
Next Step
After every cylinder completes 4-5 compression strokes, check the reading on pressure gauge.
Step 6
The symptoms relating to cylinder pressure are detailed as follows:
(a) Normal situation: The pressure of every cylinder is
even, increases quickly and can reach the specified
value.
(b) Fault of piston ring: The pressure is low in the first
compression stroke, and increases in subsequent
strokes, but does not reach the normal value. After
engine oil is added in cylinder, the pressure will
increase obviously.
(c) Valve fault: the first stroke pressure is low and unable
to increase during the following stroke; the pressure is
not high when the engine oil is added in the cylinder.
Next Step
Step 7 The check is completed.
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Engine Noise Diagnosis

The engine vibration actually represents the engine resonance noise. When the engine vibration frequency and fault vibration
frequency keep consistent, the noise will be perceived. The sound from the serious vibration is usually huge, which is usually
caused by the engine interior component rupture or severe wear. The minor vibration noise can be heard, but the noise is low.
The cause of minor vibration is that the internal components of engine are worn. The loosened or broken external components
of engine may also lead to serious or minor vibration. When diagnosing the noise fault, find out the resonance source and
eradicate the fault.
There Is Noise When The Engine Loaded

Step 1 Check the drive belt, is the belt tension too tight or damaged?
Replace/adjust the drive belt or belt

Yes
tensioning mechanism subassembly, and
confirm whether the fault has been
eliminated. EM
No
Re-position and install the exhaust

Yes
system and determine whether the fault
has been eliminated.
No
Check whether the flywheel assembly is cracked, deformed or interfered with other
Step 3
components, and whether the driving disc is normal?
Replace flywheel assembly and

Yes
determine whether the fault has been
eliminated.
No
Step 4 Check whether main clearance is too big, or beyond the specified value?
Standard value: (0~0.046mm)
Yes
Replace main bearing and determine
whether the fault has been eliminated.
No
Step 5 Check whether the connecting rod bearing clearance is beyond the specified value?
Standard value: (0.005~0.018mm)

Replace connecting rod bearing and
Yes determine whether the fault has been
removed
No
Step 6 Confirm the fault is eliminated.
Slight Vibration When Engine Is Warming Up

Step 1 Check drive belt tension for looseness, wear or any other fault.
If necessary, replace the drive belt and

Yes
eliminated.
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No
Step 2 Check whether the viscosity of the engine lubricating oil is normal.
Re-fill engine lubricant suitable to the

Yes
present season temperature and
eliminated.
No
Check whether the engine and A/C compressor work normally, and whether they make any
Step 3
noise when working?
Yes Replace fault component and check

EM
No
Use the fault diagnostic scanner to check relevant knock data in the data stream for any
Step 4
explosive combustion in the engine?
Yes Check the engine timing systems and fuel

quality. Repair the fault position.
No
Step 5 Check whether there is leakage on exhaust manifold and its connection.
Yes Replace the exhaust pipe pad and tighten

the exhaust pipe
No
Step 6 Check connecting rod bearing clearance, and does it exceed the specified value?
Standard value: （0.005~0.018mm）

No
Step 7 Confirm the troubleshooting.
Vibration at Idle and When Engine Is Warming Up

Step 1 Check drive belt tensionfor looseness, wear or any other fault.

Yes
eliminated.
No
Re-fill engine lubricant suitable to the

Yes present season temperature and
eliminated.
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No
Check whether the engine and A/C compressor work normally; does any abnormal noise come
Step 3
out during operation?
Replace fault component and check

Yes
No
Step 4 Check the operation state of the valve tappet rods, valve springs, etc. Any fault available?

whether the fault has been eliminated
No
EM
Step 5 Replace fault component and check whether the fault has been eliminated.
Standard value of piston pin and connecting rod:

(0.005-0.013mm)
Standard value of piston pin and piston pin hole:
(0-0.006mm)

Yes
No
Step 6 Check whether the connecting rod has been bent.

Yes
whether the fault has been eliminated
No
Step 7 Check the clearance valve of the piston to jacket, is it beyond the standard value?
Standard value: （0.0275~0.0575mm）

No
Engine Misfire with Abnormal Noise

Step 1 Check whether engine control system has fault code through fault diagnostic scanner?
Yes Repair the location in fault on the basis of the

fault code.
No
Use the fault diagnostic scanner to check relevant data about "knock" in the engine data
Step 2
stream, and compare it with normal vehicle for abnormity.
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No
Step 3 Check whether the valve spring is too soft or ruptured.
Yes Check whether the fuel is normal. Check

whether the timing system is normal.
Repair the fault position. Confirm whether
the fault is eliminated.
No
Step 4 Check whether the valve is catching or bent.
Repair the fault position.

EM Yes
No
Step 5 Check valve tappet, whether there is damage, catching, wear, etc?
No
Step 6 Check whether there is excessive wear or obvious fault of cam on camshaft.
Yes Replace the camshaft.
No
Step 7 Check valve guide pipe for the existence of cracks, excessive wear and tear and other faults.
Yes Replace the cylinder head component.
No
Step 8 Check valve spring seat and valve spring shim for correct assembly?
Yes Repair the fault position
No
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Check on Drive Belt
1. Conduct check in cold state or when the engine is Damaged/aged drive belt
turned off after 30min.
2. Visually check the drive belt for excessive wear or

curtain line wear, etc. If faults are found, replace the
drive belt.
3. Visually check whether the belt's interior and edge has

wear, damage, rupture. If any, replace a new belt.
Drive belt mounting
EM
Correct matching
New drive belt Old drive belt
Drive belt tension (N/lb) 400~500 / 89.9~112.4 300~400 / 67.4~89.9
 After replacing the new belt, turn the crankshaft two circles clockwise to make belt fully wedged into the pulley.
Measure tension at mark point A. The reference scope is seen in the table. In case of exceeding the table scope,
replace a new belt.
 When the tension of the using belt (i.e. used belt) is beyond the table scope, replace a new belt.
 When installing the belt, ensure its correct binding with the pulley slot.
 Please don’t let the engine oil or engine coolant drop on belt. If the engine oil or engine coolant drops on belt,
please wipe it away immediately.
 Do not over-wind or bend the drive belt.
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Drive Belt Chirp Diagnosis

Diagnosis tips:
The symptom is a intermittent fault due to wet drive belt or pulley. It may be needed to spray some water in the drive belt to
recreate the customer's fault. If the symptom reoccurs after spraying water, then clean the pulley. Loose or improper
installation of body components, suspension components or other vehicle parts can also cause the chirp sound.
Fault definition: the following conditions are the drive belt chirp sound symptoms
- A chirp noise can be heard once when rotating the drive belt for a round.
- Noise often happens on a rainy day or in a cold morning.
Step 1 Determine the fault phenomenon; does the engine really have chirp sound?
No To diagnosis tips
Yes
EM
Step 2 Remove the drive belt and determine whether the chirp sound disappears.
(a) Remove the drive belt.
(b) Run the engine, but no more than 30 s.
Does the chirp sound disappear?
No Refer to “Engine noise diagnosis”.
Yes
Step 3 Check whether the surface of the drive belt is normal. (Free from pilling, crack, etc.)
Please refer to “Drive belt inspect”.
No Replace the drive belt.
Yes
Step 4 Check whether the drive belt pulley is installed correctly. (Misaligned, etc.)
No Re-install the drive belt pulley, and

replace the drive belt pulley if necessary.
Yes
Step 5 Check whether the belt pulley is normal.
Check whether the belt pulley is bent or twisted.
No Replace faulty pulley.
Yes
Step 6 Check whether all the fasteners related to the drive belt are normal?
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No Tighten the loosen fastener.
Yes
Step 7 Replace drive belt and determine the fault has been eliminated.
Drive Belt Scream Diagnosis

Diagnosis tips:
Loose or unreasonable installation of body, suspension and other components may cause scream. In case of intermittent
noise, check various attached drive components via changing engine load. It is advised to check whether the A/C system is
filled with too much liquid, whether the hose of power steering system is pinched, and whether the alternator is in fault.
Fault definition: the following conditions are the drive belt screams symptoms
• Screaming generated by the sliding of the drive belt.
• The noise occurs when the large load is applied to the drive belt, e.g. the startup of the A/C system compressor, EM
rapid start of the throttle valve when the engine moves or the screeching noise when the belt slides in the fault drive
component.
Step 1 Confirm fault phenomenon; does the engine scream actually occur?
No To diagnosis tips
Yes
Step 2 Remove drive belt and determine whether the screaming disappears?

Does the scream disappear?
No Refer to “Engine noise diagnosis”.

Yes
Check whether all the accessory drive belt pulley bearings are normal. (The belt pulley may
Step 3
not be seized or loosened)
No Replace the damaged pulley or bearing.
Yes
Step 4 Check whether the drive belt tensioner works normally.
Tensioner pulley bearing device is not stuck, loose.

Tensioner device does not appear loose and other
damages.
No Replace the belt tensioner.
Yes
Step 5 Check whether the correct drive belt is used.
Check whether the belt is elongated. Refer to “Drive belt

inspect”.
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No Replace the belt in fault.
Yes
Step 6 Check whether all the fasteners related to the drive belt are normal.
Yes
Step 7 Check whether all drive belt pulleys are normal.

EM
Yes
Drive Belt Hum Sound Diagnosis

Diagnosis tips:
Drive belt should not produce hum sound. In case of intermittent noise, change load to check the accessory drive component
and ensure the component operates till the maximum load. These situations may be caused by (without limitation) the facts
that the A/C system is filled with too much liquid or the alternator is in fault.
Fault definition:
Continuous high noise
Step 1 Determine fault phenomenon, does the engine really have hum sound?
No To diagnosis tips.
Yes
Step 2 Remove the drive belt, and confirm whether the hum sound disappears.
(a) Remove drive belt.
Does the hum sound disappear?
No Refer to”Engine noise diagnosis”.
Yes
Check whether the bearings of all accessory drive belt pulleys are normal. (The belt pulley
Step 3
may not be seized or loosened)
Yes
Step 4 To diagnosis tips.
NL-3 01/2016
Drive Belt Falling-off Diagnosis

Diagnosis tips:
If the drive belt falls off from the pulley repeatedly, the reason may be the pulley malposition. If the attached drive component
causes huge variation of the belt load, the drive belt may detach from the pulley. Detect whether the attached drive component
works normally. If the drive belt's length is not proper, belt tensioner will not be able to maintain a suitable drive belt tension.
Fault definition:
Drive belt falls off from the pulley or drive belt is unable to be correctly installed in the pulley.
Step 1 Check the drive belt for damage. If necessary, replace the drive belt.
Next Step
Step 2 Check whether the pulley is misaligned. Repair the fault position.
Next Step
EM
Step 3 Check whether the pulley is bent or depressed. Repair the fault position.
Next Step
Step 4 Check whether the belt pulley tensioner is bent or cracked, and repair the fault position.
Next Step
Step 5 Check whether the drive belt tensioner is working properly. Repair the fault position.
Next Step
Step 6 Check whether the attached fastener is loose. Repair the fault position.
Next Step
Step 7 Confirm that the fault has been eliminated.
Excessive Wear of Drive Belt

Diagnosis tips:
Drive belt excessive wear is usually due to unreasonable installation or the use of wrong drive belt. Drive pulley slight
malposition will not cause excessive wear and tear, but it could lead to drive belt noise or fall-off. The serious malposition of
the drive belt pulley will lead to over wear and also the fall-off of the drive belt.
Fault definition:
The incorrect drive belt installation will lead to drive belt exterior edge wear.
Check whether there are frictions between drive belt and brackets, harness, hoses and other
Step 1
components.
Yes To diagnosis tips.
No
Step 2 Check whether all the accessory pulleys have abnormal scratch, edges, etc?
Yes Repair the fault position. If

necessary, replace the pulley.
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No
Step 3 Check whether the type of the installed belt is not correct?
Yes Replace the belt with the new one

of correct specification.
No
Step 4 To diagnosis tips.
EM
NL-3 01/2016
On-board Check
1. Check the engine coolant. Refer to “Coolant”
2. Check the engine oil. Refer to “Engine oil and engine

oil filter”
3. Check the battery. Refer to “Battery”
4. Check the spark plug. Refer to “Spark plug”
1) Remove air filter element.
2) Visually check air filter element subassembly for

dirt, blockage and/or damage.
Tips: EM
a. If the air filter element component is dirt or blocked,
please clean it up with compressed air.
b. If the air filter element subassembly is still dirt or

blocked after being cleaned with compressed air,
please replace it.
6. Check ignition timing
2) Start engine to normal operation temperature.
3) Turn off the A/C switch.
4) On the fault diagnostic scanner, read the

ignition advance angle of cylinder No. 1.
7. Check the engine idle speed
8. Check the compression pressure of the cylinder.
1) Disconnect the fuel injector harness connector.
2) Install the cylinder pressure test gauge in the

spark plug installation hole.
3) Start the engine, and make the engine run for

4-5 cycles.
4) Read the indication on pressure gauge for

every cylinder, and judge whether the pressure
meets the standard value.
NL-3 01/2016
EM-16 JLD-4G20/24 mechanical System - Engine Trim Cover
Engine Trim Cover

Component
EM Engine trim cover
Engine assembly 4G24
NL-3 01/2016
JLD-4G20/24 mechanical System - Engine Trim Cover EM-17
Removal
1) Pull out the trim cover of engine from trim cover

mounting bracket, and remove the trim cover of
engine.
EM
Installation
1) Install the trim cover of engine onto trim cover

mounting bracket.
NL-3 01/2016
EM-18 JLD-4G20/24 mechanical System - Cylinder Head Cover Assembly
Cylinder Head Cover Assembly

Component
EM Engine trim cover
NL-3 01/2016
JLD-4G20/24 mechanical System - Cylinder Head Cover Assembly EM-19
Engine trim cover
Ignition coil
EM
Engine assembly
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EM PCV valve component
Engine cover
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Cylinder head cover
Cylinder head
cover gasket
EM
Engine assembly
Non-reusable parts
NL-3 01/2016
Removal

cover"
4. Remove the upper trim panel of front bumper. Refer
to "Decorative covering parts of engine
compartment"
compartment"
6. Remove the upper trim panel of left fender.Refer to
EM 7. Remove the upper trim panel of right fender. Refer to
8. Remove the ignition coil. Refer to “Ignition coil”
9. Remove the PCV valve. Refer to “PCV valve
component”
10. Remove cylinder head cover assembly
hose component I of crankcase and the cylinder
head cover.

hose component II of crankcase and the
cylinder head cover
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3) Remove 12 fixing bolts and 2 fixing nuts of

cylinder head cover assembly.
EM
4) Remove cylinder head cover assembly.
Installation
1. Install cylinder head cover assembly.
1) Take a new cylinder head cover gasket, and

install it onto the cylinder head cover.
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2) Install cylinder head cover assembly.
EM
3) Install and tighten up the cylinder head cover
bolts.
Notice
When tightening the bolts and nuts, please be noted

that, the bolts and nuts shall be tightened up in
several times until the specified torque is reached.
Tightening torque: 9N·m (Metric) or 6.64lb-ft

(English)
4) Connect the crankcase vent hose component I

to cylinder head cover.
5) Connect the crankcase vent hose component II

to cylinder head cover.
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2. Install the PCV valve
3. Install the ignition coil.
EM
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EM-26 JLD-4G20/24 mechanical System - Drive Belt
Drive Belt
Component
EM
Drive belt
Idler bracket
Idler pulley Belt tensioning mechanism

subassembly
NL-3 01/2016
JLD-4G20/24 mechanical System - Drive Belt EM-27
Removal
2. Lift the vehicle
3. Remove the engine bottom guard plate. Please refer

to “Left and right engine bottom guard plate”
4. Remove the drive belt
1) Use a spanner to clockwise press down the belt

tensioning mechanism subassembly, relax the
belt, and take out the drive belt.
Notice
When taking out the belt, please prevent the drive
belt tensioning mechanism from rebounding;
otherwise the operation personnel may get injured. EM
Check
1. Check the driving belt
1) Check whether the belt is excessively worn or

whether its cord yarn is worn. If the belt is found
as defective, replace the drive belt.
Installation
1. Install the drive belt.
1) Wrap the drive belt as shown in the figure.
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EM-28 JLD-4G20/24 mechanical System - Drive Belt
2) Use a spanner to clockwise press down the

drive belt tensioning mechanism subassembly,
and put the drive belt over the tensioner.
3) Release the spanner, and make the tensioner

tense up the drive belt.
Notice
Before putting the belt on tensioning mechanism
subassembly, please confirm that the drive belt is
aligned with the grooves on all belt pulleys; otherwise
the drive belt may get damaged.
EM
NL-3 01/2016
JLD-4G20/24 mechanical System - Belt Tensioning Mechanism EM-29
Subassembly
Belt Tensioning Mechanism Subassembly

Component
EM
Drive belt
Idler bracket
Idler pulley Belt tensioning mechanism

subassembly
NL-3 01/2016
EM-30 JLD-4G20/24 mechanical System - Belt Tensioning Mechanism
Subassembly
Removal
2. Lift the vehicle
3. Remove the drive belt. Refer to “Drive belt”
4. Remove the belt tensioning mechanism
subassembly
1) Use a spanner to press down the fixing nut, and

install the spring locking pin on tensioning
spring.
EM
2) Remove the upper fixing bolt of belt tensioning

mechanism subassembly.
3) Remove the lower fixing bolt of belt tensioning

mechanism subassembly, and remove the belt
tensioning mechanism subassembly.
NL-3 01/2016
JLD-4G20/24 mechanical System - Belt Tensioning Mechanism EM-31
Subassembly
Installation
1. Install the belt tensioning mechanism subassembly
1) Install the lower fixing bolt of belt tensioning

mechanism subassembly, but don’t tighten it up.
EM
2) Install the upper fixing bolt of belt tensioning

mechanism subassembly, but don’t tighten it up.
3) Tighten up the lower fixing bolt.
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EM-32 JLD-4G20/24 mechanical System - Belt Tensioning Mechanism
Subassembly
4) Tighten up the upper fixing bolt.
Notice: After installation ,the spring shall be straight.
EM
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JLD-4G20/24 mechanical System - Damping Pulley EM-33
Damping Pulley
Component
EM
Drive belt
Idler bracket
Belt tensioning mechanism

Idler pulley subassembly
Oil pan
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EM-34 JLD-4G20/24 mechanical System - Damping Pulley
EM
Timing chain
cover
Crankshaft front
oil seal
Damping pulley
component
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JLD-4G20/24 mechanical System - Damping Pulley EM-35
Removal
2. Remove the right front wheel
3. Lift the vehicle
4. Remove the engine right guard plate Please refer to

“Engine bottom left right guard plate”
5. Remove the drive belt. Please refer to Drive belt
6. Remove the damping pulley component.
1) Turn the crankshaft until the cylinder No. 1 of

engine is at the top dead center.
Tips: EM
When the timing mark of damping belt pulley
component is aligned with the scale 0 on timing chain
cover, the cylinder No. 1 of engine is at the top dead
center.
This step is to prevent the woodruff key on crankshaft

from falling off.
2) Use the special tool to fix the damping belt

pulley component, and remove the fixing bolt of
damping belt pulley component.
3) Take out the damping belt pulley component.
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EM-36 JLD-4G20/24 mechanical System - Damping Pulley
Installation
1. Install the damping belt pulley component
1) Align the groove on damping belt pulley with the

woodruff key on crankshaft, and mount the
2) Use the special tool to fix the damping belt

pulley component, and tighten up the fixing bolt
of damping belt pulley component.

EM
5. Install the right front wheels
NL-3 01/2016
JLD-4G20/24 mechanical System - Crankshaft Front Oil Seal EM-37
Crankshaft Front Oil Seal

Component
EM
Drive belt
Idler bracket

Oil pan
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EM-38 JLD-4G20/24 mechanical System - Crankshaft Front Oil Seal
EM
Timing chain
cover
Crankshaft front
oil seal
Damping pulley
component
NL-3 01/2016
JLD-4G20/24 mechanical System - Crankshaft Front Oil Seal EM-39
Removal
2. Remove the right front wheel
3. Lift the vehicle
4. Remove the engine right guard plate Refer to

“Engine bottom left right guard plate”
5. Remove the drive belt. Refer to Drive belt
6. Remove the damping belt pulley component. Refer

to Damping belt pulley
7. Remove crankshaft front oil seal
1) Remove the crankshaft front oil seal with EM

special tools.
Installation
1. Install the crankshaft front oil seal.
1) Replace the front oil seal of crankshaft with a

new one.
2) Use the special tool to install the front oil seal of

crankshaft, and make sure that it is installed in
place.
2. Install the damping belt pulley component
5. Install the wheels.
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EM-40 JLD-4G20/24 mechanical System - Engine Suspension
Engine Suspension
Component
Engine rear vibration isolator assembly

（4G24+6AT）
Engine rear bracket（4G24_2WD）
EM
Engine left vibration isolator assembly
（4G24+6AT）
Engine assembly (4G24)
Engine front bracket（4G24+6AT）
Engine right vibration isolator assembly

（4G24+6AT）
Engine front vibration isolator assembly（4G24+6AT）
NL-3 01/2016
JLD-4G20/24 mechanical System - Engine Suspension EM-41
Engine right vibration

isolator assembly
Engine rear bracket
Engine left vibration

isolator assembly
EM
Engine left bracket
Engine assembly
Engine front bracket
Engine right vibration isolator

assembly
Engine front vibration isolator assembly
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Engine Front Vibration Isolator

Assembly
Removal
2. Lift the vehicle
“Left and right engine bottom guard plate”
4. Remove the engine front vibration isolator assembly
1) Remove the 2 connecting bolts between front
vibration isolator assembly and front
crossbeam.
EM
2) Remove the connecting bolt between front

vibration isolator assembly and front bracket.
3) Remove the front vibration isolator assembly.
5. Remove the engine front bracket

1) Remove the 2 connecting bolts between the front
bracket of engine and the cylinder block of engine,
and remove the front bracket of engine.
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Installation
1. Install the front engine bracket
1) Install and tighten up the 2 connecting bolts

between the front bracket of engine and the
cylinder block of engine.
Tightening torque: 60 N·m (Metric) or 44.28 lb-ft

(English)
EM
2. Install the front vibration isolator of engine
1) Install the connecting bolt between the front

bracket and the front vibration isolator of
engine.

(English)
2) Install 2 connecting bolts between the front

vibration isolator of engine and the front
crossbeam.

(English)
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Rear Vibration Isolator of Engine

Removal
2. Lift the vehicle
3. Remove the engine bottom guard plate. Please refer

to “Left and right engine bottom guard plate”
4. Remove the rear vibration isolator of engine
1) Remove 2 fixing bolt and 2 fixing nuts between

the rear vibration isolator of engine and the
subframe.
EM
2) Remove the penetrating bolt between the rear

vibration isolator of engine and the rear bracket.
3) Remove the rear vibration isolator of engine.
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5. Remove the rear bracket of engine
1) Remove 3 bolts between the rear bracket of

engine and the transmission, and remove the
rear bracket of engine.
EM
Installation
1. Install the rear engine bracket
1) Install and tighten up the 3 fixing bolts between

the rear bracket of engine and the transmission.

(English)
2. Install the rear vibration isolator of engine
1) Install the rear vibration isolator of engine onto

the subframe.
2) Install and tighten up the connecting bolts

between the rear vibration isolator of engine
and the rear bracket.
Tightening torque: 90 N·m (Metric) or 66.42

lb-ft (English)
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3) Install and tighten up the 2 connecting bolts and

2 connecting nuts between the rear vibration
isolator of engine and the subframe.

lb-ft (English)
EM
Left Vibration Isolator of Engine
Removal
compartment"
compartment"
4. 4. Remove the upper trim panel assembly of left
compartment"
5. Remove the battery. Refer to “Battery”
6. Remove the battery bracket.
7. Remove the air filter assembly. Refer to “Air filter”
8. Remove the engine ECU. Refer to “Engine ECU”
9. Remove the engine ECU bracket assembly. Refer to
“Engine ECU”
10. Use the jack to support the bottom of transmission
11. Remove the front/rear vibration isolator of engine.
Refer to “Engine suspension”
12. Remove the left vibration isolator of engine (MT)
1) Remove 3 bolts between the left vibration
isolator of engine and the left bracket.
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2) Remove 2 connecting bolts and 1 connecting

nut between the left vibration isolator of engine
and the vehicle body.
EM
13. Remove the left bracket of engine
1) Remove 4 connecting bolts between the left
vibration isolator of engine and the
transmission.
Installation
NL-3 01/2016
1. Install engine left bracket
1) Install 4 connecting bolts between the left

vibration isolator of engine and the
transmission.
Tightening Torque: 60 N.m (Metric) 59.04

lb-ft(English)
EM
2. Install the left vibration isolator of engine
1) Install and tighten up the 2 connecting bolts and

1 connecting nut between the left vibration
isolator of engine and vehicle body.

lb-ft(English)
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between the left vibration isolator of engine and
the left bracket.

lb-ft(English)
6. Install battery bracket
7. Install the battery.
8. Remove the jack
9. Install the upper trim panel of left fender. EM

fender.
Right Vibration Isolator of Engine

Removal and Installation

compartment"

compartment"
4. Remove the upper trim panel assembly of right

compartment"
5. Use the jack to support the bottom of engine
6. Remove the right vibration isolator of engine
1) Remove 1 fixing bolt and 2 fixing nuts between

the right vibration isolator of engine and the
right bracket of engine.
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2) Remove 2 connecting bolts and 1 penetrating

bolt between the right vibration isolator of
engine and the vehicle body.
EM
Installation
1. Install the right vibration isolator of engine

between the right vibration isolator of engine

lb-ft (English)
2) Install and tighten up the connecting bolt

between the right vibration isolator of engine

lb-ft (English)
3) Install 1 fixing bolt and 2 fixing nuts between the

right vibration isolator of engine and the right
bracket of engine.

lb-ft(English)
2. Remove the jack

fender.
7.
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JLD-4G20/24 mechanical System - Engine Assembly EM-51
Engine Assembly
Component
Engine trim cover

EM
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EM-52 JLD-4G20/24 mechanical System - Engine Assembly
Air filter element
EM

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Positive cable
Negative cable
Battery
EM
Battery pressing
plate
Battery bracket
NL-3 01/2016
Engine ECU
Engine ECU
EM
Engine ECU bracket

assembly
Engine ECU bracket

assembly
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EM
Vehicle wheel nut
Wheel assembly
N.m (lb-ft): Specified torque
NL-3 01/2016
EM
Engine right guard plate

assembly

assembly

assembly
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valve
Vent hose of carbon
Protective sleeve of canister
control valve of carbon
canister
EM
Carbon canister hose
Intake manifold
NL-3 01/2016
EM
Front auxiliary
frame assembly
Right longitudinal beam

assembly of front
suspension
Left longitudinal beam

assembly of front
suspension
Front suspension
crossbeam assembly
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Engine rear bracket
Mechanical steering gear with tie rod

assembly
Right reinforcement plate

of front suspension
EM
Front auxiliary frame

assembly
Left reinforcement plate of

front suspension

assembly of front
suspension

assembly of front
suspension
NL-3 01/2016
Right front brake assembly
Right constant velocity drive shaft assembly（4G18TD_6MT）
Right constant velocity drive

shaft assembly
Manual transmission
assembly
EM
Right front constant velocity drive shaft assembly（4G18TD_6AT）

Right front constant velocity
drive shaft assembly
Left constant velocity drive shaft assembly

Left constant velocity drive shaft
assembly Left front brake
assembly
Automatic transmission
assembly
Left front constant velocity drive

shaft assembly (AT)
Left front brake assembly
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EM
24 Front exhaust pipe
4G24 front oxygen sensor assembly
Sealing gasket of 4G24 rear oxygen sensor

exhaust pipe
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Engine rear vibration isolator assembly（4G24+6AT）

Engine left vibration isolator assembly（4G24+6AT）
Engine rear bracket（4G24_6AT_2WD）
EM
Engine（4G24）
Engine right vibration isolator assembly（4G24+6AT）
Engine front bracket（4G24+6AT）

（4G24+6AT）
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Removal
1. Remove the engine hood
“Decorative covering parts of engine compartment”
Refer to “Decorative covering parts of engine compartment”
4. Remove the upper trim panel assembly of left fender. Refer to
5. Remove the upper trim panel assembly of right fender. Refer
to “Decorative covering parts of engine compartment”
6. Remove the trim cover of engine. Refer to “Trim cover of
engine”
7. Release the pressure in fuel system. Refer to “Check
EM
procedure for fuel pressure”
8. Collect the refrigerant. Refer to “Drainage and filling of coolant”
9. Remove the intake pipe of air filter. Refer to “Intake pipe of air
filter”
12. Remove the battery bracket
14. Remove the engine ECU bracket assembly
1) Loosen the harness clamp on ECU bracket, and remove

the fixing bolt on front end of engine ECU bracket
assembly.
2) Remove 2 fixing bolts on rear end of engine ECU bracket

assembly, and remove the engine ECU bracket
assembly.
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15. Remove the right front wheel. Refer to “Wheel and tire”
17. Remove the guard plate on bottom of engine. Refer to “Left and
right guard plate on bottom of engine”
18. Remove the engine right protective plate Refer to “Engine
19. Drain the engine oil. Refer to “Drainage and filling of engine oil”
20. Drain the engine coolant. Refer to “Drainage and filling of
engine coolant”
21. Drain the transmission oil. Refer to “Transmission oil”
“Solenoid valve of carbon canister”
23. Remove the front constant velocity drive shaft. Refer to “Front
EM constant velocity drive shaft”
24. Remove the front exhaust pipe. Refer to “Exhaust pipe”
25. Remove the longitudinal beam of front suspension. Refer to
“Front suspension longitudinal beam assembly”
26. Remove the reinforcing plate of front suspension. Refer to
“Front suspension reinforcing plate”
27. Remove the lower swing arm assembly of front suspension
28. Remove the subframe. Refer to “Front subframe”
29. Remove the front suspension crossbeam. Refer to “Front
suspension crossbeam assembly”
30. Remove the power assembly (JLD-4G20_6MT)
1) Disconnect the connection between connection between
starter motor fuse and relay box.
2) Disconnect the connection between engine harness connector

and relay box.
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3) Disconnect the power line of electrical power steering

system.
4) Disconnect the connection between the grounding wire EM

of engine and the engine compartment.
5) Disconnect the grounding wire of transmission.
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6) Disconnect the connection between engine harness and

instrument harness, and draw the engine harness out
from fire wall.
EM
7) Disconnect the A/C pressure switch harness connector.
8) Disconnect the oil inlet pipe on fuel distributor assembly.
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9) Disconnect the connection between the water inlet pipe

of radiator and the water outlet of engine.
10) Disconnect the connection between the water-outlet EM

pipe of radiator and the water inlet holder of engine.
11) Disconnect the warm air water-inlet pipe and the warm
air water-outlet pipe.
NL-3 01/2016
EM
13) Pry out the oil pipe circlip, and disconnect the hydraulic
hose of clutch.
14) Press the middle portion of clip, and separate upwards

the gearshift flexible shaft assembly from bracket.
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15) Disconnect the connection between the gearshift

flexible shaft assembly and the gear shifter.
16) Use the professional sling to lift up the power assembly. EM
17) Remove the connecting bolt between the front vibration

isolator assembly of engine and the front bracket.
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18) Remove the connecting bolt between the rear vibration

isolator assembly of engine and the rear bracket.
EM
19) Remove 3 bolts between the left vibration isolator
assembly of engine and the left bracket.
20) Remove 2 nuts and 1 bolt between the right vibration

isolator assembly of engine and the right bracket of
engine.
21) Place the transportation trolley under the power
assembly, and lower down the power assembly onto
transportation trolley.
22) Lift up the vehicle, and move out the transportation
trolley.
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31. Remove the engine assembly

1) Remove the starter motor
2) Remove the crankshaft position sensor. Refer to
“crankshaft position sensor”
3) Remove the transmission assembly
4) Remove the clutch assembly (JLD-4G20_6MT)
5) Remove the double-mass flywheel assembly.
Installation
1. Install engine assembly (JLD-4G20_6MT)
1) Install the double-mass flywheel assembly
2) Install the clutch assembly (JLD-4G20_6MT)
3) Install the transmission assembly
EM
(JLD-4G20_6MT)
4) Install the crankshaft position sensor
5) Install the starter motor
2. Install the power assembly (JLD-4G20_6MT)
1) Lift up the vehicle body, and put the power
assembly under the engine compartment.
2) Lower down the vehicle body, and use the
professional sling to lift up the power assembly.
3) Install and tighten up 2 nut and 1 bolt between the
right vibration isolator assembly of engine and the
right bracket of engine.
Tightening torque: 70N·m (Metric) or 51.66 lb-ft
(English)
4) Install and tighten up the 3 bolts between the left

vibration isolator assembly of engine and the left
bracket.
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5) Install the bolt between the rear vibration

isolator assembly of engine and the rear
bracket.
(English)
EM
6) Install and tighten up the bolt between the
front vibration isolator assembly of engine
and the front bracket.
(English)
7) Lower down the power assembly, and

remove the sling.
8) Connect the gearshift flexible shaft assembly
with the gear shifter.
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9) Connect the gearshift flexible shaft assembly and

bracket.
10) Connect the hydraulic hose of clutch, and fix the EM

hose with circlip.
11) Connect the vacuum booster hose to intake

manifold.
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12) Connect the warm air water-inlet pipe and warm air
water-outlet pipe to engine.
EM
13) Connect the water inlet pipe of radiator with the
water inlet holder of engine.
14) Connect the water inlet pipe of radiator with the

water outlet of engine.
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15) Connect the fuel supply hose of engine to fuel

distributor assembly.
16) Connect the A/C pressure switch harness EM

connector.
17) Pass the engine harness through fire wall, and

connect the engine harness with instrument
harness.
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18) Connect the grounding wire of transmission.
EM
19) Connect the grounding wire of engine to the
engine compartment.
20) Connect the power wire of power steering system

with the positive pole of battery.
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21) Connect the engine harness connector with the

relay box.
22) Connect the power fuse of engine with the relay. EM
3. Lift the vehicle

4. Install the front suspension crossbeam
5. Install the auxiliary frame
6. Install the lower swing arm assembly of front
suspension
7. Install the reinforcing plate of front suspension
8. Install the front suspension longitudinal beam
10. Install the front constant velocity drive shaft
12. Install the left and right engine guard plate
14. Install the front wheels
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1) Install the engine ECU bracket assembly, and
tighten up the 1 fixing bolt on front end.
Torque: 9N.m (Metric) 6.64 lb-ft (English)
EM
2) nstall and tighten up the 2 fixing bolts on rear end of
engine ECU bracket assembly.
18. Install the battery tray
19. Install the battery
22. Fill the engine oil
23. Fill the engine coolant
24. Fill the transmission oil
31. Install the engine hood
NL-3 01/2016
JLD-4G20/24 mechanical System - Crankshaft Rear Oil Seal EM-79
Crankshaft Rear Oil Seal

Component
Trim cover of engine EM
NL-3 01/2016
EM-80 JLD-4G20/24 mechanical System - Crankshaft Rear Oil Seal
Air filter element

EM
NL-3 01/2016
Positive cable
Negative cable
Battery
EM
Battery pressing
plate
Battery bracket
NL-3 01/2016
EM
Vehicle wheel nut
Wheel assembly
N·m (lb-ft):Specified torque
NL-3 01/2016
EM
Right protective plate

assembly of engine
Left protective plate

assembly of engine
Protective plate assembly

on bottom of engine
NL-3 01/2016

Vent hose of
Protective sleeve of solenoid carbon canister
EM
Carbon canister
hose
Intake manifold
NL-3 01/2016
EM
Front auxiliary
frame assembly

assembly of front
suspension

assembly of front
suspension
Front suspension
crossbeam assembly
NL-3 01/2016
EM
Front suspension
Front bumper assembly
crossbeam assembly
NL-3 01/2016
Right constant velocity drive shaft assembly

Manual transmission assembly
EM
Right front constant velocity drive shaft assembly


Automatic transmission assembly

shaft assembly (AT)
NL-3 01/2016
EM
24 Front exhaust
4G24 front oxygen pipe assembly
sensor
Sealing gasket of 4G24 rear oxygen

exhaust pipe sensor
NL-3 01/2016
Engine rear bracket (4G24_6AT_2WD)
EM
Engine assembly
Engine front bracket (4G24+6AT)
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Engine raer vibration isolator assembly
Engine rear bracket

isolator assembly
EM
Engine left bracket
Engine assembly
Engine front
bracket

assembly
NL-3 01/2016
Removal
2. Remove the upper trim panel of front bumper. Refer to “Decorative
covering parts of engine compartment”
3. Remove the connecting plate of upper trim panel of fender. Refer to
5. Remove the trim cover of engine. Refer to “Trim cover of engine”
6. Remove the intake pipe of air filter. Refer to “Intake pipe of air filter”
EM
12. Remove the guard plate on bottom of engine. Refer to “Left and right
guard plate on bottom of engine”
13. Remove the engine right protective plate Refer to “Engine bottom left
right protective plate”
16. Remove the front constant velocity drive shaft. Refer to “Front
constant velocity drive shaft”
18. Remove the longitudinal beam of front suspension. Refer to “Front
suspension longitudinal beam assembly”
19. Remove the reinforcing plate of front suspension. Refer to “Front
suspension reinforcing plate”
22. Remove the front suspension crossbeam. Refer to “Front
suspension crossbeam assembly”
23. Remove the power assembly. Refer to “Engine assembly”
24. Remove the flywheel assembly
1) Use the special tool 47Z01305B, and prevent flywheel from
turning when the bolt is being removed.
2) Remove the fixing bolt of flywheel, and leave the 1 bolt on upper
portion of flywheel, so as to prevent the falling of flywheel.
3) Hold the flywheel and remove the last bolt, and then remove the
flywheel.
Warning:
When dismantling the last bolt, be careful not to drop the flywheel.
NL-3 01/2016
25. Remove the crankshaft rear oil seal

1) Use a screwdriver to remove the rear oil seal of
crankshaft.
Notice
Be careful not to damage the crankshaft journal during
removal. Before using the screwdriver, please wrap the
head of screwdriver with adhesive tape.
EM
Installation
1. Install the crankshaft rear oil seal
1) Use a special tool to install the crankshaft rear oil
seal.
2. Install the flywheel

3. Install the power assembly
4. Install the starter motor
5. Lift the vehicle
8. Install the lower swing arm assembly of front
suspension
NL-3 01/2016

28. Install the engine hood EM
NL-3 01/2016
EM-94 JLD-4G20/24 mechanical System - Timing Chain
Timing Chain
Component
EM Trim cover of engine
NL-3 01/2016
JLD-4G20/24 mechanical System - Timing Chain EM-95
Ignition coil
EM
Engine assembly
NL-3 01/2016
Cylinder head cover
Cylinder head cover gasket

EM
Engine assembly
NL-3 01/2016
EM

assembly of engine
Left protective plate assembly of engine
Protective plate assembly on bottom of engine
NL-3 01/2016
EM
Drive belt
Idler bracket

idle gear subassembly
Oil pan
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Timing chain tensioner EM

component
Right engine
bracket
Belt tensioning
mechanism
Engine assembly
Timing chain cover

Crankshaft front oil
seal
Crankshaft pulley
NL-3 01/2016
Engine assembly
Timing chain
EM
Timing chain tensioner rail
Timing chain guard plate
Timing chain guide rail
Crankshaft timing sprocket
Timing chain cover
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Removal
Refer to “Decorative covering parts of engine compartment”
6. Remove the trim cover of engine. Refer to “Trim cover of
engine”
EM
8. Lift the vehicle
9. Remove the guard plate on bottom of engine. Refer to “Left
and right guard plate on bottom of engine”
10. Remove the right guard plate of engine. Refer to “Left/right
guard plate on bottom of engine”
11. Drain the engine oil. Refer to “Drainage and filling of engine
oil”
“Solenoid valve of carbon canister”
15. Remove the cylinder head cover assembly. Refer to “Cylinder
head cover assembly”
17. Remove the right bracket of engine
18. Remove the belt tensioning mechanism subassembly. Refer
to “Belt tensioning mechanism subassembly”
19. Remove the damping belt pulley. Refer to “Damping belt
pulley”
20. Remove the timing chain tensioner component
1) Remove the mounting nut of timing chain tensioner
component.
2) Take out the timing chain tensioner component.
Notice that this time do not rotate the crankshaft so as to
prevent the timing sprocket teeth rolling.
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21. Remove the timing chain cover

1) Remove 3 M6 mounting bolts and nuts of timing
chain cover.
EM
2) Remove 8 M8 mounting bolts of timing chain

cover.
3) Remove 3 M10 mounting bolts of timing chain

cover.
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4) Insert a ripping bar into the projecting edge

position to loosen the timing chain cover.
5) Remove the timing chain cover
22. Remove crankshaft front oil seal EM

1) Remove the crankshaft front oil seal with special
tools.
23. Remove the timing chain

1) Remove the pin shaft of timing chain tensioning
rail component, and remove the timing chain
tensioning rail component.
Notice
Pay attention not to dropping out the tensioner shoe in
the removal process; otherwise, it is likely to result in
damage to the tensioner shoe.
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2) Remove the fixing bolts of timing chain guide rail

component and remove the timing chain guide rail
component.
EM
3) Remove the timing chain guard plate.
4) Remove the timing chain and crankshaft timing

sprocket.
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Check
1. Check the elongation of chain
1) Use the force of 147N to pull the chain.
2) Measure length of 15 chain units with vernier
caliper.
3) Carry out measurement at any 3 positions. Use the
mean value of measured values.
Notice
If the mean value of 3 measured values is higher than
the specified maximum elongation of chain, then
replace the chain.
EM
Installation
1. Install the timing chain
1) Confirm the 3 chain link marks on timing chain.
Notice
There are three chain links beyond timing mark on timing
chain. The 1st timing mark is aligned with the timing mark on
crankshaft sprocket, and the 2nd and 3rd timing marks
(yellow) (there are 7 chain links between such two marks) are
aligned with the timing mark of exhaust camshaft sprocket
and the timing mark of intake VVT respectively.
2) Install the timing chain, and successively align the

two timing marks on camshaft timing sprocket.
– Align the chain link (yellow) outside of 2nd timing mark
on chain with the timing mark of exhaust camshaft
sprocket.
– Align the chain link (yellow) outside of 3rd timing mark
on chain with the timing mark of intake VVT driver.
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3） Install the crankshaft timing sprocket, and align the

first timing mark between timing sprocket and
chain.
EM
4） Install and tighten the timing chain gurad plate and
the fastening bolt.
Tightening torque: 9N·m (Metric) 6.64lb-ft (English)
5） Install and tighten the timing chain guide rail

component and fixing bolt.
Tightening torque: 9N·m (Metric) 6.64lb-ft (English)
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6) Install and tighten up the timing chain tensioning

rail component and the timing chain tensioning
pinshaft.
Torque: 19N·m (Metric) 14.02 lb-ft (English)
2. Install the crankshaft front oil seal EM

1) Install the crankshaft rear oil seal with special tool.
Notice: Whenever repairing the front oil seal of crankshaft,
please replace it with a new one.
3. Install the timing chain cover

1) Evenly apply the 1596F silicon rubber sealant onto
the joint face between timing chain cover and
cylinder block/cylinder head.
Application diameter of sealant:
4.0mm (Metric) 0.1575 in (English)
2) Install the timing chain cover.
Notice
Before installing the timing chain cover, check whether the
mark on timing chain is at the correct position. If there is any
deviation, please re-install the timing chain.
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3) Install 3 timing chain cover fixing bolts, but do not

tighten.
EM
4) Install 8 timing chain cover fixing bolts, but do not
tighten.
5) Install the 2 fixing nuts and 1 fixing bolt of timing

chain cover.
6) In accordance with the sequence as shown in the
figure, and tighten up 14 fixing bolts and nuts of
timing chain cover.
Tightening Torque:
M6 bolt and nut:
M8 bolt:
M10 bolt:
50N·m (Metric) 36.90 lb-ft (English)
4. Install the timing chain tensioner component
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1) As shown in the figure, press in the push rod of

timing chain tensioner, so as to let the push rod
enter into the self-locked state.
Rising
Entering
Hook
Pin
2) Install the timing chain tensioner component. After EM

the installation is completed, the push rod will pop
out automatically.
3) Install 2 M6 fixing nuts.
4) Tighten the fixing nuts.
Tightening torque: 9N·m (Metric) or 6.64 lb-ft (English)
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5. Install the right engine bracket

7. Install the damping pulley
9 Install cylinder head cover assembly
10. Install the ignition coil
13. Install the right engine guard plate
EM
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JLD-4G20/24 mechanical System - Camshaft EM-111
Camshaft
Component
EM
NL-3 01/2016
EM-112 JLD-4G20/24 mechanical System - Camshaft
EM
Vehicle wheel nut
Wheel assembly
N·m (Ib- ft)Specified torque
NL-3 01/2016
EM

assembly of engine
Left protective plate assembly of engine
Protective plate assembly on bottom of engine
NL-3 01/2016

Vent hose of
Protective sleeve of solenoid carbon canister
EM
Carbon canister
hose
Intake
manifold
NL-3 01/2016
EM
Front suspension
crossbeam assembly
NL-3 01/2016
Ignition coil
EM
Engine assembly
NL-3 01/2016
Cylinder head cover
Cylinder head
cover gasket
EM
Engine assembly
Non-reusable parts
NL-3 01/2016
EM Drive belt
Idler bracket
Belt tensioning mechanism subassembly

Idler pulley
NL-3 01/2016
Timing chain tensioner

EM
component
Right engine bracket
Engine assembly
Timing chain cover

Crankshaft
front oil seal
Crankshaft pulley
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Engine assembly
Timing chain
EM
Protective plate of timing chain
Timing chain cover
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Intake camshaft
Camshaft cap EM
Exhaust camshaft
Intake VVT driver
Exhaust camshaft
sprocket
Cylinder head
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Removal
2. Remove the upper trim panel of front bumper. Refer to “Decorative
3. Remove the connecting plate of upper trim panel of fender. Refer to
5. Remove the upper trim panel assembly of right fender. Refer to
EM 7. Release the pressure in fuel system. Refer to “Check procedure for
fuel pressure”
9. Lift the vehicle
10. Remove the guard plate on bottom of engine. Refer to “Left and
right guard plate on bottom of engine”
11. Remove the engine right protective plate Refer to “Engine bottom
left right protective plate”
14. Remove the cylinder head cover assembly. Refer to “Cylinder head
cover assembly”
17. Remove the drive belt tensioner. Refer to “Belt tensioning
mechanism subassembly”
18. Remove the crankshaft belt pulley. Refer to “Damping belt pulley”
19. Remove the timing chain tensioner. Refer to “Timing chain”
20. Remove the timing chain cover. Refer to “Timing chain”
21. Remove the timing chain. Refer to “Timing chain”
22. Remove the intake VVT actuator
1) Use a spanner to fix the camshaft, and then remove the
intake VVT driver.
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23. Remove the exhaust camshaft sprocket

1) Use a spanner to fix the camshaft, and then
remove the exhaust camshaft sprocket.
EM
24. Remove the camshaft
1) Remove the camshaft bearing cover front, and
check:
Clearance of end face of camshaft and clearance of
journal of camshaft
The camshaft bearing covers are numbered, so as to
ensure that they can be installed on original positions
2) As shown in the figure, successively loosen the

intake camshaft bearing cover, with half a round to
a round loosened every time.
3. Remove the intake camshaft bearing cover.
4) Remove the intake camshaft.
Notice
Carefully remove the camshaft to prevent scratch or
damage camshaft work surface or bearing surface.
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figure, successively loosen the exhaust camshaft
bearing cover, with half a round to a round
loosened every time.
6) Remove the exhaust camshaft bearing cover.
7) Remove the exhaust camshaft.
EM
Installation
1. Install the camshaft
1) Apply a little amount of lubricating oil onto the
camshaft journal and camshaft bearing cover.
2) Install the exhaust camshaft.
3) Install the intake camshaft.

4) Install the exhaust camshaft bearing cover.
5) Install the intake camshaft bearing cover.
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figure, successively tighten up the exhaust
camshaft bearing cover bolt.
Torque:
Bolts 9 and 10: 30N·m (metric) or 22.14 lb-ft (English)
Other bolts: 13N·m (metric) or 9.59 lb-ft (English)
7) In accordance with the sequence as shown in the EM

figure, successively tighten up intake camshaft
bearing cover bolt.
Torque:
Bolts 9 and 10: 30N·m (metric) or 22.14 lb-ft (English)
Other bolts: 13N·m (metric) or 9.59 lb-ft (English)
2. Install the exhaust camshaft sprocket

1) Install the exhaust camshaft sprocket, and tighten
up the exhaust camshaft sprocket fixing bolt.
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3. Install the intake VVT actuator

1) Install the intake VVT driver, and tighten up the
fixing bolt of intake VVT driver.
Torque: 35 N·m+(90°) (Metric)
25.83 lb-ft +(90°) (English)
EM
8. Belt tensioning mechanism subassembly
11. Install the cylinder head cover assembly
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JLD-4G20/24 mechanical System - Cylinder Head Component EM-127
Cylinder Head Component

Component
Trim cover of
EM
engine
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EM-128 JLD-4G20/24 mechanical System - Cylinder Head Component
EM
Vehicle wheel nut
Wheel assembly
N·m (Ib-ft)Specified torque
NL-3 01/2016
EM

assembly of engine

assembly of engine
Protective plate assembly on

bottom of engine
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Vent hose of carbon
Protective sleeve of solenoid canister
EM
Carbon canister
hose
Intake
manifold
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EM
Front suspension
Front bumper assembly crossbeam assembly
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Ignition coil
EM
Engine assembly
NL-3 01/2016
Cylinder head cover
Cylinder head
cover gasket
EM
Engine assembly
Non-reusable parts
NL-3 01/2016
EM
Drive belt
Idler bracket
Belt tensioning
Idler pulley mechanism subassembly
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EM
component
Belt tensioning
mechanism
Engine assembly
Timing
Crankshaft chain cover
front oil seal
Crankshaft pulley
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Engine assembly
Timing chain
EM
Timing chain cover
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Intake camshaft
Camshaft cap EM
Exhaust camshaft
Intake VVT driver
Exhaust camshaft
sprocket
Cylinder head
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Cylinder head
EM
Cylinder cover
gasket
component
Cylinder block
Non-reusable parts
NL-3 01/2016
Removal
2. Remove the upper trim panel of front bumper. Refer to “Decorative covering
parts of engine compartment”
3. Remove the connecting plate of upper trim panel of fender. Refer to “Decorative
4. Remove the upper trim panel assembly of right fender. Refer to “Decorative
6. Release the pressure in fuel system. Refer to “Check procedure for fuel pressure”
8. Lift the vehicle
EM
9. Remove the guard plate on bottom of engine. Refer to “Left and right guard plate
on bottom of engine”
10. Remove the engine right protective plate Refer to “Engine bottom left right
protective plate”
12. Drain the engine coolant. Refer to “Drainage and filling of engine coolant”
13. Remove the solenoid valve of carbon canister. Refer to “Solenoid valve of carbon
canister”
14. Remove the fuel distributor assembly. Refer to “Fuel distributor assembly”
15. Remove the intake manifold component. Refer to “Intake manifold component”
16. Remove the exhaust manifold component. Refer to “Exhaust manifold”
18. Remove the cylinder head cover assembly. Refer to “Cylinder head cover
assembly”
21. Remove the drive belt tensioner. Refer to “Belt tensioning mechanism
subassembly”
22. Remove the crankshaft belt pulley. Refer to “Damping belt pulley”
26. Remove the OCV valve component. Refer to “OCV valve”
27. Remove the engine lifting hook
28. Remove the engine oil pressure alarm. Refer to “Engine oil pressure alarm”
29. Remove the water temperature sensor.Refer to “Water temperature sensor”
30. Remove the phase sensor. Refer to “Phase sensor”
31. Remove the intake VVT driver. Refer to “Camshaft”
32. Remove the exhaust camshaft sprocket. Refer to “Camshaft”
33. Remove the camshaft. Refer to “Camshaft”
34. Remove the valve tappet. Refer to “Cylinder head component”
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1) Use a magnetic bar to take out the valve tappet.

2) After taking out the valve tappet, leave mark of
installation position on it and then store it properly.
EM
35. Remove the cylinder head component
1) Remove the cylinder head bolts according to the
sequence as shown in the figure.
2) Remove the cylinder head bolts.
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3) Remove the cylinder head bolt gasket with a

magnetic stick.
4) Remove the cylinder head assembly. EM
36. Remove the cylinder head gasket component
37. Remove the valve
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1) Use a tool to compress the valve spring seat, so as

to let the valve locking plate fall off naturally.
Notice
The tool used to compress the valve spring seat shall pry out
the valve locking plate, so as to ensure that after the valve
spring seat is compressed, the valve locking plate will fall off
naturally.
EM
2) Remove the valve lock plate with a magnetic stick.
Valve lock
Valve spring seat
Valve spring
Valve oil seal assembly
Valve spring leaf
3) Remove the valve spring seat.
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4) Remove the valve spring.
5) Remove the valve spring shims with a magnetic EM

stick.
6) Take out the valve, and leave the mark of cylinder

position on valve.
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7) Use the appropriate tool to remove the oil seal of

valve.
EM
Check
1. Check the cylinder head
1) Use a precise straight edge and a feeler gauge to
measure the flatness of contact face between
cylinder head and cylinder block.
Maximum deviation of flatness:
2) Check whether there are cracks on the cylinder
head.
Note: If it is not disqualified, please replace cylinder head
component.
2. Check valve clearance

1) Assemble the valve component.
2) Assemble the intake/exhaust camshaft.
3) Turn the intake/exhaust camshaft, and make sure
that the clearance of parts such as valve and
spring has been fully released.
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4) Turn the intake/exhaust camshaft, and make the

intake/exhaust valve of cylinder No. 1 fully closed.
5) Use a feeler gauge to measure the valve
clearance indicated by arrow in the figure (the
clearance between the smallest location of cam
and the valve tappet), and record the valve
position and clearance.
6) If the standard value of valve clearance is
exceeded, replace the tappet.
Valve clearance standard value (cold):
Intake: 0.22-0.28mm (Metric) or 0.0087-0.0110 in (English);
Exhaust: 0.27-0.33mm (Metric) or 0.0106-0.0130 in (English).
7) Turn the intake/exhaust camshaft, and make the EM
intake/exhaust valve of cylinder 4 fully closed (turn
the camshaft for 1/2 round).
8) Use a feeler gauge to measure the valve
clearance indicated by arrow in the figure (the
clearance between the smallest location of cam
and the valve tappet), and record the valve
position and clearance.
9) If the standard value of valve clearance is
exceeded, replace the tappet.
Intake: 0.22-0.28mm (Metric) or 0.0087-0.0110 in (English);
Exhaust: 0.27-0.33mm (Metric) or 0.0106-0.0130 in (English).
Adjust the valve clearance
1. If the intake valve tappet has to be replaced, then in
accordance with the sequence as shown in the figure,
gradually loosen the intake camshaft bearing cover bolt,
with half a round to a round loosened every time.
Notice
Be sure to carry out the removal carefully; otherwise the
working face of bearing face of camshaft may get scratched
or damaged.
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2. If the exhaust valve tappet has to be replaced, then in

accordance with the sequence as shown in the figure,
gradually loosen the intake camshaft bearing cover bolt, with
half a round to a round loosened every time.
Notice
Be sure to carry out the removal carefully; otherwise the working
face of bearing face of camshaft may get scratched or damaged.
3. Remove the camshaft.

EM
Notice
Please take out the camshaft carefully from bearing seat;
otherwise the working face or bearing face of camshaft may get
damaged.
4. Take out the valve tappet which exceeds the standard

value of clearance, use an outside micrometer to measure
its thickness, and calculate the thickness of new valve
tappet in accordance with the following formula.
Intake: A=B+C-0.23mm (0.01 in)
Exhaust: A=B+C-0.32mm (0.13 in)
A: New valve tappet thickness
B: Used valve tappet thickness
C: Measured valve clearance
Notice
New valve tappet chosen should be near the value calculated
as much as possible.
The thickness of valve tappet may be selected by reference
to the “Repair Specification - JLD-4G20 24 Engine System -
Specification Table for Intake/Exhaust Valve Tappet”.
You may also select the valve tappet which meets the
requirements on the basis of the measured value and by
reference to the “Repair Specification - JLD-4G20 24
Engine System - Table for Selection of Intake/Exhaust
Valve Tappet”.
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Installation
1. Install valve
1) Use special tool to install valve oil seal.
EM
2) On the basis of the mark, confirm the position of

every valve on cylinder, and mount the valves.
3) Mount the valve spring gasket.
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4) Confirm the direction of valve spring: The colored

end shall face upwards.
EM
5) Mount the valve spring.
Notice
The colored end of valve spring shall face upwards.
6) Mount the valve spring seat.
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7) Use a tool to compress the valve spring seat, and

install the valve spring locking plate.
8) Confirm that the locking plate is installed in place,
slowly release the valve spring compressing tool,
and use a rubber hammer to gently vibrate the
valve, so as to install the valve in place
Warning
The force can't be too much, or else, the valve spring may
cause personal injury.
2. Install cylinder head gasket component EM

1) Install the new cylinder head gasket component.
Notice
The cylinder head gasket component is a disposable
part, and shall be replaced whenever it is removed!
3. Install cylinder head cover component

1) Install the cylinder head component onto cylinder
block.
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2) Install the cylinder head bolt gaskets.
EM
3) Install the cylinder head bolt.
figure, tighten up the cylinder head bolts.
torque: First-time 35N·m (metric) or 25.83 lb-ft
(English)
Second time: 70N (metric) 51.66 lb-ft (English)
Third time: 90N (metric) 66.42 lb-ft (English)
4. Install the valve tappet

1) On the basis of the position mark left in the course
of removal, install the valve tappet.

8. Install the phase sensor
9. Install the water temperature sensor
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10. Install the oil pressure alarm

11. Install the engine lifting hook
12. Install the OCV valve component
19 Install the cylinder head cover assembly
21. Install the exhaust manifold
22. Install the intake manifold EM
23. Install the fuel distribution pipe assembly
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EM-152 JLD-4G20/24 mechanical System - Cylinder Cover Gasket Component
Cylinder Cover Gasket Component
EM
NL-3 01/2016
JLD-4G20/24 mechanical System - Cylinder Cover Gasket Component EM-153
EM
Vehicle wheel nut
Wheel assembly
NL-3 01/2016
EM

assembly of engine

assembly of engine

on bottom of engine
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Vent hose of carbon
EM
Intake manifold
NL-3 01/2016
EM
Front bumper Front suspension

assembly crossbeam
assembly
Engine bottom
guard plate
NL-3 01/2016
Ignition coil
EM
Engine assembly
NL-3 01/2016
Cylinder head cover
Cylinder head
cover gasket
EM
Engine assembly
Non-reusable parts
NL-3 01/2016
Drive belt EM
Idler bracket

NL-3 01/2016
EM
component
Right engine
bracket
Belt tensioning
mechanism
Engine assembly
Timing chain cover

Crankshaft front oil seal
Crankshaft pulley
NL-3 01/2016
Engine assembly
Timing chain
EM
Timing chain cover
NL-3 01/2016
EM Engine assembly
Engine oil box
NL-3 01/2016
Intake camshaft
Camshaft cap EM
Exhaust camshaft
Intake VVT driver
Exhaust camshaft
sprocket
Cylinder head
NL-3 01/2016
Cylinder head
EM
Cylinder cover
gasket
component
Cylinder block
Non-reusable parts
NL-3 01/2016
Removal
2. Remove the upper trim panel of front bumper. Refer to “Decorative covering parts of
3. Remove the connecting plate of upper trim panel of fender. Refer to “Decorative
4. Remove the upper trim panel assembly of right fender. Refer to “Decorative covering
6. Release the pressure in fuel system. Refer to “Check procedure for fuel pressure”
8. Lift the vehicle
9. Remove the guard plate on bottom of engine. Refer to “Left and right guard plate on EM
bottom of engine”
10. Remove the engine right protective plate Refer to “Engine bottom left right protective
plate”
13. Remove the solenoid valve of carbon canister. Refer to “Solenoid valve of carbon
canister”
14. Remove the fuel distributor assembly
15. Remove the intake manifold component
16. Remove the exhaust manifold component
18. Remove the cylinder head cover assembly. Refer to “Cylinder head cover assembly”
21. Remove the drive belt tensioner. Refer to “Belt tensioning mechanism subassembly”
22. Remove the damping belt pulley. Refer to “Damping belt pulley”
26. Remove the OCV valve component. Refer to “OCV valve”
27. Remove the engine lifting hook
28. Remove the engine oil pressure alarm. Refer to “Engine oil pressure alarm”
29. Remove the water temperature sensor. Refer to “Water temperature sensor”
30. Remove the phase sensor. Refer to “Phase sensor”
31. Remove the intake VVT actuator
32. Remove the exhaust camshaft sprocket. Refer to “Camshaft”
34. Remove the cylinder head component. Refer to “Cylinder head component”
35. Remove the cylinder head gasket component. Refer to “Cylinder head gasket
component”
NL-3 01/2016
1) Remove the cylinder head gasket component from

cylinder block
EM
Installation
1. Install the cylinder head gasket component
cylinder block
Notice
The cylinder head gasket component is a disposable
part, and shall be replaced whenever it is removed!
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2. Install the cylinder head cover component

6. Install the phase sensor
7. Install the water temperature sensor
9. Install the engine lifting hook
10. Install the OCV valve component
13. Install the oil pan
14. Install the right engine bracket EM
18) Install the cylinder head cover assembly
20. Install the exhaust manifold
21. Install the intake manifold
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EM-168 JLD-4G20/24 mechanical System - Cylinder Block
Cylinder Block
Component
EM
NL-3 01/2016
JLD-4G20/24 mechanical System - Cylinder Block EM-169
Air filter element
EM
NL-3 01/2016
Positive cable
Negative cable
Battery
EM
Battery pressing
plate
Battery bracket
NL-3 01/2016
Engine ECU
Engine ECU
EM
NL-3 01/2016
EM
Vehicle wheel nut
Wheel assembly
NL-3 01/2016
EM

assembly of engine

assembly of engine

on bottom of engine
NL-3 01/2016
Carbon canister
control valve Vent hose of
Protective sleeve of carbon canister
solenoid valve of
carbon canister
EM
Carbon canister
hose
Intake manifold
NL-3 01/2016
Front auxiliary frame assembly
EM

assembly of front suspension

Front suspension
crossbeam assembly
NL-3 01/2016
EM
Front suspension
Front bumper
crossbeam assembly
assembly
NL-3 01/2016

EM


Left front brake
assembly
assembly
Left constant velocity
Engine assembly
NL-3 01/2016
EM
24 Front exhaust
4G24 front oxygen pipe assembly
sensor
4G24 rear oxygen

Sealing gasket of
sensor
exhaust pipe
NL-3 01/2016
Engine rear bracket
Engine left vibration isolator

assembly
EM
Engine assembly

isolator assembly
NL-3 01/2016

isolator assembly
Engine rear bracket

isolator assembly
EM
Engine left bracket
Engine assembly

isolator assembly
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Cylinder block
Crankshaft position
sensor
EM
Crankshaft
component
Compression
disc of flywheel
Driving disc assembly
Damping pulley
component
Crankcase body
NL-3 01/2016
Cylinder block
Crankshaft position
sensor
EM
Crankshaft
component
Compression disc
of flywheel
Double-mass
flywheel
Damping pulley
component
Crankcase body
NL-3 01/2016
Air filter assembly
Clamp
Electronic throttle
Intake manifold
EM
Throttle valve body

seal gasket
NL-3 01/2016

OCV valve component
EM
Engine assembly
Knock sensor
Oil strainer
NL-3 01/2016
Upper cover of intake manifold
Intake manifold
Intake manifold
gasket
EM
Intake pressure
temperature sensor
Isolating pad of
intake manifold
Lower cover of
intake manifold
Engine assembly
NL-3 01/2016
Engine assembly
EM
Front oxygen
sensor
Exhaust manifold
gasket
Lower thermal
shroud
Exhaust manifold
Heat shield
NL-3 01/2016
Drive belt EM
Idler bracket

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EM
A/C compressor
Drive belt
NL-3 01/2016
EM
Water pump belt

pulley
Water pump
casing
Water pump Water inlet seat of
engine
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Ignition coil
EM
Spark plug
Engine assembly
NL-3 01/2016
Cylinder head
cover
Cylinder head
cover gasket
EM
Cylinder
head
Cylinder cover
gasket
component
Cylinder block
Non-reusable parts
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Engine assembly
Timing chain
EM
Timing chain cover
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EM
Crankshaft engine
oil pump sprocket
Chain of engine oil pump
Engine oil pump

sealing gasket
Engine oil pump Water pump

tensioner component
Engine oil pump
sprocket
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Intake camshaft
EM Camshaft cap
Exhaust camshaft
Intake VVT driver
Exhaust camshaft
sprocket
Cylinder head
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Cylinder block
EM
Balance shaft bearing
Balance shaft
Crankcase body
Balance shaft bearing
Balance shaft bearing cover
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Removal
2. Remove the upper trim panel of front bumper. Refer to “Decorative covering parts of engine
compartment"
3. Remove the connecting plate of upper trim panel of fender. Refer to “Decorative covering
4. Remove the upper trim panel assembly of left fender. Refer to “Decorative covering parts of
engine compartment"
5. Remove the upper trim panel assembly of right fender. Refer to “Decorative covering parts of
EM 7. Release the pressure in fuel system. Refer to “Check procedure for fuel pressure”
8. Collect the refrigerant. Refer to “Drainage and filling of coolant”
9. Remove the intake pipe of air filter. Refer to “Intake pipe of air filter”
17. Remove the guard plate on bottom of engine. Refer to “Left and right guard plate on bottom of
engine”
18. Remove the engine right protective plate Refer to “Engine bottom left right protective plate”
22. Remove the solenoid valve of carbon canister. Refer to “Solenoid valve of carbon canister”
23. Remove the front constant velocity drive shaft. Refer to “Front constant velocity drive shaft”
25. Remove the longitudinal beam of front suspension. Refer to “Front suspension longitudinal
beam assembly”
26. Remove the reinforcing plate of front suspension. Refer to “Front suspension reinforcing plate”
29. Remove the front suspension crossbeam. Refer to “Front suspension crossbeam assembly”
30. Remove the power assembly. Refer to “Engine assembly”
31. Remove the engine assembly. Refer to “Engine assembly”
32. Install the engine assembly onto turnable bench for engine
33. Remove the fuel distributor assembly. Refer to “Fuel distributor assembly”
34. Remove the intake manifold component. Refer to “Intake manifold component”
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35. Remove the isolating pad of intake manifold.
36. Remove the knock sensor. Refer to “Knock sensor”

37. Remove the exhaust manifold component. Refer to EM
“Intake manifold component”
39. Remove the cylinder head cover assembly. Refer to
“Cylinder head cover assembly”
42. Remove the belt tensioning mechanism subassembly.
Refer to “Belt tensioning mechanism subassembly”
43. Remove the damping belt pulley. Refer to “Damping belt
pulley”
44. Remove the timing chain tensioner. Refer to “Timing
chain”
45. Remove the oil sump. Refer to “Engine oil sump”
47. Remove the front oil seal of crankshaft. Refer to
“Crankshaft front oil seal”
50. Remove the cylinder head component. Refer to
“cylinder head component”
51. Remove the cylinder head gasket component. Refer to
“Cylinder head gasket component”
52. Remove the A/C compressor. Refer to “Compressor
assembly (JLD-4G20/4G24)”
53. Remove the alternator. Refer to “Alternator”
54. Remove the idler bracket. Refer to “Engine assembly”
55. Remove the water pump. Refer to “Water pump”
56. Remove the engine oil filter. Refer to “Timing chain”
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57. Remove the balance shaft (4G24)

1) Remove the fixing bolts of balance shaft bearing
cap in the sequence as shown in the figure.
EM
2) Remove the balance shaft bearing cover and

bearing.
3) Remove the balance shaft component 1.
4) Remove the balance shaft component 2.
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5) Remove the balance shaft bearing on crankcase

body.
58. Remove the crankcase body EM

1) Remove the oil filter connector.
2) Remove fixing bolt of crankcase body in the

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3) Remove the crankcase body.

4) Remove the crankshaft rear oil seal.
EM
59. Remove the connecting rod piston assembly
1) Rotate the crankshaft, so that the cylinders No.1 is
at BDC positions. Remove the cylinder No.1
connecting rod bearing cap bolts.
2) Remove the connecting rod bearing cover of
cylinder No. 1, and leave the position mark on
bearing cover.
3) Use the same method to respectively remove the
connecting rod bearing cover of cylinders 2, 3 and
4.
4) Use a wooden rod to push out the connecting rod

piston component of cylinder No. 1, and leave the
position mark on connecting rod piston
component.
5) Use the same method to respectively remove the
connecting rod piston assembly of cylinders 2, 3
and 4.
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60. Remove the crankshaft

figure, evenly loosen and remove 10 main bearing
cover bolts.
EM
2) Remove the main bearing cover.
3) Remove the lower portion of main bearing on main

bearing cover.
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4) Remove the crankshaft thrust plate at the third

main bearing seat.
Notice
When dismantling the thrust bearing, please screw off
the crankshaft, and take it out together with thrust
bearing, so as to facilitate the removal.
EM
5) Take out the crankshaft.
6) Remove main bearing cover.
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61. Remove the piston fuel injector component

1) Remove fixing bolts of piston fuel injector
components.
2) Take out the piston fuel injector component.
EM
Check
1. Check the connecting rod
1) Check whether the rod is bent or distorted. If the
rod is bent or distorted, replace the connecting
rod;
Flatness: 0.03 (basic length range: 100mm)
Flatness: 0.05 (basic length range: 100mm)
2) Check whether the connecting rod's bottom is
worn;
3) Check whether the connecting rod's top has
scratch.
2. Check the connecting rod bearing

1) Check whether the connecting rod crankshaft
journal is worn.
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3. Check the piston pin and piston pin hole

1) Check whether the piston has scratch, crack and wear.
2) Use an inside micrometer to measure the diameter of
piston pin hole.
Standard piston pin hole diameter:
Group A: 22.0085±0.0015mm (Metric)
0.86648±0.000059 in (English)
Group B: 22.0115±0.0015mm (Metric)
0.86659±0.000059 in (English)
3) Use an outside micrometer to measure the diameter of
piston pin.
Standard piston pin diameter:
Group A: 22.0055±0.0015mm (Metric)
EM 0.86636±0.000059 in (English)
Group B: 22.0085±0.0015mm (Metric)
0.86648±0.000059 in (English)
Check the matching clearance between the piston pin hole and
the piston pin.
Standard value: 0~0.006mm (Metric) 0~0.002 in (English)
Notice
If the clearance does not meet the requirements, replace the
piston pin, and replace the piston if necessary.
4. Check the piston
1) Measure the piston diameter with a micrometer at a
distance of 13mm from the piston bottom in the direction
where the micrometer forms a right angle with the piston
pin hole.
Standard value:
JLD-4G20: 84.965±0.0075mm (Metric)
3.3451±0.0003 in (English)
JLD-4G24: 88.665±0.0075mm (Metric)
3.4907±0.0003 in (English)
2) Calculate the cylinder matching clearance, which equals
that the measured cylinder bore diameter minus the
measured piston diameter.
Standard clearance:
0.0275~0.0575mm (Metric) 0.0011~0.0023 in (English)
Notice
If the clearance is not within range, replace the piston. If
necessary, replace the cylinder block. (If you replace the piston,
you can select the correct piston according to the diameter
group number on the piston pin and the piston pin hole diameter
group number marked on the piston. The piston pin diameter
group number = piston pin hole diameter group number on the
piston)
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5. Check the piston ring

1) Select a set of new piston ring and use the feeler gauge to measure
piston ring end clearance.
Oil ring end clearance:
Second compression ring end clearance:
First compression ring end clearance:
6. Check the fit clearance of connecting rod bearing bushes
1) Place a plastic clearance gauge on the connecting rod journal.
2) Install connecting rod cap (the forward marking of the connecting rod
cap should toward the front end of the engine), and tighten the EM
connecting rod bolts with specified torque.
3) Remove the connecting rod cover.
4) Measure the maximum clearance point with plastic clearance gauge.
Standard value:
If the clearance goes beyond the specified range, please replace the
connecting rod bearing. When replacing the connecting rod bearing, you
may select the correct connecting rod bearing on the basis of the sum of
the group number of small head hole of connecting rod as printed on
connecting rod body and the group number of connecting rod journal as
printed on crankshaft (group number on connecting rod cover + group
number of connecting rod journal on crankshaft = number of connecting
rod bearing to be used)
7. Check the crankshaft
1) Check the machined faces of crankshaft for appearance defects
such as scratch or ablation.
2) Check the diameter of main journal.
As shown in the figure, on the two sections A and B of every connecting
rod journal. Measure the diameter in direction of X and Y axes and make
records.
Standard value of diameter of main journal:
Group 1:
54.797±0.003mm (Metric) 2.1574±0.00012 in (English)
Group 2:
Group 3:
: If the standard value is exceeded, please replace crankshaft.
Notice
If the standard value is exceeded. please replace the crankshaft.
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3) Use the dial indicator to measure the circle runout

at the crankshaft main journal.
Maximum runout: 0.02 mm (metric) 0.0008 in (English)
Notice
If the standard value is exceeded, Please replace the
crankshaft.
EM
4) Check the diameter of connecting rod journal.

As shown in the figure, on the two sections A and B of every
connecting rod journal, measure the diameter in direction of X
and Y axes, and make record.
Standard value of diameter of connecting rod journal:
Group 1:
47.997±0.003mm (Metric) 1.8895±0.00012 in
(English)
Group 2:
47.991±0.003mm (Metric) 1.8893±0.00012 in
(English)
Group 3:
47.985±0.003mm (Metric) 2.8891±0.00012 in
(English)
Notice
If the standard value is exceeded. Please replace the
crankshaft.
8. Check the piston fuel injector component
1) Check the clearness of piston fuel injector.
Supply the compressed air to piston fuel injector
component and confirm whether it is clear.
If it is blocked up and can’t be repaired. Replace
the piston fuel injector component.
Air pressure: 1.7-2.3 bar
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9. Check the cylinder block

1) Check the flatness of top face of cylinder block.
In the six directions as shown in the figure.
Measure the flatness of top face of cylinder block.
If the standard value is exceeded. Replace the
cylinder block .
Cylinder block surface flatness:
EM
2) Check the diameter of cylinder hole.
At the position which is 42mm (1.65 in) below top
face of cylinder hole, measure the diameter of
cylinder in directions of X and Y axes and make
records.
If the standard value is exceeded, then replace
the cylinder block.
Standard diameter:
JLD-4G20: 85.0075±0.0075mm (Metric)
3.3465±0.0003 in (English)
JLD-4G24: 88.7075±0.0075mm (Metric)
3.4924±0.0003 in (English)
3) Measure the diameter of hole on cylinder.
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4) Check the diameter of main bearing hole.

a. Install the main bearing seat.
b. Measure the diameter of main bearing hole:
As shown in the figure, measure the diameter on
main bearing hole in the direction of X and Y axis
respectively and make records.
Notice
If the standard value is exceeded, please replace the
cylinder block.
Standard value for diameter of main shaft hole:
Group 1:
58.811±0.003mm (Metric)
EM
2.31539±0.000118 in (English)
Group 2:
58.817±0.003mm (Metric)
2.31563±0.000118 in (English)
Group 3:
58.823±0.003mm (Metric)
2.31587±0.000118 in (English)
Installation
1. Fix the cylinder block
1) Mount the cylinder block onto turnable bench.
2) Turn the handle on bench until the bottom face of
cylinder block faces upwards.
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2. Install the piston fuel injector component

1) Install the piston fuel injector component and 1
fixing bolt in every cylinder hole.
2) Tighten up the fixing bolts of piston fuel injector
component.
Tightening torque: 7N·m (Metric) 5.17 lb-ft (English)
EM
3. Install the crankshaft
1) Install the selected crankshaft main bearing. Install
the upper portion of main bearing with engine oil
groove onto cylinder block.
2) Drip 2-3 drops of engine oil onto every main
bearing.
3) Install the crankshaft.
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4) Install the thrust bearings onto two side faces of

bearing 3 of cylinder block. With the sloted face
outwards.
EM
5) Check the axial clearance of crankshaft, and
confirm whether it meets the standard of axial
clearance of crankshaft.
Standard of axial clearance of crankshaft:
0.04-0.24mm (Metric) 0.0016-0.0094 in (English)
6) Drip 2-3 drops of engine oil onto crankshaft
journal.
7) Install the upper portion of main bearing on main
bearing cover.
8) Install the crankshaft bearing cover and fixing

bolts.
9) Turn the crankshaft for 2-3 rounds, and make sure
that it is lubricated evenly by engine oil.
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10) As per the diagram sequence, tighten the

crankshaft bearing cover bolt.
Tighten up the main bearing cover bolts in three times:
First-time tightening torque: 20N·m (Metric) 14.76 lb-ft
(English)
Second-time tightening torque: 40N·m (metric) 29.52
lb-ft (English)
Third-time tightening torque: 60N·m (metric) 44.28 lb-ft
(English)
11) Check the turning torque of crankshaft.
Turning torque ＜ 5N·m (Metric) 3.69 lb-ft (English)
12) Turn the crankshaft until the piston of cylinder is at
the top dead center. EM
4. Assemble the connecting rod and piston component
1) Turn the handle on bench, until the top face of
cylinder block is vertical to the ground.
2) Drip 3-4 drops of engine oil onto wall of cylinder
hole and then apply the engine oil evenly.
3) Select the piston connecting rod assembly

corresponding to the cylinder hole, and install the
piston ring compressing hoop onto the piston.
Notice
Make sure that the piston ring is normally compressed
in piston groove.
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4) Install the connecting rod bearing on connecting

rod.
Notice
The radial positioning key of connecting rod bearing
shall be aligned with the radial locating groove on
connecting rod.
5) Drip 2-3 drops of engine oil on bearing and apply
the engine oil evenly.
EM
6) Turn the crankshaft until the piston in hole on
cylinder is at the bottom dead center.
7) Drip 3-4 drops of engine oil onto the piston and

apply such engine oil evenly along the
circumference.
8) Mount the connecting rod into hole on cylinder and
align it with crankshaft.
Notice
The dot mark on the piston top surface should face the
engine front end.
During installation, pay attention to the connecting rod's
bottom to prevent damage due to impact on the crankshaft
journal.
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9) Use the rubber handle to install the connecting rod

component on which the position mark is left.
10) Install and tighten cylinder No.1 connecting rod EM

bearing cap bolt.
Torque:
First time: 20N·m (Metric) 14.76 lb-ft (English)
Second time: 52N·m (Metric) 38.38 lb-ft (English)
11) By the same method, install the piston connecting
rod components of the other three cylinders.
5. Install the crankcase body.

1) On the bottom face of cylinder block, apply the
1596F silicon rubber sealant onto the joint face
between cylinder block and crankcase in the area
with diameter of 3mm.
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2) Install the crankcase body, and tighten the fixing

bolts in the sequence as shown in the figure.
EM
3) Install the oil filter adapter.
6. Install the balance shaft (4G24)

1) Install the balance shaft bearing onto the
crankcase body.
2) Drip 2-3 drops of engine oil onto internal surface of
balance shaft bearing.
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3) Install balance shaft component II.

4) Drip 2-3 drops of engine oil onto the surface of
balance shaft journal.
5) Install balance shaft component I. EM

6) Drip 2-3 drops of engine oil onto the surface of
balance shaft journal.
Notice
As shown in the figure, align the balance shaft 1 and 2 to
Timing mark keep the installation reference hole within the vertical plane.
Now the piston of cylinder No. 1 of crankshaft is at the top
dead center.
Install the reference hole
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7) Install the balance shaft bearing onto balance shaft

bearing cover.
8) Drip 2-3 drops of engine oil onto internal surface of
balance shaft bearing.
EM
9) Install the balance shaft bearing cover and its
fixing bolts, and tighten up the bolts in accordance
with the sequence as shown in the figure.
The balance shaft bearing cover bolts shall be tightened
up in two times.
First-time tightening torque: 15N·m (Metric) 11.07 lb-ft
(English)
Second-time tightening torque: 38N·m (Metric) 28.04 lb-ft
(English)
7. Install the engine oil filter

8. Install the water pump
9. Install the idler bracket
10. Install the alternator
11. Install the A/C compressor
12. Install cylinder head gasket components
13. Install the cylinder head component
14. Install camshaft
16. Install the crankshaft front oil seal
18. Install the oil pan
22. Engine right bracket
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24. Install the cylinder head cover assembly

26. Install the exhaust manifold component
27. Install the knock sensor
28. Install the isolating pad of intake manifold.
29. Install the intake manifold component
31. Remove the engine assembly from its turning bench
32. Install the engine assembly
36. Install the lower swing arm assembly of front EM
suspension
41. Install the carbon canister solenoid valve
42. Install the engine oil
43. Install the engine coolant
44. Install the transmission oil
53. Install the air filter assembly
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EM
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JLE-4G18TDB mechanical System –Contents EM-1
EM JLE-4G18TDB mechanical System
Engine ....................................................................................................................................................................... EM-4

On-board Check ............................................................................................................................................... EM-4
Comprehensive Check of Engine ....................................................................................................................... EM-5
Engine Noise Diagnosis ..................................................................................................................................... EM-7
There Is Noise When the Engine Loaded ......................................................................................................... EM-7
Slight Vibration When Engine Is Warming Up .................................................................................................... EM-7
Vibration At Idle And When Engine Is Warming Up ............................................................................................ EM-8
EM
Engine Misfire With Abnormal Noise .................................................................................................................. EM-9
Check of Drive Belt............................................................................................................................................ EM-11
Drive Belt Chirp Diagnosis................................................................................................................................ EM-12
Drive Belt Scream Diagnosis ............................................................................................................................ EM-13
Drive Belt Falling-off Diagnosis ........................................................................................................................ EM-15
Excessive Wear of Drive Belt ........................................................................................................................... EM-15
Trim Cover of Engine ............................................................................................................................................. EM-17
Component ....................................................................................................................................................... EM-17
Removal ........................................................................................................................................................... EM-18
Installation ........................................................................................................................................................ EM-18
Cylinder Head Cover Assembly ............................................................................................................................ EM-19
Component ....................................................................................................................................................... EM-19
Removal ........................................................................................................................................................... EM-21
Installation ........................................................................................................................................................ EM-22
Drive Belt ................................................................................................................................................................ EM-24
Component ....................................................................................................................................................... EM-24
Removal ........................................................................................................................................................... EM-25
Installation ........................................................................................................................................................ EM-25
Damping Pulley Component ................................................................................................................................. EM-28
Component ....................................................................................................................................................... EM-28
Removal ........................................................................................................................................................... EM-30
Installation ........................................................................................................................................................ EM-30
Crankshaft Front Oil Seal ...................................................................................................................................... EM-31
Component ....................................................................................................................................................... EM-31
Removal ........................................................................................................................................................... EM-33
Installation ........................................................................................................................................................ EM-33
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EM-2 JLE-4G18TDB mechanical System –Contents
Rear Vibration Isolator of Engine.......................................................................................................................... EM-34

Component ....................................................................................................................................................... EM-34
Removal ........................................................................................................................................................... EM-36
Installation ........................................................................................................................................................ EM-37
Engine Front Vibration Isolator Assembly ........................................................................................................... EM-40
Component ....................................................................................................................................................... EM-40
Removal ........................................................................................................................................................... EM-39
Installation ........................................................................................................................................................ EM-40
Left Vibration Isolator of Engine ........................................................................................................................... EM-41
Component ....................................................................................................................................................... EM-45
EM
Removal ........................................................................................................................................................... EM-41
Installation ........................................................................................................................................................ EM-43
Right Vibration Isolator of Engine ........................................................................................................................ EM-46
Component ....................................................................................................................................................... EM-49
Removal ........................................................................................................................................................... EM-46
Installation ........................................................................................................................................................ EM-47
Engine Assembly ................................................................................................................................................... EM-48
Component ....................................................................................................................................................... EM-48
On-board Removal ........................................................................................................................................... EM-61
Re-assembly .................................................................................................................................................... EM-78
Crankshaft Rear Oil Seal Component ................................................................................................................... EM-94
Component ....................................................................................................................................................... EM-94
Removal ......................................................................................................................................................... EM-107
Installation ...................................................................................................................................................... EM-108
Timing Chain and Tensioner ................................................................................................................................EM-110
Component ...................................................................................................................................................... EM-110
Removal ......................................................................................................................................................... EM-120
Installation ...................................................................................................................................................... EM-125
Camshaft ............................................................................................................................................................... EM-130
Removal ......................................................................................................................................................... EM-147
Check ............................................................................................................................................................. EM-150
Installation ...................................................................................................................................................... EM-151
Cylinder Head Assembly .................................................................................................................................... EM-155
Component ..................................................................................................................................................... EM-155
Removal ......................................................................................................................................................... EM-169
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JLE-4G18TDB mechanical System –Contents EM-3
Check ............................................................................................................................................................. EM-173

Installation ...................................................................................................................................................... EM-176
Balance Shaft........................................................................................................................................................ EM-182
Component ..................................................................................................................................................... EM-182
Removal ......................................................................................................................................................... EM-199
Installation ...................................................................................................................................................... EM-201
Cylinder Block ...................................................................................................................................................... EM-205
Component ..................................................................................................................................................... EM-205
Removal ......................................................................................................................................................... EM-226
Check ............................................................................................................................................................. EM-229
EM
Installation ...................................................................................................................................................... EM-236
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EM-4 JLE-4G18TDB mechanical System - Engine
Engine
On-board Check
1. Check the engine coolant. Refer to "Coolant"
2. Check the engine oil. Refer to "engine oil and engine oil
filter"
3. Check the battery. Refer to "Battery cable"
4. Check the spark plug. Refer to "Spark plug"
1) Remove the air filter element.
2) Visually check the air filter element subassembly
EM for dirt, blockage and/or damage.
Tips:
a. If the air filter element component is dirt or
blocked, please clean it up with compressed air.
b. If the air filter element subassembly is still dirt or
blocked after being cleaned with compressed air,
please replace it.
6. Check the ignition timing
1) Connect the fault diagnostic scanner.
2) Start the engine to normal operation temperature.
3) Turn off the A/C switch.
4) On the fault diagnostic scanner, read the ignition
advance angle of cylinder No. 1.
7. Check the engine idle speed
8. Check the compression pressure of the cylinder
2) Install the cylinder pressure test gauge in the spark
plug installation hole.
3) Start the engine, and make the engine run for 4-5
cycles.
4) Read the indication on pressure gauge for every
cylinder, and judge whether the pressure meets
the standard value.
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JLE-4G18TDB mechanical System - Engine EM-5
Comprehensive check of engine

1. Check the engine coolant
Refer to "On-board check".
2. Check the engine oil
3. Check the battery
4. Check the spark plug.
5. Check the ignition timing
EM
Prior to checking ignition timing, the following conditions shall be met
– The engine shall reach the normal operation temperature.
1. Detection method by using the fault diagnostic scanner:
Step 1 Connect the fault diagnostic scanner.
OFF state.
interface.
(e) Select in sequence: Engine/data list/cylinder No.1 ignition
advance angle.
2. Detection method using the timing lamp:
Step 1 Connect the clip of the timing lamp to the cylinder No.1 ignition coil harness.
Next Step
Next Step
Next Step
Step 4 Remove the timing lamp and restore the mounting position of the ignition coil harness.
Next Step
3. Cylinder compression test

Notice
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Remove the fuse EF10, disconnect the fuel injector harness connector, and ensure that the fuel and ignition systems can’t
work. After the test is completed, use the fault diagnostic scanner to clear the fault diagnosis code.
Prior to the compression, the following conditions shall be met:
– The engine shall reach the normal operation temperature.
– The throttle valve shall be in fully open position.
– To remove 4 cylinder spark plugs is required.
– The battery shall be fully charged without power-lack.
Notice
During the start-up test, the starter switch can not remain at the "ST" position for more than 15s; otherwise it will damage the
starter.
EM
Diagnostic steps:
Step 1 Test pressure of each cylinder, pressure dropping may be due to valve closure or piston ring wear.
Next Step
Step 2 Apply proper amount of the engine oil inside the cylinder.
Next Step
Step 3 Install the cylinder pressure test gage to the spark plug installation port.
Next Step
Step 4 Turn the ignition switch to "ST" position and make each cylinder move 4~5 compression strokes.
Next Step
Step 5 The lowest reading of each cylinder pressure shall not be lower than 75% of the highest reading of the
single cylinder. The reading of any cylinder pressure gauge shall not be lower than 750kPa.
Next Step
Step 6 Check the pressure gage readings for each cylinder after the completion of four compression stroke.
The readings are explained as follows:
(a) Normal condition: the cylinder pressure swiftly and evenly

increases and reaches the specified pressure value.
(b) Piston ring fault: the first stroke pressure is low and increases
during the following stroke. However, the pressure fails to
reach the normal level. After adding engine oil in the cylinder,
the pressure increases significantly.
(c) Valve fault: the first stroke pressure is low and unable to
increase during the following stroke; the pressure is not high
when the engine oil is added in the cylinder.
Next Step
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Engine noise diagnosis

The engine vibration actually represents the engine resonance noise. When the engine vibration frequency and fault vibration
frequency keep consistent, the noise will be perceived. The noise of serious vibration is normally loud, and is attributable to the
situation that the any internal part of engine is broken or seriously worn. The tiny vibration noise is audible, but the sound is not
too loud. The cause of minor vibration is that the internal components of engine are worn, and the loosened or broken external
components of engine may also lead to serious or minor vibration, and if the engine exterior part is loose or broken, it may
cause serious or slight vibration. When diagnosing the noise fault, find out the resonance source and eradicate the fault.
Noisy when there is engine load
Diagnostic steps:
EM
Yes Replace/adjust the belt to the s ecified value and
determine the fault has been eliminated.
No
Step 2 Check the exhaust system. Whether the system interferes with other components or ground scratch?
Yes Re-position and install the exhaust system and

determine whether the fault has been eliminated.
No
Step 3 Check whether the flywheel assembly is cracked, deformed or interfered with other components, and
whether the driving disc is normal.
Yes Replace the flywheel assembly and determine

No
Step 4 Check whether main clearance is too big, or beyond the specified value.
Yes
Replace main bearing and determine whether the
fault has been eliminated.
No
Step 5 Check whether the connecting rod bearing clearance is beyond the specified value.
Yes Replace flywheel assembly and determine whether

the fault has been eliminated.
No

Slight Vibration When Engine is Warming Up
Diagnostic steps:
Step 1 Check the drive belt tension strength for looseness, wear and any other faults?
Yes If necessary, replace the drive belt and determine

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No
Re-fill engine lubricant suitable to the present

Yes
season temperature and determine whether
No the fault has been eliminated.
Step 3 Check whether the engine and A/C compressor work normally, and whether they make any noise when
working.
EM
Yes Replace the fault component and check
No whether the fault has been eliminated.
Step 4 Use the fault diagnostic scanner to check relevant "knock" data in the data stream for any explosive
combustion in the engine.
Yes Check the engine timing systems and fuel

No quality, and repair the faulty part.
Step 5 Check whether there is leakage on exhaust manifold and its connection.
Yes Replace the exhaust pipe pad and tighten the

No exhaust pipe
Step 6 Check the connecting rod bearing clearance, and does it exceed the specified value?

Vibration at Idle and When Engine is Warming Up

Diagnostic steps:
Step 1 Check the drive belt tension strength for looseness, wear and any other faults.
Yes
eliminated.
No
Re-fill engine lubricant suitable to the present

Yes
season temperature and determine whether
the fault has been eliminated.
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No
Step 3 Check whether the engine and A/C compressor work normally; does any abnormal noise come out
during operation?
Yes Replace fault component and check whether
No the fault has been eliminated.
Step 4 Check the operation state of the valve tappet, valve spring, etc, any fault available?
EM
Step 5 Check the piston pin clearance. Does it exceed the specified value?
Standard value of piston pin and connecting rod: (0.005~0.018mm)
Standard value of piston pin and piston pin hole: (0.004~0.013mm)
Step 6 Check whether the connecting rod has been bent.
Replace the fault component and check

Yes
Step 7 Check the clearance valve of the piston to jacket, is it beyond the standard value?
Engine Misfire with Abnormal Noise

Diagnostic steps:
Step 1 Check whether engine control system has fault code through fault diagnostic scanner?
Repair the location in fault on the basis of the

Yes
No fault code.
Step 2 Use the fault diagnostic scanner to check relevant knock data in the engine data stream; compared it
with normal vehicle, any usual?
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No
Step 3 Check whether the valve spring is too soft or ruptured.
Check whether the fuel is normal. Check

Yes
whether the timing system is normal. Repair
the faulty part. Confirm whether the fault is
fixed.
No
EM Step 4 Check whether the valve is catching or bent?
No
Step 5 Check whether the roller rocker falls off, and whether the hydraulic tappet is seized or worn.
No
Step 6 Check whether there are excessive cam wear or obvious faults.
Yes
Replace the camshaft.
No
Step 7 Check the valve guide pipe for the existence of cracks, excessive wear and tear and other faults.
No
Step 8 Check whether the valve spring seat is incorrectly mounted.
No
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Check on Drive Belt

1. Conduct check in cold state or when the engine is
turned off.
2. Visually inspect whether there is excessive wear or cord Damaged/aged drive belt
wear for V-type drive belt. In case of defectives, replace

V-shaped belt.
3. Visually check whether the belt's interior and edge has
wear, damage, rupture. Or else, replace a new belt.
4. Visually check the belt is free from conditions in above
item 2, 3, conduct belt tension measuring: turn the
EM
crankshaft belt two circles clockwise; during measuring, Drive belt mounting
the belt tension in the pulley is evenly distributed.

5. Use the sound pressure meter (via the repair tools) to
measure the tension and frequency of the belt at the
marking point A.
Correct matching
New drive belt Old drive belt

Drive belt tension (N/lb) 400~500/89.9~112.4 300~400/67.4~89.9
 After replacing the new belt, turn the crankshaft tow circles clockwise to make belt fully wedged into the pulley. Measure
tension at mark point A. The reference scope is shown in the table. In case of exceeding the table scope, replace a new
belt.
 When the tension of the using belt (i.e. used belt) is beyond the table scope, replace a new belt.
 When installing the belt, ensure its correct binding with the pulley slot.
 Don't stain the engine oil or engine coolant in the belt.
 Please don't over wind or bend the belt.
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Drive belt chirp diagnosis

Diagnosis tips:
The symptom may be due to wet drive belt or pulley and may be an intermittent fault. It may be needed to spray some water in
the drive belt to recreate the customer's fault. If the symptom reoccurs after spraying water, then clean the pulley. Loose or
improper installation of body components, suspension components or other vehicle parts can also cause the chirp sound.
Fault definition: the following conditions are the drive belt chirp sound symptoms
– A chirp noise can be heard once when rotating the drive belt for a round.
– Noise often happens on a rainy day or in a cold morning.
Step 1 Determine the fault phenomenon; does the engine really have chirp sound?
EM No To diagnosis tips.
Yes
Step 2 Remove the drive belt and determine whether the chirp sound disappeared.
a) Remove the drive belt.

Does the chirp sound disappear?
No Refer to "Engine noise diagnosis".
Yes
Step 3 Check whether the surface of the drive belt is normal. (Free from pilling, crack, etc.)
Refer to "Drive belt inspect".
No Replace the drive belt.
Yes
Step 4 Check whether the drive belt pulley is installed correctly. (No misaligned phenomena is allowed, etc.?)
Reinstall the drive belt pulley, if necessary,

No
replace the drive belt.
Yes
Step 5 Check whether the belt pulley is normal.
Check whether the pulley is bent, twisted, etc.
Yes
Step 6 Check whether all the fasteners related to the drive belt are normal?
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Yes
Drive Belt Scream Diagnosis

Diagnosis tips:
Loose or unreasonable installation of body, suspension and other components may cause scream. In case of intermittent
noise, check various attached drive components via changing engine load. It is advised to check whether the A/C system is
filled with too much liquid, whether the hose of power steering system is pinched, and whether the alternator is in fault. EM
Fault definition: the following conditions are the drive belt screams symptoms
 Screaming generated by the sliding of the drive belt.
 The noise occurs when the large load is applied to the drive belt, e.g. the startup of the A/C system compressor, rapid
start of the throttle valve when the engine moves or the screeching noise when the belt slides in the fault drive
component.
Step 1 Confirm fault phenomenon; does the engine scream actually occur?
Yes
Step 2 Remove drive belt and determine whether the scream disappears.

Does the scream disappear?
Yes
Step 3 Check whether all the accessory drive belt pulley bearings are normal. (The belt pulley may not be
seized or loosened)
Yes
Step 4 Check whether the belt tensioner works normally.

Tensioner pulley bearing device is not stuck, loose. Tensioner
device does not appear loose and other damages.
Replace the belt tensioner.

No
Yes
Step 5 Check whether the correct drive belt is used.

Check whether the belt is elongated. Please refer to "Drive
belt inspect".
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No Replace the belt in fault.
Yes
Step 6 Check whether all the fasteners related to the drive belt are normal.
Yes
Step 7 Check whether all drive belt pulleys are normal.
EM No Replace faulty pulley.
Yes
Drive Belt Hum Sound Diagnosis

Diagnosis tips:
Drive belt should not produce hum sound. In case of intermittent noise, change load to check the accessory drive component
and ensure the component operates till the maximum load. These situations may be caused by (without limitation) the facts
that the A/C system is filled with too much liquid or the alternator is in fault.
Fault definition:
Continuous high noise
Step 1 Determine fault phenomenon, does the engine really has hum sound?
Yes
Step 2 Remove drive belt and determine whether the hum sound disappears?

Does the hum sound disappear?
Yes
Step 3 Check whether all the accessory drive belt pulley bearings are normal. (The belt pulley may not be
seized or loosened)
Yes
Step 4 To diagnostic tips.
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Drive Belt Falling-off Diagnosis

Diagnosis tips:
If the drive belt falls off from the pulley repeatedly, the reason may be the pulley malposition. If the attached drive component
causes huge variation of the belt load, the drive belt may detach from the pulley. Detect whether the attached drive component
works normally. If the drive belt's length is not proper, belt tensioner will not be able to maintain a suitable drive belt tension.
Fault definition:
Drive belt falls off from the pulley or drive belt is unable to be correctly installed in the pulley.
Step 1 Check the drive belt for damage. If necessary, replace the drive belt.
Next Step
EM
Step 2 Check whether the pulley is misaligned. Repair the faulty part.
Next Step
Step 3 Check whether the pulley is bent or depressed. Repair the faulty part.
Next Step
Step 4 Check whether the belt pulley tensioner is bent or cracked, and repair the location in fault.
Next Step
Step 5 Check whether the drive belt tensioner is working properly. Repair the faulty part.
Next Step
Step 6 Check whether the attached fastener is loose. Repair the faulty components.
Next Step
Excessive Wear of Drive Belt

Diagnosis tips:
Drive belt excessive wear is usually due to unreasonable installation or the use of the wrong drive belt. Drive pulley slight
malposition will not cause excessive wear and tear, but it could lead to drive belt noise or fall-off. The serious malposition of
the drive belt pulley will lead to over wear and also the fall-off of the drive belt.
Fault definition:
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The incorrect drive belt installation will lead to drive belt exterior edge wear.
Step 1 Check whether there are frictions between drive belt and brackets, harness, hoses and other
components.
Yes To diagnostic tips.
No
Step 2 Check all belt pulleys for abnormal conditions such as abnormal scratch or arris.
Yes Repair the fault position. If necessary, replace
EM the pulley.
No
Step 3 Check whether the type of the installed belt is not correct?
Yes Replace the belt with the new one of correct

specification.
No
Step 4 To diagnostic tips.
NL-3 01/2016
JLE-4G18TDB mechanical System - Trim Cover of Engine EM-17
Trim Cover of Engine

Component
EM
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EM-18 JLE-4G18TDB mechanical System - Trim Cover of Engine
Removal
1) Pull out the trim cover of engine from trim cover
mounting bracket, and remove the trim cover of
engine.
EM
Installation
1) Install the trim cover of engine onto trim cover
mounting bracket.
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JLE-4G18TDB mechanical System - Cylinder Head Cover Assembly EM-19
Cylinder Head Cover Assembly

Component
Ignition coil EM
Engine assembly
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EM-20 JLE-4G18TDB mechanical System - Cylinder Head Cover Assembly
Cylinder head cover
EM
Cylinder head
cover gasket
Engine assembly
Non-reusable parts
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Removal
3. Remove the upper trim panel connecting plate of fender.
compartment"
4. Remove the upper trim panel of left fender. Refer
to"Decorative covering parts of engine compartment"
EM
cover"
8. Remove the ignition coil. Refer to the section about
ignition coil component
9. Remove cylinder head cover assembly
1) Disconnect the connection between the vent hose
component 1 and vent hose component 2 of
crankcase with the cylinder head cover.
2) Remove 4 cylinder head cover fixing bolts.
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EM-22 JLE-4G18TDB mechanical System - Cylinder Head Cover Assembly
3) Remove the cylinder head cover and cylinder head

cover gasket from cylinder head.
EM
Installation
1. Install cylinder head cover assembly
1) Mount the sealing gasket into the sealing groove
on cylinder head cover.
Notice
Make sure that the sealing gasket is evenly pressed in,
and avoid the situation that the sealing gasket is not
installed in place.
2) Install the cylinder head cover.
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3) Install and tighten the cylinder head cover bolts.

Notice
When tightening up the bolt, be sure to tighten up a bolt
in several times until the specified torque is reached,
and tighten up all bolts in the sequence from middle to
both ends.
Torque:
First time: 5 N·m (Metric) 3.69 lb-ft(English)
Second time: 10.5 N·m (metric) 7.75 lb-ft (English)
EM
4) Connect the vent hose component 1 and vent

hose component 2 of crankcase with the cylinder
head cover.
3. Install the front bumper upper trim panel.
9. Shut down the engine hood
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EM-24 JLE-4G18TDB mechanical System - Drive Belt
Drive Belt
Component
EM
Drive belt
Belt tensioner assembly
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JLE-4G18TDB mechanical System - Drive Belt EM-25
Removal
refer to the section about engine compartment
decorative & covering parts
compartment"
4. Remove the upper trim panel assembly of the right
EM
fender. Please refer to the engine compartment trim
cover.
5. Remove the drive belt
1) Rotate the drive belt tensioner clockwise with a
wrench to remove the drive belt.
Notice
When taking out the drive belt, prevent drive belt
tensioner from rebounding; otherwise the operation
personnel may get injured.
Check
1) Check whether the belt is excessively worn or
whether its cord yarn is worn. If the belt is found as
defective, replace the drive belt.
Installation
1) Wrap the drive belt as shown in the figure.
2) Rotate the drive belt tensioner anticlockwise with a
wrench to install the drive belt.
Notice
Before releasing the belt tensioner, confirm the drive
belt aligned with all drive belt pulley grooves; otherwise
the drive belt may be damaged.
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EM-26 JLE-4G18TDB mechanical System - Belt Tensioner Assembly
Belt Tensioner Assembly

Component
EM
Drive belt
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JLE-4G18TDB mechanical System - Belt Tensioner Assembly EM-27
Removal
compartment"
4. Remove the upper trim panel assembly of the right
fender. Refer to"Decorative covering parts of engine
EM
compartment"
5. Remove the driving belt. Refer to “Driving belt”.
6. Remove the belt tensioner assembly
1) Remove 2 fixing bolts of belt tensioner assembly.
2) Remove the belt tensioner assembly.
Installation
1. Install the belt tensioner assembly
1) Install 2 fixing bolts on upper end of belt tensioner
assembly.
Torque: 22.5 N·m (Metric) 16.60 lb-ft(English)
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EM-28 JLE-4G18TDB mechanical System - Damping Pulley Component
Damping Pulley Component

Component
EM

assembly of engine

assembly of engine

on bottom of engine
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JLE-4G18TDB mechanical System - Damping Pulley Component EM-29
EM
Damping pulley component
Drive belt
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EM-30 JLE-4G18TDB mechanical System - Damping Pulley Component
Removal
2. Remove the right front wheel. Please refer to "Wheel
and tire"
3. Lift the vehicle
4. Remove the right guard plate of engine. Please refer to
“Left and right guards at the bottom of engine”.
5. Remove the driving belt. Please refer to "Driving belt".
6. Remove the damping pulley component.
EM
1) Use the special tool to fix the damping belt pulley
component, remove the damping belt pulley
component fixing bolt, and then take out the
Installation
1. Install the damping pulley component
1) Use the special tool to fix the damping belt pulley
component, and tighten up the fixing bolt of
Special tools：47Z01303A、47Z01303B
Torque:
First time:
150 N·m + 90°( Metric )
110.7 lb-ft +90°(English)
Second time:
150 N·m + 90°+ 45°( Metric )
110.7 lb-ft + 90°+ 45°( English )
Final torque:
380 N·m
280.44 lb-ft
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JLE-4G18TDB mechanical System - Crankshaft Front Oil Seal EM-31
Crankshaft Front Oil Seal

Component
EM
Engine right guard plate assembly
Engine left guard plate assembly
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EM-32 JLE-4G18TDB mechanical System - Crankshaft Front Oil Seal
EM
Drive belt
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JLE-4G18TDB mechanical System - Crankshaft Front Oil Seal EM-33
Removal
“Decorative covering parts of engine compartment"
3. Remove the upper trim panel connecting plate of fender. Refer
4. Remove the upper trim panel assembly of right fender. Refer to
5. Remove the right front wheel. Please refer to "Wheel and tire"
6. Lift the vehicle
7. Remove the right engine guard plate. Refer to “Left and right
engine bottom guard plate” EM
9. Remove the damping belt pulley component. Refer to
"Damping belt pulley component"
10. Remove crankshaft front oil seal
1) Remove the crankshaft front oil seal with special tools.
Special tool: 47Z01218A
Installation
1) Use the special tool to install the crankshaft front oil
seal.
Special tool: 47Z01217A
2) After the installation, check whether the distance
between the upper surface of oil seal and front end face
is 1.5±0.4mm, and whether the height difference
between the same oil seal and the front end of
corresponding cover is no more than 0.2mm.

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EM-34 JLE-4G18TDB mechanical System - Rear Vibration Isolator of Engine
Rear Vibration Isolator of Engine

Component
Engine rear bracket
EM Engine left bracket
Engine
assembly

isolator assembly
Engine front vibration

isolator assembly
NL-3 01/2016
JLE-4G18TDB mechanical System - Rear Vibration Isolator of Engine EM-35
Engine rear vibration

isolator assembly
Engine rear bracket
Engine left vibration EM

isolator assembly
Engine
assembly

isolator assembly
Engine front vibration

isolator assembly
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Removal
2. Lift the vehicle
3. Remove the engine bottom guard plate. Refer to “Left
4. Remove the rear vibration isolator of engine
1) Remove 2 fixing bolts and 2 fixing nuts between
the rear vibration isolator of engine and the
auxiliary frame.
EM
2) Remove the through bolt between rear vibration

isolator and rear bracket.
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JLE-4G18TDB mechanical System - Rear Vibration Isolator of Engine EM-37
5. Remove the rear bracket of engine

1) Remove 3 connect bolts between rear bracket and
transmission.
EM
Installation
1. Install the rear engine bracket
1) Install the 3 fixing bolts between the rear bracket of
engine and the transmission.
2. Install the rear vibration isolator of engine

1) Install the rear vibration isolator of engine in the
installation hole on auxiliary frame.
2) Install the connecting bolts between rear vibration
isolator and rear bracket.
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3) Install and tighten up 2 bolts and 2 nuts of rear

vibration isolator of engine.
(English)
EM
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JLE-4G18TDB mechanical System - Engine Front Vibration Isolator Assembly EM-39
Engine Front Vibration Isolator Assembly
Removal
2. Lift the vehicle
and right engine bottom guard plate”
4. Remove the front vibration isolator assembly of engine.
1) Remove the 2 connecting bolts between front
vibration isolator assembly and front crossbeam.
EM
2) Remove the connecting bolt between front

vibration isolator assembly and front bracket.
3) Remove the front vibration isolator assembly.
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EM-40 JLE-4G18TDB mechanical System - Engine Front Vibration Isolator Assembly

1) Remove 2 connecting bolts between the front
bracket of engine and the transmission.
EM
Installation
1) Install fixing bolt of engine front bracket.
2. Install the front vibration isolator of engine

1) Install the connecting bolt between front bracket
and vibration isolator.
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JLE-4G18TDB mechanical System - Left Vibration Isolator of Engine EM-41
2) Install 2 fixing bolts between the front vibration

isolator of engine and the crossbeam.
EM
Left Vibration Isolator of Engine

Removal
Refer to "Decorative covering parts of engine compartment"
4. Remove the upper trim panel assembly of left fender. Refer
to “Decorative covering parts of engine compartment"
5. Remove the battery. Refer to “Battery cable”.
6. Remove the battery bracket. Refer to “Battery bracket”
8. Remove the engine ECU. Please refer to "Engine ECU"
9. Remove the engine ECU bracket assembly. Please refer to
"Engine ECU bracket"
10. Use the jack to support the bottom of transmission
11. Remove the left vibration isolator of engine (AT)
1) Remove 3 connecting bolts between the left vibration
isolator and the transmission.
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EM-42 JLE-4G18TDB mechanical System - Left Vibration Isolator of Engine
2) Remove 2 bolts and 1 nut between the left

vibration isolator and the vehicle body.
EM
12. Remove the left vibration isolator of engine (MT)

vibration isolator and the bracket.
2) Remove 2 bolts and 1 nut between the left

vibration isolator and the vehicle body.
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JLE-4G18TDB mechanical System - Left Vibration Isolator of Engine EM-43
13. Remove the left bracket of engine

vibration isolator of engine and the transmission.
EM
Installation
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EM-44 JLE-4G18TDB mechanical System - Left Vibration Isolator of Engine
1. Install engine left bracket

1) Install 4 connecting bolts between the left vibration
isolator of engine and the transmission.
EM
2. Install the left vibration isolator of engine (MT)

1) Install and tighten up the 2 bolts and 1 nut between
left vibration isolator and vehicle body.
Tightening torque: 80 N·m (Metric) 59.04 lb-ft (English)
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JLE-4G18TDB mechanical System - Engine left vibration isolator EM - 45

3. Install the left vibration isolator of engine (AT) EM

1) Install and tighten up 2 bolts and 1 nut between left
vibration isolator and vehicle body.

9. Remove the jack
11. Install the upper trim panel connecting plate of fender.
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EM - 46 JLE-4G18TDB mechanical System - Right vibration isolator of engine
Right vibration isolator of engine

Removal
1). Open the engine hood.
5. Use the jack to support the bottom of engine
6. Remove the right vibration isolator of engine
1) Remove 1 fixing bolt and 2 fixing nuts between the right
vibration isolator of engine and the right bracket of engine.
EM
2) Remove 2 connecting bolts and 1 through bolt between the

right vibration isolator of engine and the vehicle body.
JLE-4G18TDB mechanical System - Right vibration isolator of engine EM - 47
Installation
1. Install the right vibration isolator of engine
1) Install and tighten up 2 connecting bolts between the right
vibration isolator of engine and the vehicle body.
2) Install and tighten up the through bolt between the right
vibration isolator of engine and the vehicle body.
EM
3) Install and tighten 1 fixing bolt and 2 fixing nuts connecting

the right vibration isolator to the engine support.
Tightening Torque: 80 N.m (Metric) 59.04 lb-ft(English)
2. Remove the jack
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EM - 48 JLE-4G18TDB mechanical System - Engine assembly
Engine Assembly
Component
Engine trim cover
EM
JLE-4G18TDB mechanical System - Engine assembly EM - 49
Air flowmeter
Engine intake hose

Upper cover of air filter
EM
Air filter element
Lower cover of air filter
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Engine ECU
EM
The negative battery cable EM
Battery positive cable
Battery pressing plate
Battery
Battery harness bracket Battery bracket
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EM
Vehicle wheel nut
Wheel assembly
N·m (Ib - ft) Specified torque

EM
Engine bottom guard plate assembly
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Right front constant velocity drive shaft assembly (4G18TD_6MT)
EM
Left front constant velocity drive shaft assembly (4G18TD_6MT)
Right front brake assembly Left front brake assembly
Right front constant velocity drive shaft assembly (4G18TD_6AT)
Left front constant velocity drive shaft assembly (4G18TD_6AT)

EM
Vehicle wheel nut
Wheel assembly
N·m (Ib – ft) Specified torque
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Right longitudinal beam assembly
EM of front suspension
Left longitudinal beam assembly of
front suspension
Front suspension crossbeam
assembly
EM
Right reinforcement plate of front suspension Left longitudinal beam assembly
Left reinforcement plate of front suspension
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Front oxygen sensor
Rear oxygen sensor
EM
Three-Way Catalytic Converter

Assembly
Catalytic converter bracket

Engine assembly 4G18TD
EM
Starter motor (MT)
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EM
Starter motor (AT)

On-board Removal
2. Remove the engine trim cover. Refer to “Engine trim
cover”.
to "Decorative covering parts of engine compartment"
EM
8. Recover the refrigerant. Refer to "Recovery and filling of
A/C refrigerant"
9. Remove the air filter intake pipe. Refer to “Air filter intake
pipe”
15. Remove the front wheel. Refer to “Wheel and tire”
17. Remove the engine bottom guard plate. Refer to “Left and
right engine bottom guard plate”
18. Remove the engine left/right guard plate Refer to
“Engine bottom left right protective plate”
filling for engine coolant”
22. Remove the front constant velocity drive shaft. Refer to
“Front constant velocity drive shaft”
23. Remove the transmission shaft (four-wheel drive). Refer
to "transmission shaft assemble (4WD)"
24. Remove power take off(four-wheel drive). Refer to "Power
take off"
25. Remove the front suspension longitudinal beam. Refer to
"Front suspension longitudinal beam assembly"
"Front suspension reinforcing plate"
27. Remove the subframe. Refer to "Front subframe"
Refer to "Exhaust manifold"
29. Remove the front suspension crossbeam. Refer to "Front
suspension crossbeam assembly"
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30. Remove the power assembly (JLE-4G18TDB_6AT)

Notice
The following steps are engine harness assembly
disconnection [engine harness assembly
(JLE-4G18TDB_6AT)]
1) Disconnect the connection between starter motor fuse
and relay box.
EM
2) Disconnect the connection between engine harness

connector and relay box.

system.
4) Disconnect the connection between negative battery

wire and transmission.
EM
5) Disconnect the gearshift switch harness connector.
6) Disconnect the harness connector of transmission

power.
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instrument harness assembly.
EM bottom plate assembly.
10) Pull out the engine harness from the firewall.
Notice
The following steps are used to disconnect the gearshift
flexible shaft assembly from the transmission [only applicable
to the power assembly (JLE-4G18TDB_6AT)].
11) Disconnect the gearshift flexible shaft assembly from
the gearshift rocker arm subassembly.
12) Press the middle portion of clip, and separate upwards
the gearshift flexible shaft assembly from bracket.
Notice
The following steps are used to disconnect the clutch
hydraulic pipeline [only applicable to the power assembly
(JLE-4G18TDB_6MT)].
13) Disconnect the clutch hydraulic hose from the clutch
release bearing.
EM
Notice
The following steps are used to disconnect the oil cooler pipe
[only applicable to power assembly (JLE-4G18TDB_6AT)].
14) Disconnect the automatic transmission fluid inlet hose
1.
15) Disconnect the automatic transmission fluid outlet hose
2.
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Notice
The following steps are used to disconnect the fuel system
pipeline.
16) Disconnect the engine oil supply hose.
17) Disconnect the canister inlet control valve hose.
EM Notice
The following steps are used to disconnect the cooling
system pipeline.
18) Disconnect the radiator water inlet hose from the
engine.
19) Disconnect the radiator water outlet hose from the

engine thermostat cap.
Notice
The following steps are used to disconnect the A/C system
pipeline.
20) Disconnect the heater water inlet pipe 1 from the
engine.
21) Disconnect the heater water outlet pipe 2 from the
engine.
EM
22) Disconnect the compressor suction hose assembly

from the compressor.
23) Disconnect the compressor exhaust hose assembly
Notice
The following steps are used to disconnect the vacuum pipe.
25) Fasten the power assembly with special lifting appliance.
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26) Remove the through bolt between the front vibration

isolator assembly to the front bracket.
27) Remove the through bolt between the rear engine

vibration isolator assembly to the rear bracket.
EM
28) Remove 3 connecting bolts between the left engine

vibration isolator assembly and the transmission.
29) Remove 2 connecting nuts and 1 connecting bolt

between the right engine vibration isolator assembly and
the engine support.
30) Lower the power assembly.
Notice
Adjust the power assembly direction if the power assembly is
lowered difficultly.
EM
Notice:
The early-stage preparation work of removing the power
assembly (JLE-4G18TDB_6MT) is (steps 1- 26).
31. Remove the power assembly (JLE-4G18TDB_6MT)
Notice
The following steps are engine harness assembly
disconnection [engine harness assembly
(JLE-4G18TDB_6MT)]
1) Disconnect the connection between starter motor fuse
and relay box.
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2) Disconnect the connection between engine harness

connector and relay box.

system.
EM
4) Disconnect the connection between negative battery

wire and transmission.
EM

instrument harness assembly.
bottom plate assembly.
8) Pull out the engine harness from the firewall.
Notice
The following steps are used to disconnect the gearshift
flexible shaft assembly from the transmission [only applicable
to the power assembly (JLE-4G18TDB_6MT)].
9) Disconnect the connection between gearshift flexible
shaft 1 and shift level component.
10) Disconnect the connection between gear selector
flexible shaft 2 and shift level component.
11) Press the clip to the middle, disconnect the gear
selector flexible shaft assembly from the bracket upward.
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Notice
The following steps are used to disconnect the oil cooler pipe
[only applicable to power assembly (JLE-4G18TDB_6AT)].
12) Disconnect the automatic transmission fluid inlet hose
1.
13) Disconnect the automatic transmission fluid outlet hose
2.
EM Notice
The following steps are used to disconnect the fuel system
pipeline.
14) Disconnect the engine oil supply hose.
15) Disconnect the canister inlet control valve hose.
Notice
The following steps are used to disconnect the cooling
system pipeline.
16) Disconnect the radiator water inlet hose from the
engine.
EM
17) Disconnect the radiator water outlet hose from the

engine thermostat cap.
Notice
The following steps are used to disconnect the A/C system
pipeline.
18) Disconnect the heater water inlet pipe 1 from the
engine.
19) Disconnect the heater water outlet pipe 2 from the
engine.
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20) Disconnect the compressor suction hose assembly

21) Disconnect the compressor exhaust hose assembly
Notice
The following steps are used to disconnect the vacuum pipe.
EM
23) Fix the power assembly with the professional sling.

24) Remove the through bolt between front vibration
isolator assembly and front bracket.
25) Remove the through bolt between the rear engine

vibration isolator assembly to the rear bracket.
EM
26) Remove 3 connecting bolts between the left engine

vibration isolator assembly and the left bracket.
27) Remove 2 connecting nuts and 1 connecting bolt

between the right engine vibration isolator assembly and
the engine support.
28) Lower the power assembly.
Notice
Adjust the power assembly direction if the power assembly is
lowered difficultly.
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Disassemble below the vehicle.

1. Remove the starter motor (6AT). Refer to “Starter motor
AT”.
2. Remove the starter motor (6MT). Refer to “Starter motor
MT”.
3. Remove the engine assembly. (JLE-4G18TDB_6AT)
1) Remove the rubber stopper of engine cylinder block.
EM
2) Rotate the damping pulley component, and successively

expose 6 connecting bolts between flywheel and hydraulic
torque converter.
3) Lock the crankshaft flywheel assembly, and
successively remove 6 bolts connecting the torque
converter.
4) Remove 3 connecting bolts between the transmission

assembly and the engine upper end.

assembly and the lower end of the engine.
EM

assembly and the middle part of the engine.
7) Separate the engine assembly from the transmission
assembly.
4. Remove the engine assembly. (JLE-4G18TDB_6MT)

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2) Remove 1 connecting bolt between the transmission

assembly and the engine from the starter motor mounting
hole.
3) Remove 1 connecting bolt between the transmission

assembly and the rear end of the engine middle part.
EM

assembly to the engine lower part.
assembly.
Re-assembly
1. Assemble the power assembly (JLE-4G18TDB_6AT).
1) Fix the engine assembly, and install the transmission
assembly onto the engine assembly horizontally.
2) Install and tighten three connecting bolts between the

engine assembly and the upper end of the transmission.
Torque:
M12: 60 N.m (Metric) 44.28 lb-ft(English)
EM
3) Install and tighten 2 connecting bolts between the

transmission assembly and the lower end of the engine.
Torque:

engine assembly and the middle part of the transmission.
Torque:
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5) Rotate the damping pulley component, and successively

install 6 bolts connecting the hydraulic torque converter.
2. Assemble the power assembly (JLE-4G18TDB_6MT).

assembly on the engine assembly in parallel.
EM 2) Install and tighten 3 connecting bolts between the
engine assembly and the upper end of the transmission.
Torque:

transmission assembly and the lower end of the engine.
Torque:
4) Install and tighten 1 connecting bolt between the engine

assembly and the transmission middle part rear end.
Torque:
EM
5) Install and tighten 1 connecting bolt between the engine

assembly and the transmission from the starter motor
mounting hole.
Torque:
3. Install the starter motor (6AT)

4. Install the starter motor (6MT)
On-board Installation
1. Install the power assembly (JLE-4G18TDB_6AT).
1) Place the power assembly below the engine
compartment, and lift the power assembly.
2) Install 2 connecting nuts and 1 bolt between the right
engine vibration isolator and the engine support.
Torque:
M12 Hexagon flange nut:
80 N.m (Metric) 59.04 lb-ft(English)
M12 Hexagon flange bolt:
Notice
Adjust the power assembly direction if the bolts are installed
with difficulty.
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3) Install 3 connecting bolts between the left engine

vibration isolator and the transmission.
Tightening torque: 60 N·m (Metric) or 44.28 lb-ft (English)
4) Install 2 connecting bolts between the engine front

bracket and the engine.
Tightening torque: 70 N·m (Metric) or 51.66 lb-ft (English)
EM
5) Install the through bolt connecting the front vibration

Notice
The following steps are used to connect the gearshift flexible
shaft assembly [only applicable to power assembly
(JLE-4G18TDB_6AT)].
6) Connect the gearshift flexible shaft assembly to the
gearshift rocker arm subassembly.
7) Connect the gear selector flexible shaft assembly to the
bracket.
EM
Notice
The following steps are used to connect the cooling system
pipeline.
8) Connect the radiator water outlet hose to the thermostat
cap assembly, fix the clamp.
9) Connect the radiator water inlet hose to the engine

water outlet hose, fix the clamp.
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Notice
The following steps are used to connect the A/C system
pipeline.
10) Connect the A/C heater water outlet pipe 1 to the
engine heater water outlet pipe component.
11) Connect the A/C heater water inlet pipe 2 to the engine
heater water pipe component tee joint.
EM 12) Connect the compressor suction hose assembly to the

compressor assembly.
13) Connect the compressor exhaust hose to the
Notice
The following steps are used to connect the vacuum booster
hose.
14) Connect the vacuum booster hose to the vacuum
pump assembly.
Notice
The following steps are used to connect the fuel pipeline.
15) Connect the engine oil supply hose 1 to the engine
metal fuel pipe component.
16) Connect the canister inlet control valve hose to the
engine canister control valve air inlet pipe component 2.
EM
Notice
The following steps are used to connect the engine harness
assembly [power assembly (JLE-4G18TDB_6AT) ].
17) Connect the engine harness connector to the relay
box.
18) Connect the power fuse of engine to the relay.
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19) Connect the power wire of power steering system to

the positive pole of battery.
EM
21) Connect the engine harness and instrument harness

assembly
22) Connect the engine harness and the bottom plate
harness assembly.
23) Connect the A/C pressure switch harness connector
EM
2. Install the power assembly (JLE-4G18TDB_6MT).

1) Place the power assembly below the engine
compartment, and lift the power assembly.
2) Install 2 nuts and 1 bolt connecting the right engine
vibration isolator to the engine support.
Torque:
M12 Hexagon flange nut:
M12 Hexagon flange bolt:
Notice
Adjust the power assembly direction if the bolts are installed
with difficulty.
3) Install 3 connecting bolts between the left engine
vibration isolator to the left bracket. [Power assembly
(JLE-4G18TDB_6MT)]
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4) Install 2 connecting bolts between the engine front

bracket and the engine.
5) Install the through bolt connecting the front vibration

EM
Notice
The following steps are used to connect the gearshift flexible
shaft assembly [only applicable to power assembly
(JLE-4G18TDB_6MT)].
6) Connect the gearshift flexible shaft 1 and the shift level
component.
7) Connect the gear selector flexible shaft 2 to the shift
level component.
8) Fix the selector flexible shaft assembly to the bracket.
Notice
The following steps are used to connect the cooling system
pipeline.
9) Connect the radiator water outlet hose to the thermostat
cap assembly, fix the clamp.
EM
10) Connect the radiator water inlet hose to the engine

water outlet hose, fix the clamp.
Notice
The following steps are used to connect the A/C system
pipeline.
11) Connect the A/C heater water outlet pipe 1 to the
engine heater water outlet pipe component.
12) Connect the A/C heater water inlet pipe 2 to the engine
heater water pipe component tee joint.
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13) Connect the compressor suction hose assembly to the

14) Connect the compressor exhaust hose to the
Notice
The following steps are used to connect the vacuum booster
hose.
EM 15) Connect the vacuum booster hose to the vacuum
pump assembly.
Notice
The following steps are used to connect the fuel pipeline.
16) Connect the engine oil supply hose 1 to the engine
metal fuel pipe component.
17) Connect the canister inlet control valve hose to the
engine canister control valve air inlet pipe component 2.
Notice
The following steps are used to connect the engine harness
assembly [applicable to power assembly
(JLE-4G18TDB_6AT)].
18) Connect the engine harness connector to the relay
box.
EM
19) Connect the power fuse of engine to the relay.
20) Connect the power wire of power steering system to

the positive pole of battery.
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22) Connect the engine harness and instrument harness

assembly
23) Connect the engine harness and the bottom plate
EM harness assembly.
24) Connect the A/C pressure switch harness connector


4. Install the three-way catalytic purifier assembly.
5. Install the subframe.
8. Install the power takeoff (4WD)
9. Install the transmission shaft (4WD)
11. Install the canister solenoid valve.
12. Install the left and right engine guard plate of the engine. EM
16. Fill the transmission gear oil.
17. Install the front wheels.
20. Install the battery tray.
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EM - 94 JLE-4G18TDB mechanical System - Crankshaft rear oil seal component
Crankshaft Rear Oil Seal Component

Component
Engine trim cover
EM
JLE-4G18TDB mechanical System - Crankshaft rear oil seal component EM - 95
Air flowmeter
Engine intake hose

EM
Air filter element
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Negative battery cable
Positive battery cable
EM
Battery

EM
Vehicle wheel nut
Wheel assembly
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EM


EM
Left constant velocity drive shaft assembly (4G18TD_6MT)
Right front constant velocity drive shaft assembly (4G18T_6AT)
Left constant velocity drive shaft assembly (4G18TD_6AT)
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EM
Torque manager assembly
Intermediate shaft
Power take off (PTO)


EM
Right longitudinal beam assembly of
front suspension
Left longitudinal beam assembly
of front suspension
assembly
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EM

Front oxygen sensor
EM
Rear oxygen sensor
Assembly
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EM
Starter motor (MT)

EM
Starter motor (AT)
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Clutch pressure plate assembly
EM
Clutch driven disc assembly
Removal
6. Remove the engine trim cover. Refer to "Engine trim cover" EM
pipe”
14. Remove the engine left/right guard plate Refer to “Engine
15. Drain the engine oil. Refer to “Drainage and filling of
engine oil”
“Front constant velocity drive shaft”
to "Transmission shaft assemble (4WD)"
19. Remove power take off (four-wheel drive). Refer to
"Power take off"
23. Remove the front suspension crossbeam. Please refer to
"Front suspension crossbeam assembly"
24. Remove the starter motor. Refer to “Starter motor AT”.
25. Disassemble the clutch assembly. Refer to "Clutch
assembly".
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26. Disassemble the flywheel (MT)/drive disc (AT).

1) Use special tools: 47Z01305A, fix dual mass flywheel
assembly (JLE-4G18TDB-6MT) /drive disc
(JLE-4G18TDB-6AT).
2) Remove the flywheel bolt according to graphical order.
Notice
Leave one bolt on the dual mass flywheel assembly
(JLE-4G18TDB-6MT)/the drive disc upper part
(JLE-4G18TDB-6AT) to prevent flywheel from dropping.
3) Firmly grasp the dual mass flywheel assembly
(JLE-4G18TDB-6MT) and remove the last bolt, take down
the dual mass flywheel assembly (JLE-4G18TDB-6MT)
and gasket (JLE-4G18TDB-6MT).
Warning
Pay attention to preventing the dual mass flywheel assembly
EM from falling (JLE- 4G18TDB-6MT) while removing the last
bolt.
4) Firmly grasp the drive disc (JLE-4G18TDB-6AT) and

disassemble the last bolt, take down the drive disc
(JLE-4G18TDB-6AT) and the drive disc gasket
(JLE-4G18TDB-6AT).
Warning
Pay attention to preventing the drive disc
(JLE-4G18TDB-6AT) from falling while removing the last bolt.
27. Remove crankshaft rear oil seal component

1) Remove 8 fixing bolts of the rear oil seal component.
2) Take down the rear oil seal component.
Notice
Be careful not to damage the crankshaft journal during
removal. Before using the screwdriver, please wrap the head
of screwdriver with adhesive tape.
Installation
1. Install crankshaft rear oil seal component

1) Use a special tool to install the crankshaft rear oil seal
component.
2) Install and tighten 8 fixing bolts of the rear oil seal
component.
2. Install the flywheel (MT)/drive disc (AT).
1) Install the engine flywheel bolts and tighten the eight
bolts evenly according to the sequence in the figure.
(JLE-4G18TDB+6MT) EM
Torque: 40 N·m+40°(Metric) 29.52 lb-ft +40°(English)
2) Install the engine flywheel bolts and tighten the eight
bolts evenly according to the sequence in the figure.
(JLE-4G18TDB+6AT)
3. Install the clutch assembly
12. Install the left and right engine guard plate.
15. Fill the engine oil.

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EM - 110 JLE-4G18TDB mechanical System - Timing chain tensioner
Timing Chain Tensioner

Component
Engine trim cover
EM
JLE-4G18TDB mechanical System - Timing chain tensioner EM - 111
EM
Vehicle wheel nut
Wheel assembly
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EM


EM
Right longitudinal beam assembly

of front suspension


assembly
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Front oxygen sensor
Rear oxygen sensor
EM
Assembly

Engine right vibration isolator assembly (4G18TD)
Engine rear bracket
EM
Engine left vibration isolator assembly (4G18TD)
Engine left bracket (4G18 + 6MT)
Engine assembly (4G18TD + 6MT)
Engine front vibration isolator assembly (4G18TD)
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Engine rear bracket
EM
Engine assembly (4G18TD + 6AT)

EM
Drive belt
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EM
Cylinder block
Timing chain cover

EM
Timing chain upper guide rail
Timing chain
assembly
Cylinder block
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Removal
5. Remove the engine trim cover. Refer to "Engine trim cover"
7. Lift the vehicle
9. Remove the engine right guard plate Please refer to "Left
10. Drain the engine oil. Refer to "Drainage and filling of
engine oil"
“Damping belt pulley component”
EM
13. Remove the timing chain cover
1) Remove 3 fixing bolts in the center of timing chain cover,

and take down the timing chain cover blimp.
2) Remove 25 bolts on the edge of timing chain cover, and

take down the timing chain cover.
14. Remove timing chain tensioner

1) Make original location marks on the intake VVT and
chain with a marking pen, and fix the chain and camshaft
with a suitable tool.
2) Install the timing chain tensioner locking special tool, to
prevent the spring in the tensioner from popping out when
removing the tensioner.
Special tool: 15P0025
EM
3) Remove 2 fixing bolts of timing chain tensioner

component.
Notice
At this time do not rotate the crankshaft in order to prevent
the crankshaft timing sprocket teeth slipping.
15. Remove the oil pump chain component.

1) Remove the fixing bolt 1 of engine oil pump chain
tensioning rail, and remove engine oil pump chain
tensioning rail 2 together.
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2) Take off the oil pump chain and the crankshaft sprocket.
Notice
If chain wheel is damaged and in abnormal rotation, replace
engine oil pump assembly.
16. Remove the timing chain.

1) Remove the fixing bolt 1 of timing chain tensioning rail,
and the fixing bolt 2 of timing chain guide rail.
EM
2) Remove the timing chain guide rail and timing chain

tensioning rail.
3) Remove the timing chain upper guide rail.
EM
4) Remove timing chain component.
17. Remove the balance shaft chain component.

1) Remove the balance shaft chain tightener component.
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2) Remove 5 fixing bolts on the balance shaft chain

tensioner rail and the upper and lower rails, and take down
the balance shaft chain component, chain tensioner rail
and upper and lower rails.
Check
1. Check on timing chain
1) Check timing chain guide rail for cracking, wear and
tear.
EM
Notice
If the timing chain guide rail surface wear is deeper than 1
mm (0.04in), replace the timing chain guide rail.
2) Check abrasion depth of upper guide rail of upper chain.
Notice
If the wear depth is greater than the standard value, replace
the upper guide rail of upper chain.
3) Check the wear depth of the timing chain tensioning rail.
Notice
If the timing chain tensioner rail components surface wear is
deeper than 1 mm (0.04 in), replace the timing chain
tensioner rail.
4) Check the wear of the oil pump chain tensioner rail.
Notice
If the oil pump chain tensioner rail surface wear is deeper
than 1 mm (0.04 in) then replace the oil pump chain tensioner
rail.
5) Check whether the balance shaft chain guide rail is
worn.
Notice
If the balance shaft chain upper/lower guide rail surface wear
is deeper than 1 mm (0.04 in), then replace the balance shaft
chain upper/lower guide rail.
6) Check the wear of the balance shaft chain tensioner rail.
Notice
If the balance shaft chain tensioner rail surface wear is
deeper than 1 mm (0.04 in) then replace the balance shaft
chain tensioner rail.
7) Check the intake camshaft timing sprocket teeth and
chain for excessive wear, broken, or stuck with timing
chain.
8) Check the exhaust camshaft timing sprocket teeth and
chain for excessive wear, broken, or stuck with timing
chain.
9) Check the crankshaft timing sprocket teeth and chain for

excessive wear,broken, or stuck with timing chain.
10) Check the crankshaft oil pump sprocket teeth, oil pump
sprocket teeth and oil pump chain for excessive wear,
damage, or stuck with the oil pump chain, etc.
11) Check the balance shaft sprocket teeth and chain for
excessive wear, broken, or stuck with balance shaft chain.
12) Check the timing chain tightener component for
damage. If damaged, replace the timing chain tightener
component. EM
Installation
1. Install the balance shaft chain component.
1) Install balance shaft chain, while rotating crankshaft or
balance shaft, so that the three markers on the balance
shaft chain (blue link) align with the mark on balance shaft
1 (a dot on the teeth), 2 (blue link) with mark of balance
shaft 2 (a dot on the teeth), and 3 (yellow link) with balance
shaft drive sprocket mark (a dot on the surface).
2) Install the balance shaft chain guide rail, and tighten 5

fixing bolts of the balance shaft chain guide rail.
Torque: 22.5 N·m(Metric) 16.6 lb-ft (English)
Notice
The balance shaft chain tensioner bolt shall be applied with
anaerobic threadlocker (Loctite, 243).
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3) Install and tighten balance shaft chain tensioner rail.

2. Install the engine oil pump chain component.

1) Install the crankshaft sprocket
Notice
EM The double wedge alignment mark on camshaft timing
sprocket 1 is inserted in groove on the balance shaft drive
sprocket 2 correspondingly to ensure they are refitted in
place.
2) Install the oil pump chain.

3) Install the oil pump chain tensioner rail 1 and the oil
pump chain tensioner rail bolt 2, and the bolt shall be
applied with anaerobic threadlocker (Loctite, 243).
3. Install the timing chain.

1) Confirm the three timing marking external link on the

timing chain component.
Notice
There are two timing mark outer links on the oil pump
chain, and two timing mark outer links (yellow) are aligned
to oil pump sprocket timing mark; one timing mark outer
link (yellow) is aligned to the crankshaft oil pump sprocket
timing mark.
EM
2) When installing the timing chain component, align the

timing mark 1 outer link on the chain with the timing mark
of the exhaust VVT sprocket (with a dot in the middle of the
tooth), align the timing mark 2 outer link on the chain with
the timing mark of the intake VVT sprocket (with a dot in
the middle of the tooth), and align the timing mark 3 on the
chain with the crankshaft timing sprocket mark (with a dot
on the crankshaft sprocket plane).
Notice
There are total three outer links on the timing chain, including
two outer links (a difference of 10 links between the two) and
aligned with the intake and exhaust VVT sprocket timing
marks.
Notice
If intake and exhaust VVT sprocket timing mark is difficult to
align, rotate the camshaft to make it aligned.
3) Install upper guide rail of timing chain.
Notice
If the timing chain is provided with a guide rail, turn the intake
camshaft anticlockwise to loosen timing chain.
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4) Install and tighten the fixing bolt 1 of timing chain fixed

guide rail and fixing bolts 2 on the timing chain tensioning
rail.
4. Install the timing chain tensioner.

1) Install the timing chain tensioner and tighten the 2 fixing
bolts.
EM Torque:10.5 N (Metric) 7.74 lb-ft (English)
Notice
Pull out the special tool of the tensioner lock pin.

1) Install 25 timing chain cover fixing bolts around the
timing chain cover, but do not tighten them.
Notice
Tighten the bolts in two times in the sequence of first middle
and then both sides.
Torque: First time: 10 N·m(Metric) 7.38 lb-ft (English)
Second time: 22.5 N (metric) 16.6 lb-ft (English)
2) Install 3 fixing bolts between timing chain cover blimp

and timing chain cover.
13. Install the upper trim panel connecting plate of fender EM
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EM - 130 JLE-4G18TDB mechanical System - Camshaft
Camshaft
Component
Engine trim cover
EM
JLE-4G18TDB mechanical System - Camshaft EM - 131
EM
Vehicle wheel nut
Wheel assembly
N·m (Ib – ft )Specified torque
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EM


EM
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EM
Intermediate shaft
Power takeoff (PTO)

Front oxygen sensor
EM
Rear oxygen sensor

Assembly
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Ignition coil
EM
EM
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Cylinder head cover
EM
Engine assembly
Non-reusable parts
High pressure fuel pump

High pressure fuel pump seat
EM
Cylinder head
Oil pump tappet
Cylinder head gasket assembly
Cylinder block
Non-reusable parts
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OCV valve component

EM
EM
Engine rear bracket
Engine rear vibration isolator assembly (4G18TD)
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Engine rear bracket
EM

EM
Drive belt
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EM
Cylinder block
Timing chain cover

EM
Timing chain

assembly
Cylinder block
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Camshaft bearing cap
Exhaust camshaft component
Intake camshaft component
EM
Exhaust VVT
component
Intake VVT component
Cylinder head
Removal
Refer to "Decorative covering parts of engine compartment" EM
9. Lift the vehicle
11. Remove the engine left/right guard plate Refer to “Left
engine oil"
13. Drain the engine coolant. Refer to “Drainage and filling for
engine coolant”
"Front constant velocity drive shaft"
16. Remove the ignition coil. Refer to "Ignition coil
component"
17. Remove the camshaft position sensor. Refer to
"Camshaft".
18. Remove the cylinder head cover assembly. Refer to
"Cylinder head cover assembly"
19. Remove high pressure fuel pump. Refer to "Fuel pump
with the fuel sensor assembly".
20. Remove the oil control valve. Refer to “oil control valve
(OCV)”.
21. Remove the dipstick tube component.
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22. Remove the drive belt. Refer to "Drive belt"

25. Remove the timing chain cover. Refer to "Timing chain
and tensioner"
26. Remove the timing chain tensioner. Refer to the "Timing
chain and tensioner"
27. Remove the timing chain. Refer to "Timing chain and
tensioner"
28. Remove the intake camshaft VVT actuator assembly
1) Remove intake air VVT actuator assembly fixing bolt.
2) And take down the intake air VVT actuator assembly.
Notice
EM Remove the camshaft VVT actuator fixing bolt with a
wrench holding the camshaft.
29. Remove the exhaust VVT actuator assembly

1) Remove the exhaust VVT actuator assembly fixing bolt.
2) And take down the exhaust VVT actuator assembly.
Notice
Remove the camshaft VVT actuator fixing bolt with a
wrench holding the camshaft.
30. Remove the exhaust camshaft

1) Gradually loosen the camshaft bearing cap bolts in the
order as shown in the figure and loosen by half or one
circle each time.
Notice
Carefully remove the camshaft to prevent from scratching
or damaging camshaft working surface or bearing surface.
EM
2) Take down the camshaft bearing cap.
3) Remove the intake camshaft.
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4) Remove the exhaust camshaft.
Check
1. Check the camshaft.
1) Check the camshaft and cylinder head working surface
EM for scratches, cracks and abnormal wear, and replace
parts if necessary. Check the camshaft bearing cap joint
surface for scratches, cracks, deformation and warping,
and replace the camshaft bearing cap if necessary.
2) Check radial play eccentricity of camshaft. Put the #1
and #5 journals of camshaft on "V" frame, and measure
radial play eccentricity of camshaft.
Maximum wear: 0.03 mm (Metric) 0.001 in (English)
Notice
If it exceeds the technical specifications, replace the
camshaft.
3) Check the protuberance of camshaft: Measure the
height of the camshaft lobe in the two positions as shown.
If it is less than the specified value, replace the camshaft.
Standard height:
Intake camshaft: 38.20 ~ 38.30 mm (Metric), 1.5039
~1.5078in ( English).
Exhaust camshaft: 36.77 ~ 36.87 mm(Metric), 1.447 ~1.451in
(English).
Notice
camshaft.
4) Measure the journal diameter in the two points (A and B
points) along the X and Y directions. Replace the camshaft
if it is less than the specified value.
Standard diameter:
24 mm (Metric) 0.944 in (English)
Minimum diameter:
23.947 mm (Metric) 0.942 in (English)
Notice
camshaft.
5) Check camshaft axial clearance: Remove the roller

rocker arm hydraulic tappet component, clean the cylinder
head, camshaft, camshaft bearing cap, install the camshaft
bearing cap and fasten the camshaft bearing cap fixing bolt
as specified, and measure the camshaft axial clearance.
Notice
If it is not within the specification, replace cylinder head or
camshaft.
Standard end gap: Intake side: 0.1 ~ 0.174 mm (Metric)
0.003 ～ 0.0068 in( English ) EM
Exhaust side: 0.1 ~ 0.174 mm (Metric)
0.003 ～ 0.0068 in( English )
The maximum axial movement of crankshaft: 0.174 mm
(Metric) 0.00696 in (English).
6) Check on variable valve timing actuator:
a. Confirm the notch on the variable valve timing actuator
rotor aligns and fits with the projections on the cover.
b. If the notch and projections are not aligned, rotate the
rotor by hand so that it reaches the valve timing delay
position until positioning.
c. If you still cannot fix them when the rotor notch and the
cover groove are aligned, replace the variable valve timing
actuator.
Installation
1. Install camshaft
1) Apply little lubricating oil to the exhaust camshaft journal
and camshaft bearing cap.
2) Install exhaust camshaft.
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3) Apply little lubricating oil to the intake camshaft journal.

4) Install intake camshaft.
Notice
Apply lubricating grease to journals 1 and 6 before installation
of intake camshaft.
Apply lubricating grease to journal 1 before installation of
exhaust camshaft.
5) Apply evenly special engine sealant on camshaft

bearing cap sealing surface, and lubricate the camshaft
journal and camshaft cap working surface with appropriate
EM amount of engine oil.
6) Install camshaft bearing cap.

7) Tighten camshaft bearing cap fixing bolts in the

sequence as shown, and tighten sequentially according to
the following steps.
Torque:
First time: 5 N·m(Metric) 3.69 lb-ft (English)
Second time: 8 N·m(Metric) 5.9 lb-ft (English)
Notice
Tighten the bolts by several stages. Do not tighten at once
which may damage the camshaft and camshaft cap. EM
2. Install intake VVT actuator assembly

1) Install intake VVT actuator assembly.
2) Tighten and fasten the intake air VVT actuator assembly
fixing bolt.
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3. Install the exhaust VVT actuator

1) Install the exhaust VVT actuator assembly.
2) Tighten and fasten the exhaust VVT actuator assembly
fixing bolt.
4. Timing chain
5. Timing chain tensioner
6 .Timing chain cover
7. Crankshaft front oil seal
8. Damping pulley component
9. Drive belt
10. Dipstick tube assembly
11. Engine front bracket
12. Oil control valve
13. High pressure fuel pump
EM 14. Engine cylinder head cover assembly
16. Ignition coil
18. Install the left and right engine guard plate of the engine.
JLE-4G18TDB mechanical System - Cylinder head assembly EM - 155
Cylinder Head Assembly

Component
EM
Engine trim cover
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EM - 156 JLE-4G18TDB mechanical System - Cylinder head assembly
EM
Vehicle wheel nut
Wheel assembly

Engine trim cover EM
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Front oxygen sensor
Rear oxygen sensor
EM

Assembly

EM
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Cylinder head cover
EM
Engine assembly
Non-reusable parts
High pressure fuel pump
High pressure fuel pump seat

EM
Cylinder head
Oil pump tappet
Cylinder head gasket assembly
Cylinder block
Non-reusable parts
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Engine assembly (4G18TD
OCV valve component

EM
Engine front vibration isolator assembly（4G18TD）
EM
Engine right vibration isolator assembly（4G18TD）
Engine left bracket（4G18+6MT）
Engine assembly（4G18TD+6MT）
Engine rear bracket
Engine left vibration isolator assembly（4G18TD）
Engine rear vibration isolator assembly（4G18TD）
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Engine rear bracket
EM
Engine assembly（4G18TD+6AT）
Engine right vibration isolator assembly（4G18TD）

EM
Drive belt
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EM
Cylinder block
Timing chain cover

EM
Timing chain
Timing chain tensioner assembly
Cylinder block
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Bearing cover of camshaft
Exhaust camshaft component
Intake camshaft component
EM
Exhaust VVT component
Intake VVT component
Cylinder head
Removal
Refer to "Decorative covering parts of engine compartment" EM
9. Lift the vehicle
engine oil"
engine coolant”
16. Remove the ignition coil. Refer to "Ignition coil
component"
17. Remove the camshaft position sensor. Refer to
"Camshaft".
18. Remove the cylinder head cover assembly.Refer to
19. Remove the vacuum pump.
20. Remove the high pressure fuel pump. Refer to the "Fuel
rail injector subassembly".
21. Remove the oil control valve. Refer to the "Oil control
valve (OCV)".
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24. Remove the damping pulley component. Refer to
25. Remove the crankshaft front oil seal. Refer to “Crankshaft
front oil seal”
and tensioner"
tensioner"
29. Remove the intake VVT actuator. Refer to "Camshaft".
30. Remove the exhaust VVT actuator. Refer to "Camshaft".
31. Remove the camshaft. Refer to "Camshaft"
32. Remove cylinder head assembly
EM
1) Remove the cylinder head bolts according to the

2) Remove the cylinder head bolts.

3) Remove the cylinder head bolt gasket with a magnetic

stick.
EM
4) Remove cylinder head assembly.

5) Remove the cylinder head gasket.
33. Remove the valve assembly.

1) Use a general tool to compress the valve springs.
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2) Remove the valve lock plate with a magnetic stick.
3) Remove the valve spring retainer, valve spring, valve

spring shim and valve in sequence.
EM
4) Remove the oil seals with appropriate tools.

Check
1. Check the cylinder head
1) Measure warpage of contact surface between the
cylinder head assembly and cylinder block with precision
straight edge and feeler gauge.
2) Check whether there are cracks on the cylinder head.
EM
2. Check valve clearance

1) Assemble the valve component.
2) Assemble the intake/exhaust camshaft.
3) Turn the intake/exhaust camshaft, and make sure that
the clearance of parts such as valve and spring has been
fully released.
intake/exhaust valve of cylinder No. 1 fully closed.
5) Use a feeler gauge to measure the valve clearance
indicated by arrow in the figure (the clearance between the
smallest location of cam and the valve tappet), and record
the valve position and clearance.
6) If the standard value of valve clearance is exceeded,
replace the tappet.
Intake: 0.22-0.28 mm (Metric) or 0.0087-0.0110 in (English);
Exhaust: 0.27~0.33 mm (Metric) 0.0106~0.0130 in (English)

intake/exhaust valve of cylinder 4 fully closed (turn the
camshaft for 1/2 round).
8) Use a feeler gauge to measure the valve clearance
indicated by arrow in the figure (the clearance between the
smallest location of cam and the valve tappet), and record
the valve position and clearance.
9) If the standard value of valve clearance is exceeded,
replace the tappet.
Intake: 0.22-0.28 mm (Metric) 0.0087-0.0110 in (English);
Exhaust: 0.27~0.33 mm (Metric) 0.0106~0.0130 in (English)
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Adjust valve clearance.

1. If the intake valve tappet has to be replaced, then in
accordance with the sequence as indicated in the figure,
half a round to a round loosened every time.
Notice
or damaged.
2. If the exhaust valve tappet has to be replaced, then in

accordance with the sequence as indicated in the figure,
EM half a round to a round loosened every time.
Notice
or damaged.
3. Remove the camshaft.

Notice
Please take out the camshaft carefully from bearing seat;
otherwise the working face or bearing face of camshaft may
get damaged.
4. Take out the valve tappet which exceeds the standard

value of clearance, use an outside micrometer to measure its
thickness, and calculate the thickness of new valve tappet in
accordance with the following formula.
Exhaust: A=B+C-0.23 mm(0.01 in)
Exhaust: A=B+C-0.32 mm(0.13 in)
A: New valve tappet thickness
B: Used valve tappet thickness
C: Measured valve clearance
Notice EM
New valve tappet chosen should be near the value calculated
as much as possible.
The thickness of valve tappet may be selected by reference
to the “Repair Specification - JLD-4G20 24 Engine System –
Specification Table for Intake/Exhaust Valve Tappet”.
You may also select the valve tappet which meets the
requirements on the basis of the measured value and by
reference to the “Repair Specification - JLD-4G20 24 Engine
System – Table for Selection of Intake/Exhaust Valve Tappet”.
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Installation
1. Install the valve component.
1) Use special tool 47Z01104A to install valve oil seal.
2) Use a general tool to compress the valve springs and

EM install the valve locking pieces.
3) Confirm the valve lock clamp is installed in place, slowly
remove the valve spring compression tool, and lightly
knock at the valve with wooden hammer to make it
installed in place.
Warning!
The force can't be too much, or else, the valve spring may
cause personal injury.
2. Install cylinder head assembly

1) Clean the sealing surface of the cylinder head and
engine body.
2) Install a new cylinder head gasket component.

Notice
The cylinder head gasket component is a disposable part,
and shall be replaced whenever it is removed!
3) Align the locating pin on the cylinder head assembly,
and install the cylinder cover on cylinder block.
EM
4) Install the cylinder head bolt gaskets.
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5) Install the cylinder head bolts.

6) In accordance with the sequence as indicated in the
figure, tighten up the cylinder head bolts.
Torque: First time: 30 N·m (Metric) or 22.14 lb-ft (English)
Second time: 35 N (Metric) 25.83 lb-ft (English)
Third time: 95 N (Metric) 70.11 lb-ft (English)
3. Install camshaft
5. Install exhaust VVT actuator
6. Timing chain
7. Timing chain tensioner
8 .Timing chain cover
9. Crankshaft front oil seal
10. Damping pulley component
11. Drive belt
EM 12. Dipstick tube assembly
13. Oil control valve
14. High pressure fuel pump
15 Vacuum pump
16. Engine cylinder head cover assembly
18. Ignition coil
19. Install the three-way catalytic purifier assembly
JLE-4G18TDB mechanical System - Cylinder cover gasket component EM - 179
Cylinder cover gasket component

Removal
1. Open the engine hood
6. Remove the engine trim cover. Refer to "Engine trim cover" EM
9. Lift the vehicle
11. Remove the engine left/right guard plate Refer to “Left and
12. Drain the engine oil. Refer to "Drainage and filling of engine
oil"
engine coolant”
15. Remove the three-way catalytic converter assembly Refer to
"Exhaust manifold"
16. Remove the ignition coil. Refer to "Ignition coil component"
17. Remove the camshaft position sensor. Refer to "Camshaft".
18. Remove the cylinder head cover assembly. Refer to "Cylinder
head cover assembly"
20. Remove the high pressure fuel pump. Refer to the "Fuel rail
injector subassembly".
21. Remove the oil control valve. Refer to "Oil control valve
(OCV)".
24. Remove the damping pulley component. Refer to “Damping
belt pulley component”
25. Remove the crankshaft front oil seal. Refer to “Crankshaft
front oil seal”
26. Remove the timing chain cover. Refer to "Timing chain and
tensioner"
tensioner"
29. Remove the intake camshaft VVT actuator assembly
30. Remove the exhaust camshaft VVT actuator assembly
31. Remove the exhaust camshaft. Please refer to "Camshaft".
32. Remove the cylinder head assembly. Please refer to
"Cylinder head assembly".
33. Remove the cylinder head gasket component
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EM - 180 JLE-4G18TDB mechanical System - Cylinder cover gasket component

cylinder block
EM
JLE-4G18TDB mechanical System - Cylinder cover gasket component EM - 181
Installation
1. Install the head gasket component.
1) Install a new cylinder head gasket component.
Notice
The cylinder head gasket component is a disposable part,
and shall be replaced whenever it is removed!
2. Install cylinder head assembly
3. Install camshaft
5. Install exhaust VVT actuator EM
7. Install the timing chain tensioner .
9. Install the crankshaft front oil seal.
12. Install the dipstick tube component
13. Install the oil control valve
14. Install the high pressure fuel pump
15. Install the vacuum pump.
16. Install engine cylinder head cover assembly
17. Install camshaft position sensor
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EM - 182 JLE-4G18TDB mechanical System - Balance shaft
Balance Shaft
Component
Engine trim cover
EM
JLE-4G18TDB mechanical System - Balance shaft EM - 183
Air flowmeter
Engine intake hose

EM
Air filter element
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Battery negative cable
EM Battery pressing plate
Battery
Battery bracket
Battery harness bracket
EM
Engine ECU (4G18TD)
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EM
Vehicle wheel nut
Wheel assembly

EM
Engine right guard plate

assembly
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EM

EM
Intermediate shaft
Power takeoff (PTO)
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Front suspension right longitudinal beam

assembly
EM
Front suspension left longitudinal

beam assembly

assembly
EM
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Front oxygen sensor
Rear oxygen sensor
EM
Three-Way Catalytic Converter Assembly

EM
Engine assembly (4G18 + 6MT)
Engine rear bracket
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Engine rear bracket
EM

EM
Drive belt
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EM
Cylinder block
Timing chain cover

EM
Timing chain
Timing chain tensioner component
Cylinder block
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Cylinder block
EM
Balance shaft I sheath
Balance shaft component I
Balance shaft component II

Idler pulley fixed axle
Idler pulley component of balance shaft

Removal
procedure for fuel pressure". EM
8. Recover the refrigerant. Refer to "Recovery and filling of
A/C refrigerant"
pipe”
10. Remove the air filter assembly. Refer to "Air filter"
11. Remove the battery. Refer to Battery cable.
12. Remove the battery bracket. Refer to "Battery bracket"
13. Remove the engine ECU. Refer to "Engine ECU"
engine oil"
engine coolant”
21. Drain the transmission oil. Please refer to Transmission
oil
22. Remove the solenoid valve of carbon canister. Please
refer to “Control valve of carbon canister”
23. Remove the front constant velocity drive shaft. Please
refer to "Front constant velocity drive shaft"
to "Transmission shaft assemble (4WD)"
25. Remove power take off (four-wheel drive). Refer to
"Power takeoff"
31. Remove the power assembly. Refer to "Engine assembly"
32. Remove the flywheel. Refer to "Power assembly".
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35. Remove the damping pulley component. Refer to
“Damping pulley component”
and tensioner"
tensioner"
39. Remove the oil pump chain. Refer to "Timing chain and
tensioner"
40. Remove balance shaft chain. Refer to "Timing chain and
tensioner"
41. Remove the balance shaft
1) Remove the fixing bolt of idler pulley component of
EM balance shaft, take down the idler pulley component.
Notice
Balance shaft 2 bevel gear mark 2 is in the middle of balance
shaft idler bevel gears mark 3 and 4.
2) Remove the fixed axle of idler pulley of balance shaft.

3) Remove the fixing bolt of balance shaft components I

and II, take down the balance shaft components I and II.
4) Take out the balance shaft sheath.
EM
Installation
1. Install the crankcase and balance shaft.
1) Apply the oil on the internal surface of the balance shaft
bearing.
2) Install the balance shaft bearing onto the crankcase.
3) Install and tighten the fixing bolts of balance shafts 1

and 2.
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4) Install the fixed axle of idler pulley of balance shaft.
5) Install balance shaft idler pulley component, and tighten

the fixing bolt 1 of balance shaft idler pulley component.
Notice
EM Balance shaft 2 bevel gear mark 2 is in the middle of
balance shaft idler bevel gears mark 3 and 4.
Notice
Do not forget to put in the balance shaft idler pulley fixing
bolt gasket.
Second time: 90°
Notice
After installing the idler pulley assembly and balance shaft
component Ⅱ, before installing chain, it is not allowed to
rotate the idler pulley assembly of balance shaft and
balance shaft component Ⅱ.
6) After press fitting, the distance from the oil seal
assembly of balance shaft 2 to the rear end face of balance
shaft component 2 ranges from 10.5mm to 12mm. In press
fitting process, prevent the oil seal lip from being scratched
and damaged, and ensure that oil seal assembly end face
of balance shaft 2 is not tipped after assembly. 2 The front
end face (with trademark) of oil seal assembly of balance
shaft 2 faces the rear end of engine.
2. Install the balance shaft chain.

3. Install the oil pump chain.
10. Install the cylinder head cover
11. Install the ignition coil. EM
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EM
JLE-4G18TDB mechanical System - Cylinder block EM - 205
Cylinder Block
Component
EM
Engine trim cover
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EM - 206 JLE-4G18TDB mechanical System - Cylinder block
Air flowmeter
Engine intake hose

Air filter element
EM Lower cover of air filter

Battery negative cable EM
Battery
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Engine ECU (4G18TD)
EM
EM
Vehicle wheel nut
Wheel assembly
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EM


EM
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EM
Intermediate shaft
Power takeoff (PTO)


EM
Right longitudinal beam assembly of

front suspension

of front suspension

assembly
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EM

Front oxygen sensor
EM
Rear oxygen sensor

Assembly
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EM
Starter motor (MT)

EM
Starter motor (AT)
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EM
Engine rear bracket

Engine rear bracket
EM
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EM
Drive belt

Cylinder block
EM
Oil sump
Drain plug
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EM
Cylinder block
Timing chain cover

EM
Timing chain
Timing chain tensioner assembly
Cylinder block
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Cylinder block
EM
Balance shaft I sheath
Balance shaft component I
Balance shaft component II

Idler pulley fixed axle
Idler pulley component of balance shaft

Fuel distribution pipe EM
Fuel injector
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Removal
5. Remove the upper trim panel assembly of right fender.Refer to
8. Recover the refrigerant. Refer to "Recovery and filling of A/C
refrigerant"
9. Remove the air filter intake pipe. Refer to “Air filter intake pipe”
12. Remove the battery bracket. Refer to Battery bracket
13. Remove the engine ECU. Refer to Engine ECU
EM 16. Lift the vehicle
18. Remove the engine left/right guard plate Refer to “Left and
19. Drain the engine oil. PRefer to "Drainage and filling of engine
oil"
engine coolant”
21. Drain the transmission oil. Refer to Transmission oil
24. Remove the transmission shaft (four-wheel drive). Refer to
"Transmission shaft assemble (4WD)"
25. Remove power take off (four-wheel drive). Refer to "Power
take off"
29. Remove the three-way catalytic converter assembly Refer to
"Exhaust manifold"
31. Remove the power assembly. Refer to "Engine assembly"
32. Remove the starter motor. Refer to the "Starter motor MT"
33. Remove the engine assembly. Refer to "Engine assembly"
34. Remove the flywheel. Refer to “Flywheel”
35. Remove the intake manifold assembly. Refer to "Intake
manifold component".
36. Remove the exhaust manifold assembly. Refer to “Intake
manifold component”.
37. Remove the ignition coil. Refer to "Ignition coil component"
38. Remove the camshaft position sensor. Please refer to

"Camshaft".
39. Remove the cylinder head cover assembly. Refer to "Cylinder
head cover assembly"
40. Remove the oil control valve. Refer to "Oil control valve (OCV)".
42. Remove the high pressure fuel pump. Refer to the "Fuel rail
injector subassembly".
45. Remove the alternator. Refer to “Alternator”
46. Remove the A/C compressor. Refer to”Compressor assembly
(JLE-4G18TDB)”. EM
48. Remove the oil sump. Refer to “Oil sump”.
49. Remove the damping pulley component. Refer to “Damping
pulley component”
50. Remove the timing chain cover. Refer to "Timing chain and
tensioner"
51. Remove the timing chain tensioner. Refer to the "Timing chain
and tensioner"
52. Remove the timing chain. Refer to "Timing chain and tensioner"
53. Remove the intake and exhaust camshaft. Please refer to
“Camshaft”.
54. Remove the cylinder head assembly. Refer to "Cylinder head
assembly".
55. Remove the oil pump chain. Refer to "Timing chain and
tensioner"
56. Remove balance shaft chain. Refer to “Balance shaft”.
57. Remove the balance shaft. Refer to “Balance shaft”.
58. Remove the piston connecting rod assembly.
1) Before removing the connecting rod bearing cap, check the

connecting rod side play.
Standard value: 0.018~0.044 mm (Metric) 0.0007~-0.0017
in(English)
Notice
If the clearance exceeds the maximum range, replace the
connecting rod bearing.
Notice
If you replace the connecting rod bearing, the correct connecting rod
bearing bush can be selected according to the connecting rod big
end hole group number on the connecting rod body plus the
connecting rod journal group number on the crankshaft. (Group
number on the connecting rod cap + connecting rod journal group
number on the crankshaft = the number of connecting rod bearing
bush to be used)
2) Rotate the crankshaft, so that the corresponding cylinder piston
is at BDC position. Remove the connecting rod bearing cap bolts.
3) Use hand to hold the connecting rod bolt, remove connecting
rod bearing cap and make position mark for corresponding
cylinder in the bearing cap.
4) Remove the piston connecting rod component.
59. Remove the crankshaft
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1) Check the crankshaft end play.

Standard clearance: 0.005~0.018mm (Metric)
0.0002~-0.0007 in (English)
The maximum clearance: 0.046 mm (Metric) 0.0018 in
(English).
2) Remove the 3 fixing bolts of the intake main bearing cap.
3). Remove 3 fixing bolts of the exhaust main bearing cap.
EM
4). Evenly loosen and remove the 10 main bearing cap bolts
from both sides to the center, as the sequence shown in the
figure.
EM
6) Remove the crankshaft and thrust plate.
60. Remove the piston fuel injector components

1) Remove the set screw of piston cooling nozzle
component, and take down the nozzle.
Check
1. Check connecting rod
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1) Check whether the connecting rod is bent or distorted. If

the rod is bent or distorted, replace the connecting rod.
Parallelism degree: 0.015 (basic length 100mm)
Flatness: 0.04 (basic length 100mm)
2) Check connecting rod bearing
3) Check whether the connecting rod's bottom is worn
4) Check whether the connecting rod's top has scratch.
5) Check whether the crankshaft connecting rod bearing
journal is worn.
6) Install the connecting rod bearing cap

7) Measure the larger end clearance of connecting rod
Clearance measurement ： 0.1~0.26 mm(Metric )
0.0039~0.011 in(English )
EM
Radial direction：0.22~0.44 mm(Metric ) 0.0086~0.0173
in(English )
Notice
Replace the connecting rod if it is out of specification range.
8) Check the fit clearance of connecting rod bearings.

(a) Place a plastic clearance gauge on the connecting rod
journal.
(b) Install connecting rod cap (the forward marking of the
connecting rod cap should face the front end of the
engine), and tighten the connecting rod bolts with specified
torque.
(c) Remove the connecting rod cap.
(d) Measure the maximum clearance point with plastic
clearance gauge.
Standard value: 0.022~0.044 mm (Metric) 0.0009~0.0017
in(English)
Notice
If the clearance exceeds the maximum range, replace the
connecting rod bearing. If you replace the connecting rod
bearing, the correct connecting rod bearing bush can be
selected according to the connecting rod big end hole group
number on the connecting rod body plus the connecting rod
journal group number on the crankshaft. (Group number on
the connecting rod cap + connecting rod journal group
number on the crankshaft = the number of connecting rod
bearing bush to be used)
2. Check connecting rod bearing
1) Check whether the crankshaft connecting rod bearing
journal is worn.
3. Check the piston
1) Check whether the piston has scratch, crack and wear.

2) Measure the diameter of the piston pin hole with caliper
gauge.
Piston pin-hole diameter (mm/in)
23.004 ～ 23.010 mm ； 0.9056 ～ 0.9059
3) Check the fit clearance between the piston pin hole and
the piston pin.
Standard value:
0.004~0.013 mm (Metric) 0.00013~0.00043 in(English)
Notice
If the clearance does not meet the requirements, replace the EM
piston pin, and replace the piston if necessary.
4) Check the clearance fit between the piston pin and the
connecting rod.
5) Check the cylinder bore diameter of the engine body.
Standard value:
φ82.5 mm( Metric ) φ3.248 in( English )
6) Measure the piston diameter with a micrometer at a
distance of 10mm from the piston bottom in the direction
where the micrometer forms a right angle with the piston
pin hole.
Standard value:
φ82.42±0.009 mm( Metric ) φ3.244±0.003 in( English )
7) Check the cylinder fit clearance, which equals that the
measured cylinder bore diameter minus the measured
piston diameter.
Standard value:
0.076 ~ 0.104 mm (Metric)
0.0025 ～ 0.0035 in( English )
Notice
If the clearance is not within range, replace the piston. If
necessary, replace the cylinder block.
8) Check the cylinder bore diameter of the engine body.
Standard value:
φ82.5 mm( Metric ) φ3.248 in( English )
9) Select a set of standard piston rings and use the
clearance gauge to measure piston ring, oil ring closing
clearance.
Closing clearance of oil ring:
Second compression ring closing clearance:
First compression ring closing clearance:
Maximum closing clearance:
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10) Measure the clearance between the piston ring and the
groove along the entire circumference. If it is not within
the specification. Replace the pistons, piston pins, piston
ring and connecting rod as a whole.
Oil ring end clearance:
Second compression ring end clearance
First compression ring end clearance
Maximum end clearance:
4. Check the fit clearance of connecting rod bearing bushes
1) Check for the corrosive pitting and scratching on the
main bearing journal and main bearing bush.
EM 2) Install the upper bearing bush of the crankshaft main
bearing.
3) Place the crankshaft on the cylinder block.
4) Place one plastic clearance gauge over each journal.
5) Install the main bearing cap with lower bearing bush on
the cylinder block, and make the forward mark of the main
bearing cap towards the front of the engine. Tighten the
main bearing cap bolt with the specified torque.
Notice
Do not rotate the crankshaft.
7) Measure the maximum clearance point with plastic
clearance gauge.
0.0002~-0.0007 in (English)
(English).
Notice
If the clearance exceeds this range, replace the main bearing
of this crankshaft. If necessary, replace the crankshaft. To
replace the crankshaft main bearing, the main bearing with
the same number should be chosen. If the number of the
main bearing can not be identified, the sum of the numbers
printed on the cylinder block and crankshaft is the correct
main bearing number. Then use the calculated number to
choose a new main bearing. (Cylinder block main bearing
hole group No. + crankshaft)
5. Check the crankshaft main journal.
1) Use the dial indicator to measure the circle runout at the

crankshaft main journal.
The maximum run-out: 0.03mm
Notice
If the circular runout is not proper, replace the crankshaft.
EM
6. Check the crankshaft for thrust clearance.

1) Install the crankshaft
2) Install main bearing cap with lower bearing bush and
bolts of main bearing cap, and ensure that forward mark of
main bearing cap faces front end of engine.
3) Pry the crankshaft forward and backward with a
screwactuator, while measuring the thrust clearance with a
dial indicator.
Standard thrust clearance:
Notice
If the thrust clearance does not meet the requirement, thrust
plates should be replaced in set.
7. Check the diameter of crankshaft journal.
1) Measure the journal diameter at two points (A and B) in
X and Y directions as shown.
Notice
If it is beyond range in specifications, please replace
crankshaft and grind journal and install a smaller bearing.
Main bearing journal diameter:
φ51.985-φ52.000 mm(Metric) φ2.04665-φ2.0472
in( English )
The maximum axial movement of crankshaft: 0.31 mm
(Metric) 0.0122 in (English).
The diameter of connecting rod journal:
The maximum circle deviation of connecting rod journal:
0.006 mm (Metric) 0.00096 in ( English).
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8. Check the fit clearance of the crankshaft main bearing

bush
1) Check for the corrosive pitting and scratching on the
main bearing journal and main bearing bush.
2) Install the upper bearing bush of the crankshaft main
bearing.
3) Place the crankshaft on the cylinder block.
4) Place one plastic clearance gauge over each journal.
5) Install the main bearing cap with lower bearing bush on
the cylinder block, and make the forward mark of the main
bearing cap towards the front of the engine. Tighten the
main bearing cap bolt with the specified torque.
Notice
Do not rotate the crankshaft.
7) Measure the maximum clearance point with plastic
clearance gauge.
EM
0.0009~-0.0018 in (English)
(English).
Notice
If the clearance exceeds this range, replace the main bearing
of this crankshaft. If necessary, replace the crankshaft. To
replace the crankshaft main bearing, the main bearing with
the same number should be chosen. If the number of the
main bearing can not be identified, the sum of the numbers
printed on the cylinder block and crankshaft is the correct
main bearing number. Then use the calculated number to
choose a new main bearing. (Cylinder block main bearing
hole group No. + crankshaft)
9. Check the main bearing cap bolt.

1) Measure the length of main bearing cap bolt (only
applicable to fixing bolt in plastic area).
Standard: 80.5~81.5 mm (Metric) 3.16~3.20 in(English)
Notice
New bolt must be used in each maintenance.
10. Check the conductivity of piston fuel injector component.

1. Add compressed air to piston the fuel injector, and confirm

air goes through the piston fuel injector component.
Air pressure: 1.6bar
Notice
If air does not flow, replace the piston fuel injector
component.
EM
11. Check the cylinder block for crack, scratch and leakage.
1) Clean the joint surface with the cylinder sealing gasket.
2) Clean the mating face between crankcase and cylinder
block.
3) Implement color comparison and penetration check on
the cylinder head surface.
4) Check and confirm that the joint surface between
cylinder block and cylinder sealing gasket have no
scratches.
5) Check and confirm that the joint surface between
cylinder block and cylinder sealing gasket have no leakage
or channeling gas.
6) Check the cylinder block for crack.
Notice
Replace the cylinder block if necessary.
12. Check the flatness of cylinder block.
1) Measure flatness at top surface of cylinder block in the
six directions shown in the figure.
Maximum planeness of cylinder block: 0.03 mm (Metric)
0.001 in (English)
Notice
If it exceeds the maximum value, change the cylinder block.
NL-3 01/2016
13. Check the diameter of cylinder.

1) Measure cylinder diameter along X and Y direction at
the place 6,60,108 mm below top surface.
Minimum/maximum hole diameter limit: 80.505~82.515
mm( Metric )
3.169 ～ 3.248 in( English )
Notice
If it is not within the specified range, replace the cylinder
block.
Installation
1. Fix the cylinder block
EM 1) Clean all relevant components.
2. Install the piston fuel injector component
1) Install the piston cooling nozzle component, and fasten
the set screw of piston cooling nozzle component.
3. Install the crankshaft

1) Clean all relevant components.
2) Apply a small amount of engine lubrication oil to the
crankshaft main bearing.
3) Install the chosen crankshaft main bearing (lower)

(install the upper main bearing with oil groove on the
cylinder block).
EM
4) Install the crankshaft.
5) Install the thrust plate under the third bearing of cylinder

block, and the side with groove faces the crank arm.
NL-3 01/2016
6) Install the crankshaft main bearing (lower) to the

crankshaft bearing cap.
7) Install crankshaft bearing cap.
EM
8) Install the crankshaft bearing cap fixing bolts according

to the sequence shown in the graph, and do not tighten.
9) Install 3 hexagon flange fixing bolts of the intake main

bearing cap, but do not tighten them.
EM
10) Install 3 hexagon flange fixing bolts of the exhaust

main bearing cap, but do not tighten them.
Notice
After all other fixing bolts of the main bearing cap are installed
to the cylinder block, sequentially tighten following steps
below.
Main bearing cap bolt (M10×1.5×81)
Torque:
Second time: 30 N·m(Metric) 21.14 lb-ft (English)
Third time: 40 N·m+90°(Metric) 29.52 lb-ft +90°(English)
Hexagon flange fixing bolts (M8×1.25×50)
Notice
First tighten one side, and then tighten the other side.
Torque:
Second time: 22.5 N·m(Metric) 16.60 lb-ft (English)
11) Check whether crankshaft axial clearance is within
allowable range.
Standard thrust clearance:
Notice
If the thrust clearance does not meet the requirement, thrust
plates should be replaced in set.
4. Install the connecting rod and piston component
NL-3 01/2016
1) Lubricate the cylinder wall with the new engine

lubricating oil.
2) Lubricate the piston with new engine lubricating oil, and
install the cylinder No.1 piston connecting rod component
with cylinder No.1 position marking with special tool
47Z01219A and wooden handle.
Notice
The mark on the top of piston shall face the engine air inlet
EM side.
Intake pipe side
Front end of
engine
3) Install the cylinder No.1 connecting rod bearing cap

marked with cylinder No.1 position.
Notice
The side with mark on the bearing cap faces the engine front
end.
4) Install and tighten cylinder No.1 connecting rod bearing

cap bolts.
Notice
During assembly of bearing cap with connecting rod, tighten
bolts of bearing cap of connecting rod by two times.
Torque:
First time: 20 N.m (Metric) 14.76 lb-ft(English)
Second time: 30 N·m+90° (Metric)
22.14+90°lb-ft( English )
Notice EM
When assembling the connecting rod bearing cap, the rough
surface of piston connecting rod shall be aligned with that of
connecting rod bearing cap.
5) By the same method, install the piston connecting rod
components of the other three cylinders.
6) Install connecting rod bearing to bearing cap of
connecting rod.
Notice
The connecting rod shall be center aligned with the
connecting rod bearing cap.
7) When assembling connecting rod bearing cap, the

rough surface of piston connecting rod shall be aligned
with that of connecting rod bearing cap.
8) During assembly of bearing cap of with connecting rod,
tighten bolts of bearing cap of connecting rod by two times.
Torque:
First time: 20 Nm·m(Metric) 14.76 lb-ft (English)
Second time: 30 Nm·m+90°(Metric) 22.14 lb-ft
+90°(English)
Notice: Assemble 2-4 cylinder piston according to this
method.
NL-3 01/2016
9) Measure the larger end play of connecting rod.

Clearance measurement: 0.1~0.33 mm (Metric)
0.0039~0.013 in (English)
Radial: 0.24~0.46 mm (Metric) 0.0009~0.018 in(English)
Notice
If it is not within the specification, replace connecting rod.
5. Install the balance shaft.

6. Install the balance shaft chain.
EM 8. Install cylinder head assembly
9. Install intake and exhaust camshaft
14. Install the oil pan.
16. Install A/C compressor
17). Install the alternator.
20. Install the high pressure fuel pump
21. Install the vacuum pump.
22. Install the oil control valve
23 Install cylinder head cover assembly.
24. Install camshaft position sensor
26. Install the exhaust manifold assembly
27. Install the intake manifold assembly
28. Install the flywheel
29. Install the engine assembly

38. Install the transmission shaft (4WD) EM
NL-3 01/2016
EM
This Repair Manual provides the information about specification, diagnosis and repair of NL-3 model (2016 version)

All Rights Reserved
Foreword
whole or part.
Warning
– Carefully read through this manual. It is especially important to fully understand all "Warnings" and "Notices" in
Section "General" relating to fault diagnostic interface.
– Repair methods described in this manual are helpful for the repair work. When following the repair procedures in this
procedures, prior to commencing repair, ensure the safety of technical personnel and prevent personal injury or
damage to customer vehicles.
– When replacing parts, please use parts approved by Geely Automobile Co., Ltd. with the same part numbers. Do not
use inferior parts.
– In order to reduce the risk of personal injury in the course of repair, or reduce the likelihood that the vehicle becomes
damaged or unsafe owing to incorrect repair, please strictly comply with all "Warnings" and "Notes" relating to fault
diagnostic interface in this Manual. Just as important, please be noted that the "Warnings" and "Notes" relating to
fault diagnostic interface in this Manual are not exaggerative. Non-compliance may lead to dangerous
consequences.
– Before carrying out any repair on or near any component or circuit of airbag system, please refer to the Position
Diagram of Components of Airbag System in Section "Safety Protection Devices" relating to fault diagnostic
interface in this Manual and the Position Diagram of Harnesses relating to fault diagnostic interface in circuit album,
and understand the position of airbag system on vehicle. Strictly follow all of the contents in the "Warnings and
Notices". Violating them will result in airbag deployment, personal injury or unnecessary maintenance to airbag
system.
General Contents
Overview IN-1
JLE-4G18TDB Engine Control System ES-1
Clutch System CL-3
Brake System BR-3

Brake Control BC-4
Constant-velocity drive Shaft DS-4
Power takeoff System TP-4
TPMS System TP-4
Tire and Wheel TW-4
A/C System AC-4
Horn System HO-5
Door Lock DL-5
Sunroof System RF-6
Seat Belt SB-6
Door CD-6
Seats SE-6
Interior Trim IR-6

JLD-4G20/24 Lubrication System –Contents LU-1
LU JLD-4G20/24 Lubrication System
Lubrication System .......................................................................................................................LU-2

Component Position ............................................................................................................................. LU-2
Abnormal Engine Oil Consumption Diagnosis. .................................................................................... LU-3
Engine Oil Pressure Diagnosis and Test. ............................................................................................ LU-4
Engine Oil Leakage Diagnosis ............................................................................................................. LU-6
On-board Check ................................................................................................................................... LU-7
Engine Oil and Oil Filter ...............................................................................................................LU-8
Oil Drainage and Filling ........................................................................................................................ LU-8
Oil Pan .........................................................................................................................................LU-10 LU
Component ......................................................................................................................................... LU-10

Removal ............................................................................................................................................. LU-12
Installation .......................................................................................................................................... LU-13
Oil Pan and Oil Strainer ..............................................................................................................LU-14
Component ......................................................................................................................................... LU-14
Removal ............................................................................................................................................. LU-25
Disassembling .................................................................................................................................... LU-27
Check ................................................................................................................................................. LU-28
Assembling ......................................................................................................................................... LU-28
Installation .......................................................................................................................................... LU-29
Engine Oil Pressure Alarm .........................................................................................................LU-32
Component ......................................................................................................................................... LU-32
Removal ............................................................................................................................................. LU-34
Installation .......................................................................................................................................... LU-35
NL-3 01/2016
LU-2 JLD-4G20/24 Lubrication System –Lubrication System
Lubrication System
Component Position
Engine oil pressure Oil filter Engine oil pump Oil strainer
alarm
LU
Oil sump
NL-3 01/2016
JLD-4G20/24 Lubrication System Lubrication System LU-3
Abnormal Engine Oil Consumption Diagnosis

When the engine oil consumption (non-leaking) exceeds the acceptable range, abnormal engine oil consumption diagnosis
must be carried out.
Diagnostic steps:
Step 1 Check whether the engine oil has leakage.
Yes Refer to "Engine oil leakage diagnosis"
No
Step 2 Check whether the engine oil viscosity is abnormal. Check whether poor quality engine oil is used.
Yes Replace the oil filter and engine oil

LU
No
Step 3 Check whether the vehicle sustained high speed/or excessive use.
Yes Service the engine.
No
Step 4 Check whether the forced ventilation system of crankcase is blocked, and whether the components
are working normally.
Yes Replace the damaged parts and components.
No
Step 5 Check whether the valve guide pipe / or the valve stem is worn, whether the valve stem oil seal is
worn, missing or improperly installed.
No
Step 6 Check whether the piston and piston rings in the cylinder are improperly installed.
No
Step 7 Check whether there is correct piston ring seal, whether there are broken or worn piston rings. If
necessary, repair the fault position.
Next Step
NL-3 01/2016
Engine Oil Pressure Diagnosis and Test

Operation steps:
Next Step
Step 2 Park the vehicle on a horizontal ground and let the engine run for a few minutes, waiting for a long
enough period of time (2-3min) to let the engine oil return. Measure whether the engine oil level is too
low.
Next Step
Step 3 If necessary, fill the recommended grade engine oil, until the engine oil level reaches the full scale on
the oil level indicator.
LU
Next Step
Step 4 Let the engine short-time run for 10~15s. Confirm the vehicle indicator lamp does not show that the
pressure is too low or no engine oil pressure.
Next Step
Step 5 Verify whether there is noise or knock sound in the valve system.
Next Step
Step 6 Check whether there are the following situations:
(a) Engine oil has bubbles.

(b) Idle speed is too low.
(c) Oil filter is blocked.
(d) Engine oil is diluted by water or the engine coolant and so on.
(e) Oil filter bypass valve fault.
(f) Oil pressure indicator lamp is incorrect or fault.
(g) Oil pressure sensor plug is incorrect or fault.
(h) Engine oil viscosity is not suitable for the expected temperature.
No
Step 7 Operate the starter switch to turn the power supply mode to OFF state, and remove the oil pressure
alarm.
Next Step
Step 8 Install the engine oil pressure test tool to the oil pressure alarm seat on the oil filter.
Next Step
Step 9 Start the engine and measure engine oil pressure.
Next Step
NL-3 01/2016
JLD-4G20/24 Lubrication System Lubrication System LU-5
Step 10 Compare the readings with the pressure value Engine oil pump specification. If the engine oil
pressure is less than the specified value, check whether there are one or more of the following
conditions:
(a) The bolts of oil filter are loose.

(b) Oil filter seat O-ring or seal is missing or damaged.
(c) Oil pump is worn or dirty.
(d) Oil pump to cylinder block bolts are loose.
(e) Oil pump filter screen is loose, blocked or damaged.
(f) Oil pump filter O-ring is missing or damaged.
(g) Oil pump filter screen inlet pipes are damaged or
leaking.
(h) Oil pump pressure regulating valve fault.
(i) The engine oil passage hole plug is missing or
improperly installed. LU
(j) Bolts on the intermediate drive shaft of camshaft are
loose.
(k) When bearing clearance of the following parts
exceeds acceptable tolerance range, repair or replace
relevant parts when necessary.
1. Connecting rod
2. Crankshaft
3. Camshaft
4. Sprocket of the intermediate drive shaft of camshaft
(l) Engine oil passage cracks. There are holes or
blockage.
(m) Valve tappet rod fracture.
Next Step
NL-3 01/2016
Engine Oil Leakage Diagnosis

In case of engine oil leakage, it is necessary to check whether the following occur:
Operation steps
Step 1 Check whether the engine oil level is too high.
Yes Drain the engine oil to the specified level.
No
Step 2 Check whether the engine oil pressure is too high
Yes Check the engine oil filter or pressure bypass

valve for fault or blockage.
LU
No
Step 3 Check whether the engine ventilation system is blocked or has fault
No
Step 4 Check whether the fastener has improper fastening or damage.
Yes Replace the broken component and tighten it

according to the specified torque.
No
Step 5 Check whether the relevant component has rupture or hole clearance.
No
Step 6 Check whether the seal surface is worn, seal installation improve or incorrect.
Next Step
NL-3 01/2016
On-board Check
1. Check oil levels
1) Warm up the engine, then shut it down, and wait
for 5 minutes.
2) Check whether the engine oil level is between low
position and full position on the dipstick. If the oil
level is too low, check for leakage, and fill the
engine with a proper amount of oil.
2. Check whether the engine oil is deteriorated
1) Check whether the oil is deteriorated,
contaminated by water, discolored or thinned. If it
is observed visually that the quality of engine oil is
worse, the oil shall be changed.
3. Check the engine oil pressure.
LU
NL-3 01/2016
LU-8 JLD-4G20/24 Lubrication System –Engine Oil and Oil Filter
Engine Oil and Oil Filter
Oil Drainage and Filling

2. Lift the vehicle
3. Remove the engine bottom guard plate; refer to "Left
and right engine bottom guard plates"
4. Drain the engine oil
1) Open the oil filler cap.
2) Remove the drain plug and sealing gasket, and
drain the oil into a container.
Notice
The used oil and oil filter must be scrapped and
LU disposed at the specified scrapping point to protect
the environment.
3) Clean the drain plug, replace the gasket with a
new one, and install the plug.
Tightening torque: 50 N·m (Metric) 36.90 lb-ft
(English)
5. Replace engine oil filter.

1) Remove the oil filter with an oil filter wrench.
NL-3 01/2016
JLD-4G20/24 Lubrication System Engine Oil and Oil Filter LU-9
2) Wipe the oil filter mounting surface on the cylinder

block clean with a cloth.
3) Replace the oil filter with a new one, and apply
clean engine oil to the oil filter mounting surface.
4) Install and tighten the oil filter with a wrench.
Tightening torque: 20 N·m (Metric) 14.76 lb-ft
(English)
6. Lower the vehicle LU

1) Add the clean engine oil.
Oil type: SAE 5W-30 API Quality Grade SL and above
Quantity of added oil: Added to the upper line of the
dipstick (about 4.5L)
2) Install the oil filler cap.
8. Check for fuel leakage
2) Check the oil filter and drain plug for trace of
engine oil leakage.
NL-3 01/2016
LU-10 JLD-4G20/24 Lubrication System –Oil Pan
Oil Pan
Component
LU
NL-3 01/2016
JLD-4G20/24 Lubrication System Oil Pan LU-11
Engine assembly
LU
Oil pan
NL-3 01/2016
LU-12 JLD-4G20/24 Lubrication System –Oil Pan
Removal
2. Lift the vehicle
3. Remove the engine bottom guard plate; refer to
"Left and right engine bottom guard plates"
4. Drain the engine oil; refer to "Engine oil and oil Filter"
5. Remove the oil pan
1) Remove the fixing bolts of oil pump.
LU
1) Take down the oil pan.
NL-3 01/2016
JLD-4G20/24 Lubrication System Oil Pan LU-13
Installation
1. Install the oil pan.
1) Clean the oil pan mounting surface of the
crankcase.
2) Apply the sealant to the oil pan evenly.
3) Install the oil pan.
4) Fasten 14 fixing bolts and nuts in the sequence
as shown.
Torque: 9N·m (Metric) 6.7lb-ft (English)
LU
NL-3 01/2016
LU-14 JLD-4G20/24 Lubrication System –Oil Pan and Oil Strainer
Oil Pan and Oil Strainer

Component
LU Engine trim cover
NL-3 01/2016
JLD-4G20/24 Lubrication System Oil Pan and Oil Strainer LU-15
LU
Vehicle wheel nut
Wheel assembly
N·m(lb-ft) specified torque
NL-3 01/2016
LU
Engine right guard

plate assembly

assembly
Engine bottom guard

plate assembly
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Vent hose of carbon
LU
Intake manifold
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Engine trim cover
Ignition coil
LU
Engine assembly
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Cylinder head cover
LU
Engine assembly
NL-3 01/2016
LU Drive belt
Idler bracket

NL-3 01/2016
Timing chain tensioner LU

component
Belt tensioning
mechanism
Engine assembly
Timing chain cover

Crankshaft pulley
NL-3 01/2016
Engine assembly
Timing chain
LU
Timing chain guard plate
Timing chain cover
NL-3 01/2016
LU
Crankshaft engine oil

pump sprocket
Engine oil pump

chain
Engine oil pump sealing

gasket
Engine oil pump

Water pump
Engine oil pump chain tensioner component
Engine oil pump sprocket
NL-3 01/2016
Engine assembly
LU
Oil pan
NL-3 01/2016
Removal
Warning!
The oil pump shall be removed in a cold state to prevent scald
injuries!
Warning!
After the oil pump is replaced with a new one, the oil strainer
installed in the oil pan must be checked, refer to "Oil pan".
2. Remove the upper trim panel of front bumper; refer to
3. Remove the upper trim panel connecting plate of fender;
compartment"
4. Remove the upper trim panel assembly of right fender; LU
compartment"
5. Remove the engine trim cover; refer to "Engine trim
cover"
6. Remove the front wheel; refer to "Wheel and tire"
7. Lift the vehicle
9. Remove the engine left/right guard plate; refer to "Left
10. Drain the engine oil; refer to "Drainage and filling of
engine oil"
11. Drain the engine coolant; refer to "Drainage and filling
for engine coolant"
12. Remove the canister solenoid valve; refer to "Canister
solenoid valve"
13. Remove the ignition coil; refer to "Ignition coil"
14. Remove the cylinder head cover assembly; refer to
15. Remove the drive belt; refer to "Drive belt"
17. Remove the belt tensioning mechanism subassembly
Refer to "Belt tensioning mechanism subassembly"
18. Remove the belt tensioning mechanism subassembly;
refer to "Belt tensioning mechanism subassembly"
19. Remove the damping pulley; refer to "Damping pulley"
20. Remove the oil pan; refer to "Oil pan"
21. Remove the timing chain tensioner component; refer to
"Oil pan"
22. Remove the timing chain cover; refer to "Timing chain"
23. Remove the crankshaft front oil seal; refer to
"Crankshaft front oil seal"
24. Remove the timing chain; refer to "Timing chain"
25. Remove the oil pump sprocket and chain
NL-3 01/2016
1) Remove the oil pump chain tensioning pin shaft.

2) Take down the oil pump chain tensioning rail.
LU 3) Remove the oil pump sprocket nuts.
4) Remove the oil pump chain and sprocket.
NL-3 01/2016
26. Remove the oil pump and oil strainer assembly

1) Remove 3 fixing bolts of the oil pump.
LU
2) Take off the oil pump and oil strainer assembly.
3) Take off the oil pump gasket
Disassembling
1. Remove the engine oil strainer.
1) Remove 2 fixing bolts of the oil pump sump
strainer.
2) Take off the oil pump sump strainer.
NL-3 01/2016
3) Take off the oil pump suction filter gasket.
LU
Check
1. Check of oil pump safety valve
1) Remove the safety valve bolts; remove the
springs and the slide valve.
2) Check whether the surface of slide valve is worn,
whether the hole wall is worn. Whether the slide
valve and the inner hole clearance is normal.
3) Apply lubricating oil on the slide valve, install the
slide valves and springs, and tighten safety valve
bolts.
Assembling
1. Install the engine oil strainer.
1) Install the oil pump suction filter gasket.
2) Install the oil pump suction filter and 2 fixing
bolts.
3) Tighten fixing bolts of the oil pump suction filter.
NL-3 01/2016
Installation
1.Install the oil pump and oil strainer assembly
1) Clean the crankshaft oil pump mounting surface.
2) Install the gasket of oil pump
Notice
The oil pump gasket is a disposable part, and must be
replaced with a new one every time it is removed or a
new one is installed.
3) Install and tighten the fixing bolts of engine oil LU

pump.
2. Install the oil pump sprocket and chain

1) Install the oil pump chain and sprocket.
NL-3 01/2016
Notice
There are a total of two timing mark outer links on the
oil pump chain, one timing mark outer link (yellow) is
aligned with the oil pump sprocket timing mark; the
other timing mark outer link (yellow) is aligned with
the crankshaft oil pump sprocket timing mark.
LU
2) Install and tighten the oil pump sprocket nut.
Torque: 30 N (Metric) 22.14 lb-ft (English)
3) Install the oil pump chain tensioning rail and pin

shaft.
NL-3 01/2016

7. Install the oil sump.
8. Install the right engine bracket.
10. Install the damping pulley.
12. Install cylinder head cover assembly.
15. Install the left and right engine guard plates LU
21. Fill the refrigerant.
26. Install the engine shield.
NL-3 01/2016
LU-32 JLD-4G20/24 Lubrication System –Engine Oil Pressure Alarm
Engine Oil Pressure Alarm

Component
NL-3 01/2016
JLD-4G20/24 Lubrication System Engine Oil Pressure Alarm LU-33
LU
NL-3 01/2016
Removal
3. Remove the trim cover of engine; refer to "Engine trim
cover"
4. Remove the oil pressure alarm
1) Disconnect the harness connector of the oil
pressure alarm.
LU
2) Remove the oil pressure alarm.
NL-3 01/2016
JLD-4G20/24 Lubrication System Engine Oil Pressure Alarm LU-35
Installation
1) Apply thread sealant to the oil pressure alarm
threads.
2) Tighten the oil pressure alarm.
LU
3) Connect the harness connector of the oil

pressure sensor, and check to make sure that
connection is in place.
NL-3 01/2016
LU
NL-3 01/2016
JLE-4G18TDB Lubrication System –Contents LU-1
LU JLE-4G18TDB Lubrication System
Lubrication System .......................................................................................................................LU-2

Component Position ............................................................................................................................. LU-2
On-board Check ................................................................................................................................... LU-3
Abnormal Engine Oil Consumption Diagnosis..................................................................................... LU-4
Engine Oil Pressure Diagnosis and Test. ............................................................................................ LU-5
Engine Oil Leakage Diagnosis ............................................................................................................. LU-7
Oil and Oil Filter ............................................................................................................................LU-8
LU
Component ........................................................................................................................................... LU-8
Oil Drainage and Filling ........................................................................................................................ LU-9
Oil Sump ......................................................................................................................................LU-11
Component ..........................................................................................................................................LU-11
Removal ............................................................................................................................................. LU-13
Installation .......................................................................................................................................... LU-13
Oil Pump and Oil Strainer ...........................................................................................................LU-15
Component ......................................................................................................................................... LU-15
Removal ............................................................................................................................................. LU-17
Installation .......................................................................................................................................... LU-19
Engine Oil Pressure Alarm .........................................................................................................LU-22
Component ......................................................................................................................................... LU-22
Removal ............................................................................................................................................. LU-24
Installation .......................................................................................................................................... LU-25
NL-3 01/2016
LU-2 JLE-4G18TDB Lubrication System –Lubrication System
Lubrication System
Component Position
LU
Oil filter Engine oil pump Engine oil pressure alarm

Oil sump Oil strainer
NL-3 01/2016
JLE-4G18TDB Lubrication System –Lubrication System LU-3
On-board Check
1. Check the engine oil level.
1) Warm up the engine, then shut it down, and wait for
5 minutes.
2) Check whether the engine oil level is between low
position and full position on the dipstick. If the oil
level is too low, check for leakage, and fill the
engine with a proper amount of oil.
2. Check whether the engine oil is deteriorated
1) Check whether the oil is deteriorated, contaminated
by water, discolored or thinned. If it is observed
visually that the quality of engine oil is worse, the oil
shall be changed.
3. Check the engine oil pressure.
LU
NL-3 01/2016
Abnormal Engine Oil Consumption Diagnosis

When the engine oil consumption (non-leaking) exceeds the acceptable range, abnormal engine oil consumption diagnosis
must be carried out.
Diagnostic steps:
Step 1 Check whether the engine oil has leakage.
Yes Refer to "Engine oil leakage diagnosis"
No
Yes Replace the oil filter and engine oil

LU
No
Step 3 Check whether the vehicle sustained high speed/or excessive use.
Yes Service the engine.
No
Step 4 Check whether the forced ventilation system of crankcase is blocked, and whether the components are
working normally.
Yes Replace the damaged parts and components.
No
Step 5 Check whether the valve guide pipe or the valve stem is worn, whether the valve stem oil seal is worn,
missing or improperly installed.
No
Step 6 Check whether the piston and piston rings in the cylinder are improperly installed.
No
Step 7 Check whether there is correct piston ring seal, whether there are broken or worn piston rings. If
necessary, repair the fault part.
Next Step
NL-3 01/2016
Engine Oil Pressure Diagnosis and Test

Operation steps:
Next Step
Step 2 Park the vehicle on a horizontal ground and let the engine run for a few minutes, waiting for a long enough
period of time (2-3 min) to let the engine oil return. Measure whether the engine oil level is too low.
Next Step
Step 3 If necessary, fill the recommended grade engine oil, until the engine oil level reaches the full scale on
the oil level indicator.
Next Step
LU
Step 4 Let the engine short-time run for 10~15 s. Confirm the vehicle indicator lamp does not show that the
pressure is too low or no engine oil pressure.
Next Step
Step 5 Verify whether there is noise or knock sound in the valve system.
Next Step
Step 6 Check whether there are the following situations:

(a) Engine oil has bubbles.
(b) Idle speed is too low.
(c) Oil filter is blocked.
(d) Engine oil is diluted by water or the engine coolant and so on.
(e) Oil filter bypass valve fault.
(f) Oil pressure indicator lamp is incorrect or fault.
(g) Oil pressure sensor plug is incorrect or fault.
(h) Engine oil viscosity is not suitable for the expected temperature.
Refer to "User’s manual", according to local

Yes
temperatures, use the Geely Automobile
recommended grade and viscosity engine oil
No
Step 7 Operate the starter switch so that the power supply mode turns to the OFF state, and remove the oil
pressure alarm.
Next Step
Step 8 Install the engine oil pressure test tool to the oil pressure alarm seat on the oil filter.
Next Step
Step 9 Start the engine and measure engine oil pressure.
Next Step
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Step 10 Compare the readings with the pressure value of engine oil pump specification. If the engine oil
pressure is less than the specified value, check whether there are one or more of the following
conditions:
(a) The bolts of oil filter are loose.

(b) Oil filter seat O-ring or seal is missing or damaged.
(c) Oil pump is worn or dirty.
(d) Oil pump to cylinder block bolts are loose.
(e) Oil pump filter screen is loose, blocked or damaged.
(f) Oil pump filter O-ring is missing or damaged.
(g) Oil pump filter screen inlet pipes are damaged or leaking.
(h) Oil pump pressure regulating valve fault.
(i) The engine oil passage hole plug is missing or improperly installed.
LU (j) Bolts on the intermediate drive shaft of camshaft are loose.
(k) When bearing clearance of the following parts exceeds acceptable
tolerance range, repair or replace relevant parts when necessary.
1. Connecting rod
2. Crankshaft
3. Camshaft
4. Sprocket of the intermediate drive shaft of camshaft
(l) Engine oil passage cracks. There are holes or blockage.
(m) Valve tappet rod fracture.
Next Step
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Engine Oil Leakage Diagnosis

In case of engine oil leakage, it is necessary to check whether there are following conditions:
Operation steps
Step 1 Check whether the engine oil level is too high.
Yes Drain the engine oil to the specified level.
No
Step 2 Check whether the engine oil pressure is too high
Yes Check the engine oil filter or pressure bypass

valve for fault or blockage.
LU
No
Step 3 Check whether the engine ventilation system is blocked or has fault
No
Step 4 Check whether the fastener has improper fastening or damage.
Yes Replace the broken component and tighten it

according to the specified torque.
No
Step 5 Check whether the relevant component has rupture or hole clearance.
No
Step 6 Check whether the seal surface is worn, and whether the gasket is improperly or incorrectly installed.
Next Step
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LU-8 JLE-4G18TDB Lubrication System –Oil and Oil Filter
Oil and Oil Filter

Component
Engine trim cover
LU
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JLE-4G18TDB Lubrication System –Oil and Oil Filter LU-9
Oil Drainage and Filling

4. Drain the engine oil
1) Open the oil filler cap.
LU
2) Remove the oil drain plug (with oil drain plug

gasket) of engine oil pan components to drain
engine oil into a container.
Notice
The used oil and oil filter must be disposed at the
specified scrapping point to protect the environment.
3) Clean the drain plug, and install with a new
gasket.
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LU-10 JLE-4G18TDB Lubrication System –Oil and Oil Filter
5. Remove the oil filter.

Notice: To replace the oil filter, wrap the replaced oil filter
with an oil-absorbing sheet or a strip of cloth, take the oil
filter away, and put oil-absorbing cloth around to prevent
fluid from dripping onto the engine.
LU


1) Add the clean engine oil.
Oil type: SAE 5W-40 API Quality Grade SN and
above
Areas below -30℃: SAE 0W-40 API Quality Grade
SN and above
Quantity of added oil: Added to the upper line of
the dipstick (about 5L)
2) Install the filler flap.
8. Check engine oil for leakage
2) Check the oil filter and the drain plug for engine
oil leakage.
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JLE-4G18TDB Lubrication System –Oil Sump LU-11
Oil Sump
Component
LU
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LU-12 JLE-4G18TDB Lubrication System –Oil Sump
Engine assembly （4G18TD）
LU
Oil sump
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JLE-4G18TDB Lubrication System –Oil Sump LU-13
Removal
2. Lift the vehicle
4. Drain the oil; refer to "Oil drainage and filling"
5. Remove the oil sump.
1) Remove the steel gasket of the oil sump and 21
fixing bolts.
2) Remove the oil sump from the crankcase.
LU
Installation
1) Clean the oil sump mounting surface of the
crankcase.
2) Apply sealant to the engine oil sump component
by continuous dispensing.
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LU-14 JLE-4G18TDB Lubrication System –Oil Sump
3) Install the engine oil sump components and steel

gasket of oil sump.
Notice
Check intactness of oil drain plug gasket before
installation, and replace the gasket in case of
abnormal conditions.
4) Fasten 21 fixing bolts and nuts in the sequence
as shown in the figure.
5. Closing the engine hood
LU
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JLE-4G18TDB Lubrication System –Oil Pump and Oil Strainer LU-15
Oil Pump and Oil Strainer

Component
LU
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LU-16 JLE-4G18TDB Lubrication System –Oil Pump and Oil Strainer
4G18TD Engine
LU
Oil strainer
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Removal
3. Remove the upper trim panel connecting plate of fender;
compartment"
4. Remove the upper trim panel assembly of left fender; refer
5. Remove the engine trim cover; refer to Engine trim cover.
6. Remove the front wheel; refer to "Wheel and tire"
7. Lift the vehicle
8. Remove the engine bottom guard plate; refer to "Left and
right engine bottom guard plates" LU
9. Remove the engine left/right guard plate; refer to "Left and
right engine bottom guard plates"
11.Remove the drive belt tensioner; refer to "Belt tensioner
assembly"
12.Remove the crankshaft pulley; refer to "Damping pulley
component"
13. Remove the oil sump; refer to "Oil sump".
14. Remove the timing chain cover; refer to "Timing chain and
tensioner"
15. Remove the timing chain tensioner; refer to the "Timing
16. Remove the timing chain; refer to "Timing chain and
tensioner"
17. Remove the oil baffle
1) Remove 3 fixing screws at the bottom of the oil baffle.

2) Remove the oil baffle.
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18. Remove the filters.

1) Remove 2 fixing bolts of the strainer.
2) Take down the strainer.
LU
19. Remove the oil pump chain

1) Remove the tensioning rail fixing bolt 1 of chain
of oil pump, and remove tensioning rail 2 of chain
of engine oil pump together.
2) Take off the oil pump chain and the crankshaft

sprocket.
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20. Remove the oil pump

1) Remove 3 fixing bolts at the bottom of the oil
pump.
2) Remove the oil pump.
LU
Installation
1. Install the oil pump assembly.
1) Install the engine oil pump.
2) Fasten 3 fixing bolts of the oil pump.
Torque: 22.5 N (Metric) 16.6 lb-ft (English)

1) Install the crankshaft sprocket.
Notice
The convex-tooth alignment mark on the crankshaft
sprocket 1 is inserted into the groove in the balance
shaft drive sprocket 2 to ensure that installation is in
place.
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2) Install the oil pump chain.

3) Install the oil pump chain tensioner component 1
and its fixing bolt 2.
LU 3. Install the strainer.

1) Install the strainer.
2) Fasten 2 fixing bolts of the sump strainer.
4. Install the oil baffle

1) Install the oil baffle.
2) Fasten 3 fixing bolts at the bottom of the oil
baffle.
6. Install the timing chain tensioner.
9. Install the crankshaft pulley.
11. Install the drive belt tensioner.
13. Install the dipstick
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14. Install the left and right engine guard plates

LU
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LU-22 JLE-4G18TDB Lubrication System –Engine Oil Pressure Alarm
Engine Oil Pressure Alarm

Component
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JLE-4G18TDB Lubrication System –Engine Oil Pressure Alarm LU-23
LU
Engine oil pressure

alarm
4G18TD Engine
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Removal
cover"
5. Remove the upper trim panel connecting plate of
fender; refer to "Decorative covering parts of engine
compartment"
6. Remove the upper trim panel assembly of left fender;
compartment"
LU 7. Remove the oil pressure alarm
1) Disconnect the harness connector of the oil
pressure alarm.
2) Remove the oil pressure alarm
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JLE-4G18TDB Lubrication System –Engine Oil Pressure Alarm LU-25
Installation
1) Apply thread sealant to the oil pressure alarm
threads.
2) Install and fasten the oil pressure alarm.
LU
3) Connect the harness connector of the oil

pressure sensor, and check to make sure that
connection is in place.
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LU
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JLD-4G20/24 Auxiliary Emission Control Device –Contents EC-1
EC JLD-4G20/24 Auxiliary Emission Control Device
Auxiliary Emission System ......................................................................................................... EC-2

Component Position ............................................................................................................................. EC-2
System Diagram ................................................................................................................................... EC-3
The Canister Solenoid Valve Doesn't Work. ........................................................................................ EC-4
Positive Crankcase Ventilation (PCV) System Check / Diagnosis ...................................................... EC-9
On-board Check ................................................................................................................................. EC-10
Carbon Canister ..........................................................................................................................EC-11
Component ......................................................................................................................................... EC-11 EC
Removal ............................................................................................................................................. EC-12
Check ................................................................................................................................................. EC-13
Installation .......................................................................................................................................... EC-14
Carbon Canister Solenoid Valve ............................................................................................... EC-16
Component ......................................................................................................................................... EC-16
Removal ............................................................................................................................................. EC-18
Check ................................................................................................................................................. EC-19
Installation .......................................................................................................................................... EC-19
PCV Valve Component............................................................................................................... EC-20
Component ......................................................................................................................................... EC-20
Removal ............................................................................................................................................. EC-22
Check ................................................................................................................................................. EC-22
Installation .......................................................................................................................................... EC-23
Front Oxygen Sensor................................................................................................................. EC-24
Component ......................................................................................................................................... EC-24
Removal ............................................................................................................................................. EC-25
Installation .......................................................................................................................................... EC-25
Rear Oxygen Sensor .................................................................................................................. EC-27
Component ......................................................................................................................................... EC-27
Removal ............................................................................................................................................. EC-29
Installation .......................................................................................................................................... EC-30
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EC-2 JLD-4G20/24 Auxiliary Emission Control Device –Auxiliary Emission System
Auxiliary Emission System

Component Position
EC
PCV valve
Carbon canister
Front oxygen Carbon canister solenoid valve

sensor
Rear oxygen
sensor
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JLD-4G20/24 Auxiliary Emission Control Device –Auxiliary Emission System EC-3
System Diagram
Intake Exhaust
EC
Sensor Engine
Intake air quantity Voltage of

signal voltage Injection feedback signal
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The Canister Solenoid Valve Doesn't Work

1. Circuit diagram:
Carbon canister
Main relay solenoid valve
ERO5
EC
Diagnostic steps:
Step 1 Check the engine emission fault warning lamp.
(a) Start the engine.

(b) Check whether the engine emission fault warning lamp lights on.
No Go to step 3
Yes
Step 2 Repair the engine control system fault.
(a) Repair the engine control system for the fault of the engine
emission fault warning lamp; refer to "The table of fault
symptoms".
(b) Is the canister solenoid valve working properly?
No
Step 3 Check the canister solenoid valve power supply circuit.
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to ON state.
(b) Measure the voltage of terminal 1 of the canister solenoid
valve harness connector EG16.
EG16 Canister control valve harness connector
Yes Go to Step 6
EC
No
Step 4 Check the circuit between terminal 1 of the canister solenoid valve harness connector EG16 and fuse
EF10.
OFF state.
(b) Measure the resistance of the circuit between fuse EF10
and terminal 1 of the canister solenoid valve harness
connector EG16.
(c) Confirm whether the resistance meets the standard value.
Yes Go to Step 6
No
Step 5 Repair the circuit between the canister solenoid valve wiring harness connector and the fuse EF10.
OFF state.
(b) Repair the open circuit fault between the canister solenoid
valve harness connector EG16 terminal 2 and fuse EF10.
(c) Check whether the canister solenoid valve is working
properly.
No
Step 6 Check the circuit between canister solenoid valve harness connector and EMS harness connector.
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OFF state.
(b) Check the resistance between terminal 2 of the canister
EG16 Canister control valve harness connector solenoid valve harness connector EG16 and terminal 30 of the
EMS harness connector EG24, and determine the continuity.
Yes Go to Step 8
EC
EG24 Canister control valve harness connector 2
No
Step 7 Repair canister solenoid valve harness connector and EMS harness connector.
OFF state.
(b) Repair the open circuit fault between terminal 2 of the canister
solenoid valve harness connector EG16 and terminal 30 of the
EMS harness connector EG24.
(c) Is the canister solenoid valve working normally?
No
Step 8 Use the active test function to check the voltage between the canister solenoid valve terminals.
OFF state.
(b) Disconnect canister solenoid valve wiring harness connector.
(c) Connect the test lamp.
(d) In the engine active test, connect the diagnostic scanner and
drive the canister solenoid valve.
(e) Ensure that the system is normal.
(f) Is the test lamp on?
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No

mode to OFF state.
CA45 Engine management system harness connector (b) Measure the resistance value between B＋ of battery
and fuse EF09.
(c) Measure the resistance between the fuse EF09 and the EC
terminals 15 and 16 of EMS harness connector CA45.
Yes
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mode to OFF state.
CA45 Engine management system harness connector (b) Measure the resistance between terminals 63 and 64 of
grounding point.
EC
Yes
Step 11 Replace the canister solenoid valve.

mode to OFF state.
(b) Replace the canister solenoid valve, refer to "Canister
solenoid valve".
(c) Confirm that the repair is completed.
Next Step

Next Step
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Positive Crankcase Ventilation (PCV) System Check / Diagnosis

Diagnostic steps:
Step 1 Check the crankcase ventilation hose interior for vacuum and there should be manifold vacuum in the
hose. If not, check whether the hose is blocked, leaking or ventilation tube connector is blocked.
Next Step
Step 2 When the engine is running, block the ends of the vacuum hose. When the hose ends are blocked,
check whether all parts of the hose collapse. If hose collapses, the hose should be replaced.
Next Step
EC
Step 3 If the engine oil gathered in the intake pipe, check whether there are the following situations.
(a) Crankcase ventilation shield interior vacuum hole is

blocked.
(b) Crankcase ventilation shield is blocked.
(c) Crankcase pressure or channeling gas exceeds the
acceptable tolerance scope.
Next Step
Step 4 Check other items:
Next Step
Consequences of incorrect operation

1. If the crankcase ventilation hose is blocked, it will cause the following faults:
– Unstable idle speed.
– Speed miss or idle speed is too low
– Engine oil leakage
– Engine oil enters the intake pipe.
– Sludge appeared in the engine
2. Ventilation hood or hose leakage may lead to the following faults:
– Idle traveling block.
– Stall.
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On-board Check
1. Check the working condition of the oxygen sensor.
2) Continuously observe the operating voltage of the
oxygen sensor through the fault diagnostic scanner
2. Visually check the hose, connector and gasket.
1) Check for rupture, leakage or damage.
EC
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JLD-4G20/24 Auxiliary Emission Control Device –Carbon Canister EC-11
Carbon Canister
Component
Fuel tank body
EC
valve hose outlet
Carbon canister
Right mounting bracket Left mounting bracket

of canister of canister
Hose to canister control
valve
Guard plate on bottom

of carbon canister
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EC-12 JLD-4G20/24 Auxiliary Emission Control Device –Carbon Canister
Removal
1. Lift the vehicle
2. Remove the bottom guard plate of canister
1) Remove 4 fixing screws of the bottom guard plate
of the canister, and take down the bottom guard
plate.
EC
3. Remove the canister and bracket assembly

1) Disconnect the canister from the fuel tank
connecting line 1.
2) Disconnect the canister from the canister
solenoid valve connecting line 2.
3) Disconnect the canister from the refueling
breather connecting line 3.
4) Remove 2 fixing bolts of the left canister

mounting bracket and the body.
5) Remove 1 fixing bolt of the right canister
6) Take down the canister and bracket assembly.
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4. Disassembly of Canister and Bracket Assembly

1) Remove 2 fixing bolts of the left bracket from the
canister, and take down the left bracket.
EC
2) Remove 2 fixing bolts of the right bracket from

the canister, and take down the right bracket.
Check
1. Check the canister

1) Visually check the canister for rupture or
damage.
2) Check the airtightness and liquidity of the
canister. Determine the method according to
related data.
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EC-14 JLD-4G20/24 Auxiliary Emission Control Device –Carbon Canister
Installation
1. Assembly of Canister and Bracket Assembly
1) Install the right bracket to the canister, and
tighten 2 fixing bolts.
EC
2) Install the left bracket to the canister, and tighten

2 fixing bolts.
2. Install the canister and bracket assembly

1) Install 2 fixing bolts of the left canister mounting
bracket and the body.
2) Install 1 fixing bolt of the right canister mounting
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3) Connect the canister and the canister solenoid

connecting line 2.
4) Connect the canister and the fuel tank
connecting line 1.
5) Connect the canister and the refueling breather
connecting line 3.
EC
3. Install the bottom guard plate of canister

1) Install the bottom guard plate of the canister, and
tighten 4 fixing screws of the guard plate.
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EC-16 JLD-4G20/24 Auxiliary Emission Control Device –Carbon Canister Solenoid Valve
Carbon Canister Solenoid Valve

Component
EC
Engine trim cover
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JLD-4G20/24 Auxiliary Emission Control Device –Carbon Canister Solenoid Valve EC-17

Vent hose of carbon
canister
Protective sleeve of solenoid
EC
Intake manifold
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EC-18 JLD-4G20/24 Auxiliary Emission Control Device –Carbon Canister Solenoid Valve
Removal
3. Lift the vehicle
5. Remove the canister solenoid valve.
1) Disconnect carbon canister solenoid valve harness
connector.
EC
2) Disconnect the connecting line between canister

solenoid valve and canister.
3) Disconnect the connecting hose between canister
solenoid valve and intake manifold.
4) Take down the canister solenoid valve from the
protective sleeve of canister solenoid.
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JLD-4G20/24 Auxiliary Emission Control Device –Carbon Canister Solenoid Valve EC-19
Check
1. Check the canister solenoid valve
1) Measure the resistance value between 2
terminals of the canister solenoid.
2) Check whether the canister solenoid operates
normally.
EC
Installation
1. Inst all the canister solenoid valve.
1) Install the canister solenoid valve into the
protective sleeve of canister solenoid on the
intake manifold.
2) Connect the hose between canister solenoid
valve and intake manifold.
3) Connect the connecting line between canister
solenoid and canister.
4) Connect carbon canister solenoid valve harness

connector.
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EC-20 JLD-4G20/24 Auxiliary Emission Control Device –PCV Valve Component
PCV Valve Component

Component
EC
Engine trim cover
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JLD-4G20/24 Auxiliary Emission Control Device –PCV Valve Component EC-21
EC
PCV valve
component
Cylinder head cover
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EC-22 JLD-4G20/24 Auxiliary Emission Control Device –PCV Valve Component
Removal
cover"
3. Remove the PCV valve component
1) Disconnect the crankcase breather connected

with the PCV valve component,
EC
2) Remove the PCV valve component.
Check
1. Check the PCV valve component

1) Blow air into the cylinder head side of the PCV
valve, and check whether air passes smoothly.
Cylinder cover side
Otherwise replace the PCV valve component.
Clean the hose
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JLD-4G20/24 Auxiliary Emission Control Device –PCV Valve Component EC-23
2) Blow air into the intake manifold side of the PCV

valve, and check for air circulation difficulties.
Otherwise replace the PCV valve component.
Intake
manifold side
Clean the hose
EC
Installation
1. PCV valve component
1) Apply sealant to the PCV valve component, and
install the PCV valve component to the cylinder
head cover.
2) Connect crankcase ventilation tube.

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EC-24 JLD-4G20/24 Auxiliary Emission Control Device –Front Oxygen Sensor
Front Oxygen Sensor

Component
EC
4G20 Front oxygen sensor
4G20 Rear oxygen sensor
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JLD-4G20/24 Auxiliary Emission Control Device –Front Oxygen Sensor EC-25
Removal
3. Remove the front oxygen sensor.
1) Disconnect the front oxygen sensor harness
connector.
EC
2) Remove the front oxygen sensor.
Installation

1) Tighten the front oxygen sensor.
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EC-26 JLD-4G20/24 Auxiliary Emission Control Device –Front Oxygen Sensor
2) Connect the front oxygen sensor harness connector.

EC
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JLD-4G20/24 Auxiliary Emission Control Device –Rear Oxygen Sensor EC-27
Rear Oxygen Sensor

Component
EC
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EC-28 JLD-4G20/24 Auxiliary Emission Control Device –Rear Oxygen Sensor
4G20 Front oxygen sensor
EC
4G20 Rear oxygen sensor
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JLD-4G20/24 Auxiliary Emission Control Device –Rear Oxygen Sensor EC-29
Removal
3. Lift the vehicle
5. Remove the rear oxygen sensor.
1) Disconnect rear oxygen sensor harness connector.
EC
2) Remove the rear oxygen sensor.
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EC-30 JLD-4G20/24 Auxiliary Emission Control Device –Rear Oxygen Sensor
Installation
1. Install the rear oxygen sensor.
1) Install and tighten the rear oxygen sensor.
EC
2) Connect the rear oxygen sensor harness connector.

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JLE-4G18TDB Auxiliary Emission Control Device –Contents EC-1
EC JLE-4G18TDB Auxiliary Emission Control Device
Auxiliary Emission System ......................................................................................................... EC-2

Component Position ............................................................................................................................. EC-2
System Diagram ................................................................................................................................... EC-3
On-board Check ................................................................................................................................... EC-3
The Canister Solenoid Valve Doesn't Work. ........................................................................................ EC-4
Positive Crankcase Ventilation (PCV) System Check / Diagnosis ...................................................... EC-9
Carbon Canister ......................................................................................................................... EC-10
Component ......................................................................................................................................... EC-10 EC
Removal ............................................................................................................................................. EC-11
Check ................................................................................................................................................. EC-12
Installation .......................................................................................................................................... EC-13
Carbon Canister Solenoid Valve ............................................................................................... EC-15
Component ......................................................................................................................................... EC-15
Removal ............................................................................................................................................. EC-16
Check ................................................................................................................................................. EC-17
Installation .......................................................................................................................................... EC-17
Front Oxygen Sensor................................................................................................................. EC-19
Component ......................................................................................................................................... EC-19
Removal ............................................................................................................................................. EC-20
Installation .......................................................................................................................................... EC-21
Rear Oxygen Sensor .................................................................................................................. EC-22
Component ......................................................................................................................................... EC-22
Removal ............................................................................................................................................. EC-23
Installation .......................................................................................................................................... EC-24
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EC-2 JLE-4G18TDB Auxiliary Emission Control Device – Auxiliary Emission System
Auxiliary Emission System

Component Position
EC
PCV valve
Carbon canister
Front oxygen
sensor
Rear oxygen sensor
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JLE-4G18TDB Auxiliary Emission Control Device – Auxiliary Emission System EC-3
System Diagram
Intake Exhaust
EC
Sensor Engine
Intake air quantity Feedback

signal voltage signal voltage
Injection
On-board Check
1. Check the oxygen sensor
2) Continuously observe the operating voltage of
the oxygen sensor through the fault diagnostic
scanner
3) Check the hose, connector and gasket for
rupture, leakage or damage.
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The Canister Solenoid Valve Doesn't Work

2、Circuit diagram:
Main relay Carbon canister

solenoid valve
ER05
EC
Diagnostic steps
Step 1 Check the engine emission fault warning lamp.
(a) Start the engine.

(b) Check whether the engine emission fault warning lamp
lights on.
No Go to step 3
Yes
Step 2 Repair the engine control system fault.
(a) Repair the engine control system for the fault of the
engine emission fault warning lamp, refer to "List of
symptoms".
(b) Is the canister solenoid valve working properly?
No
Step 3 Check the canister solenoid valve power supply circuit.
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mode to ON state.
EN16 Carbon canister control valve harness connector (b) Measure the voltage of terminal 2 of the canister
solenoid harness connector EN16.
(c) Confirm whether the voltage meets the standard value.
Yes Go to Step 6
EC
No
Step 4 Check the circuit between terminal 2 of the canister solenoid harness connector EN16 and fuse EF10.

mode to OFF state.
(b) Measure the resistance of the circuit between fuse
EF10 and terminal 2 of the canister solenoid harness
connector EN16.
value.
Yes Go to Step 6
No
Step 5 Repair the circuit between the canister solenoid valve harness connector and the fuse EF10.

mode to OFF state.
(b) Repair the open circuit fault between the canister
solenoid valve harness connector EN16 terminal 2 and
fuse EF10.
(c) Check whether the canister solenoid valve is working
properly？
No
Step 6 Check the circuit between canister solenoid valve harness connector and EMS harness connector.
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OFF state.
EN16 Canister control valve harness connector
(b) Check the resistance between terminal 1 of the canister
solenoid harness connector EN16 and terminal 35 of the EMS
harness connector EN35, and determine the continuity.
Yes Go to Step 8
EC
EN35 Engine management system (plug-in part A) harness

connector 1
No
Step 7 Repair canister solenoid valve harness connector and ECM harness connector.
OFF state.
(b) Repair the open circuit fault between terminal 1 of the canister
solenoid valve harness connector EN16 and terminal 35 of the
EMS harness connector EN35.
(c) Is the canister solenoid valve working normally?
No
Step 8 Use the active test function to check the voltage between the canister solenoid valve terminals.
OFF state.
(b) Disconnect canister solenoid valve wiring harness connector.
(c) Connect the test lamp.
(d) In the engine active test, connect the diagnostic scanner and
drive the canister solenoid valve.
(e) Ensure that the system is normal.
(f) Is the test lamp on?
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No

mode to OFF state.
CA01 Engine management system (plug-in part K) harness connector 2 (b) Measure the resistance value between B＋ of battery
and fuse EF09.
terminals 3, 5, 6 of EMS harness connector CA01.
EC
Yes
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mode to OFF state.
(b) Measure the resistance between terminals 1, 2, 4 of
EMS harness connector CA01 and reliable ground
CA01 Engine management system (plug-in part K) harness connector 2 point.
EC
Yes
Step 11 Replace the canister solenoid valve.

mode to OFF state.
(b) Replace the canister solenoid valve; refer to "Canister
solenoid valve".
(c) Confirm that the repair is completed.
Next Step
(a) Replace the EMS; refer to "Engine ECU".

Next Step
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Positive Crankcase Ventilation (PCV) System Check / Diagnosis

Diagnostic steps:
Step 1 Check the crankcase ventilation hose interior for vacuum and there should be manifold vacuum in the
hose. If not, check whether the hose is blocked, leaking or ventilation tube connector is blocked.
Next Step
Step 2 When the engine is running, block the ends of the vacuum hose. When the hose ends are blocked,
check whether all parts of the hose collapse. If hose collapses, the hose should be replaced.
Next Step
EC
Step 3 If the engine oil gathered in the intake pipe, check whether there are the following situations.
(a) Crankcase ventilation shield interior vacuum hole is

blocked.
(b) Crankcase ventilation shield is blocked.
(c) Crankcase pressure or channeling gas exceeds the
acceptable tolerance scope.
Next Step
Step 4 Check other items:
Next Step
Consequences of incorrect operation

1、If the crankcase ventilation hose is blocked, it will cause the following faults:
– Unstable idle speed.
– Speed miss or idle speed is too low
– Engine oil leakage
– Engine oil enters the intake pipe.
– Sludge appeared in the engine
2、Ventilation hood or hose leakage may lead to the following faults:
– Idle traveling block.
– Stall.
NL-3 01/2016
EC-10 JLE-4G18TDB Auxiliary Emission Control Device – Carbon Canister
Carbon Canister
Component
EC
valve hose outlet
Right mounting
bracket of canister
Carbon
canister
Fuel tank body
Hose to canister control valve
Left mounting bracket of canister
Carbon canister bottom guard plate
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JLE-4G18TDB Auxiliary Emission Control Device – Carbon Canister EC-11
Removal
1. Lift the vehicle
2. Remove the bottom guard plate of canister
1) Remove 4 fixing screws of the bottom guard plate
of the canister, and take down the bottom guard
plate.
EC
3. Remove the canister and bracket assembly

1) Disconnect the canister from the fuel tank
connecting line 1.
2) Disconnect the canister from the canister
solenoid valve connecting line 2.
3) Disconnect the canister from the refueling
breather connecting line 3.
4) Remove 2 fixing bolts of the left canister

5) Remove 1 fixing bolt of the right canister
6) Take down the canister and bracket assembly.
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4. Disassembly of canister and bracket assembly

1) Remove 2 fixing bolts of the left bracket from the
canister, and take down the left bracket.
EC
2) Remove 2 fixing bolts of the right bracket from the

canister, and take down the right bracket.
Check
1. Check the canister
1) Visually check the canister for rupture or damage.
2) Check the airtightness and liquidity of the canister.
NL-3 01/2016
JLE-4G18TDB Auxiliary Emission Control Device – Carbon Canister EC-13
Installation
1. Assembly of canister and bracket assembly
1) Install the right bracket to the canister, and tighten 2
fixing bolts.
EC
2) Install the left bracket to the canister, and tighten 2

fixing bolts.
2. Install the canister and bracket assembly

1) Install 2 fixing bolts of the left canister mounting
2) Install 1 fixing bolt of the right canister mounting
NL-3 01/2016
3) Connect the canister and the canister solenoid

connecting line 2.
4) Connect the canister and the fuel tank
connecting line 1.
5) Connect the canister and the refueling breather
connecting line 3.
EC
3. Install the bottom guard plate of canister

1) Install the bottom guard plate of the canister, and
tighten 4 fixing screws of the guard plate.
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JLE-4G18TDB Auxiliary Emission Control Device – Carbon Canister Solenoid Valve EC-15
Carbon Canister Solenoid Valve

Component
Engine trim cover
EC
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EC-16 JLE-4G18TDB Auxiliary Emission Control Device – Carbon Canister Solenoid Valve
Removal
cover"
4. Remove the canister control valve
1) Disconnect canister control valve harness
connector.
EC
2) Disconnect the connection between carbon

canister control valve hose outlet and carbon
canister control valve.
3) Disconnect the connection between carbon

canister control valve hose inlet and carbon
canister control valve.
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JLE-4G18TDB Auxiliary Emission Control Device – Carbon Canister Solenoid Valve EC-17
4) Remove the canister control valve from the

canister control valve bracket.
EC
Check
1. Check the canister control valve
1) Measure the resistance value between 2
terminals of the canister control valve.
2) Check whether the canister control valve
operates normally.
Installation
1. Install the canister control valve
1) Install the canister control valve to the canister
control valve bracket.
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EC-18 JLE-4G18TDB Auxiliary Emission Control Device – Carbon Canister Solenoid Valve
2) Connect carbon canister control valve hose inlet
EC
3) Connect carbon canister control valve hose outlet
4) Connect canister control valve harness connector

NL-3 01/2016
JLE-4G18TDB Auxiliary Emission Control Device – Front Oxygen Sensor EC-19
Front Oxygen Sensor

Component
EC
Front oxygen sensor（4G18TD）
Rear oxygen sensor（4G18TD）
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EC-20 JLE-4G18TDB Auxiliary Emission Control Device – Front Oxygen Sensor
Removal
compartment"
compartment"
6. Remove the front oxygen sensor.
1) Disconnect the front oxygen sensor harness
CH connector.
2) Remove the front oxygen sensor.
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JLE-4G18TDB Auxiliary Emission Control Device – Front Oxygen Sensor EC-21
Installation
1) Tighten the front oxygen sensor.
EC
2) Connect the front oxygen sensor harness connector.

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EC-22 JLE-4G18TDB Auxiliary Emission Control Device – Rear Oxygen Sensor
Rear Oxygen Sensor

Component
CH Front oxygen sensor（4G18TD）
Rear oxygen sensor（4G18TD）
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JLE-4G18TDB Auxiliary Emission Control Device – Rear Oxygen Sensor EC-23
Removal
3. Lift the vehicle
4. Remove the rear oxygen sensor.
1) Disconnect rear oxygen sensor cable connector.
EC
2) Remove the rear oxygen sensor.
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EC-24 JLE-4G18TDB Auxiliary Emission Control Device – Rear Oxygen Sensor
Installation
1. Install the rear oxygen sensor.
1) Install and tighten the rear oxygen sensor.
CH

NL-3 01/2016
JLD-4G20/24 Ignition System –Contents LG-1
IG JLD-4G20/24 Ignition System
Ignition System ..............................................................................................................................lG-2

Component Position .............................................................................................................................. lG-2
No Power Output from Main Relay IGN after Starting .......................................................................... lG-3
Spark Plug No Arcing Fault ................................................................................................................... lG-7
Spark Plug Check and Diagnosis........................................................................................................ lG-12
Common Spark Plug Fault Phenomenon in Use ................................................................................ lG-14
On-board Check .................................................................................................................................. lG-17
Ignition Coil ..................................................................................................................................lG-18
Component .......................................................................................................................................... lG-18 LG
Removal .............................................................................................................................................. lG-19
Installation ........................................................................................................................................... lG-20
Spark Plug ....................................................................................................................................lG-21
Component .......................................................................................................................................... lG-21
Removal .............................................................................................................................................. lG-22
Installation ........................................................................................................................................... lG-22
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IG-2 JLD-4G20/24 Ignition System –Ignition System
Ignition System
Component Position
Ignition coil
Spark plug
IG
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JLD-4G20/24 Ignition System –Ignition System IG-3
No Power Output from Main Relay IGN after Starting

Notice
First determine whether there is engine DTC when overhauling there is no power output of the ignition relay, whether the
signal transmissions between engine anti-theft passive entry passive start (PEPS), BCM, and engine control module are
normal, and they should be repaired first if not normal.
Cylinder No.1 ignition coil Cylinder No.2 ignition coil Cylinder No.3 ignition coil Cylinder No.4 ignition coil
IG
Main relay
ER05
Diagnostic steps:
Step 1 Check whether the fuse EF10 is blown out.
(a) Remove the fuse EF10.
Engine compartment fuse, relay

(b) Measure the resistance value at both ends of the fuse
box with a multimeter.
value.
No Replace the fuse EF10.
Yes
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Step 2 Check the conductivity of the power supply wire of the main relay ER05.

Engine compartment fuse and relay box. mode to OFF state.
(b) Remove the main relay ER05.
(c) Measure the voltage value between B+ and terminal 86
of main relay ER05.
(d) Measure the voltage value between B+ and terminal 30
of main relay ER05.
(e) Confirm whether the voltage meets the standard value.
IG
Yes
Step 3 Check the harness between main relay ER05 and control module.
(g) Disconnect the negative battery cable.
(h) Remove the main relay ER05.
(i) Disconnect the EMS harness connector CA45.
(j) Measure the resistance value between terminal 5 of EMS
harness connector CA45 and terminal 85 of main relay
ER05.
(k) Confirm whether the resistance value meets the standard
value.
Yes
Step 4 Replace the main relay ER05.
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mode to OFF state.
(b) Remove and replace the main relay ER05.
(c) Measure the output voltage value at terminal 30 of the
main relay ER05.
(d) Confirm whether the voltage value meets the standard
value.
No Replace the main relay ER05.
IG
Yes
Step 5 Check the fuse EF09 of EMS power circuit.

Engine compartment fuse, relay box (b) Measure the resistance value at both ends of the fuse
with a multimeter.
value.
No Replace fuse EF09 after overhaul of

harness short circuit fault
Yes

mode to OFF state.
(b) Measure the resistance value between B＋ of battery
and fuse EF09.
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Yes

mode to OFF state.
CA45 Engine management system

(b) Measure the resistance between terminals 63 and 64 of
harness connector EMS harness connector CA45 and the reliable
grounding point.

IG
Next Step

Next Step
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Spark Plug No Arcing Fault

Notice
Before diagnosis of spark plug not arcing, make sure the engine anti-theft locking system is not activated and is working
properly.
Notice
When the ignition coil is under arcing test, it is prohibited to connect the ignition coil directly with grounding, which may
damage the ignition coil or engine control module. The correct method is to connect one end of a good spark plug to the
ignition coil, and the other end to the reliable grounding.
IG
Main Cylinder No.1 ignition coil Cylinder No.2 ignition coil Cylinder No.3 ignition coil Cylinder No.4 ignition coil
relay
ER05
Diagnostic steps:
Notice
Before overhauling non-ignition of the spark plug, first determine whether the main relay has power output.
NL-3 01/2016

with a multimeter.
value.
IG
Yes
Step 2 Check the voltage on terminals 1 of ignition coil EN10

mode to OFF state.
(b) Disconnect the negative battery cable, and disconnect
the harness connector EG10 of the cylinder No.1
EG10 Ignition coil 1 harness connector
ignition coil.
(c) Connect the negative battery cable.
(d) Operate the power switch to turn the power supply
mode to ON state.
(e) Measure the voltage between terminal 2 of the harness
connector EG10 of the cylinder No.1 ignition coil and a
reliable ground point.
value.
No
Maintain or replace the harness.
Yes
(a) Remove the spark plug; refer to "Spark plug".

(b) Confirm whether the spark plug is working properly.
No Replace the spark plug.
Yes
Step 4 Check ignition coil control line
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mode to OFF state.
(d) Disconnect EMS harness connector EG24.
EG10 Ignition coil 1 harness connector

(e) Disconnect the ignition coil harness connector EG10.
EMS harness connector EG24 and terminal 1 of ignition
coil harness connector EG10.
(g) Measure the resistance between terminal 1 of ignition
coil harness connector EG10 and reliable grounding.
(h) Measure resistance between terminal 1 of ignition coil
harness connectors EG10 and EN31 and power supply.
IG
(i) Confirm whether the resistance is normal.

Yes
Step 5 Check the ignition coil working performance.
(a) Replace with new ignition coil.

(b) Confirm if the system is working normally.
Notice
The time for starter switch in "ST" position should not be
longer than 5 seconds; otherwise it will damage the starter
motor.
Notice
It can also connect the fault diagnostic scanner, when the
starter switch is in the "ST" position, and observe the data
stream in the fault diagnostic scanner: Engine/Data
list/"Engine speed".
Yes Replace the ignition coil, and confirm the

system is working properly.
No
Step 6 Check the ignition coil grounding circuit.
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mode to OFF state.
(b) Disconnect the ignition coil harness connectors EG10
EG10 Ignition coil 1 harness connector (c) Measure the resistance between terminal 3 of ignition
coil harness connectors EG10 and reliable grounding.
value.
IG
Yes
Step 7 Turn the starter switch to "ST" position, and observe whether the engine speed is displayed in the
instrument.
(a) Confirm whether the speed is displayed.
Yes Go to step 10
No
Step 8 Check speed sensor signal fault.
Next Step

mode to OFF state.
CA45 Engine management system (b) Measure the resistance value between B＋ of battery
harness connector and fuse EF09.
Yes
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mode to OFF state.
CA45 Engine management system harness connector (b) Measure the resistance between terminals 63 and 64 of
grounding point.
IG
Next Step

Next Step
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Spark Plug Check and Diagnosis

1. Drawing of spark plug structure:
IG
Step 1 Remove the spark plug; refer to "Spark plug".
Next Step
Step 2 Check whether terminal A is bent or broken, and inspect whether terminal A is loose through twisting
and pulling the terminal.
Next Step
Step 3 Check whether the insulator B has arcing or signs of leakage, which is due to discharging between
the two ends of terminal B which lies between terminal A and the grounding point.
Check whether there are the following situations:

(a) Check the ignition coil for damage.
(b) Check whether the cylinder head spark plug groove is
wet. Whether there is engine oil, engine coolant or
water. Damped spark plug will cause arc discharge.
Next Step
Step 4 Check whether the insulator B has crack, or else, it may cause discharge.
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Next Step
Step 5 Check whether there is any indication of abnormal discharge of the center electrode C, and measure
the clearance between the center electrodes.
(a) Check whether the spark plug torque is correct. The

spark plug tightening torque is 25Nm (18.45 lb-ft). The
spark plug will not work properly due to insufficiency of
the torque, and insulator B cracking will be caused by
too large spark plug tightening torque.
(b) Check whether there is power loss in the insulator tip
instead of the center electrode D.
(c) Check for the electrode C-side fracture and worn.
(d) Check whether the center electrode D is broken, worn IG
or loosen by shaking spark plug. It means that the
internal parts are damaged if crackling sound is heard.
The loosen center electrode D will decrease the spark
strength.
(e) Check whether there is short circuit connection in
electrode C and D; the reduced deposit in electrode C
will reduce or even eliminate their clearance.
(f) Check whether the electrode is too dirty.
Next Step
Step 6 Check whether there is debris in the spark plug slot of the cylinder lid. Or else, it may damage the
spark plug during installation.
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Common Spark Plug Fault Phenomenon in Use

Serious burn of the spark plug: the scar in the spark plug top, damage or electrode melting and burning indicate the spark plug
has been damaged. The same shall be replaced. During replacement, the symptom of ablation and color changes shall be
checked in order to analyze the cause of fault:
a. If the electrode is melting and the insulator becoming white, it indicates that the overtemperature occurs in combustion
chamber. This may be due to there is too much carbon residue in the combustion chamber, so that valve clearance is too
small caused by overheating or cooling fault. Another possible reason is that the tightening torque of spark plug does
not match the specified value.
b. The round electrode and insulator joint scar indicates the early combustion of the engine. It may be caused by earlier
ignition time, low octane value of the gasoline or over high spar plug's calorific value, etc.
c. Insulator top rupture. Knock combustion is the main reason of the insulator rupture. Premature ignition timing, lowoctane
gasoline or too high combustor temperature may lead to engine knocking combustion.
d. The insulator top has grey black stripe. Such stripe means that the spark plug has leakage. A new one shall be replaced.
IG Spark plug deposit: with respect to the sticky deposit between the spark plug insulator top and electrode, if the scenario is
severe, the engine will stop work; if the spark plug is cleaned, it may be temporarily remedied. In order to sustain good
performance, the fault root cause shall be determined.
a. Oily deposit. The oily deposit of the spark plug shows the lubricant has entered the combustion chamber. In case of only
the individual spark plug, possibly, the valve tappet lute is damaged. If every cylinder spark plug has oily residue, it
indicates that there is cylinder channeling oil. Check whether the air filter and ventilation device is blocked.
b. Black deposit. There is black residue on the spark plug electrodes and inside the spark plug, indicating that the mixture is
too thick. Increase the engine running speed and retain for a few minutes to burn the layer of black soot on the electrode.
1. With normal spark plug, center electrode is gray or yellow.
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2. With excessive fuel combustion, spark plug center electrode has serious corrosion.
IG
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3. The incorrect calorific value of the spark plug or the fault phenomenon caused by the engine fuel system fault, the spark
plug's center electrode and insulation magnet has very serious carbon deposit.
IG
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On-board Check
1. Check the ignition coil assembly and perform the spark
test.
1) Open the engine hood.
3) Remove the engine trim cover. Refer to "Engine
trim cover".
4) Remove the ignition coil. Refer to "Ignition coil"
5) Remove the spark plug. Refer to "Spark plug"
6) Disconnect 4 fuel injector harness connectors.
7) Install the tested spark plug to the ignition coil.
8) Ground the tested spark plug, rotate the engine, IG
and check the spark plug for spark.
9) Check other spark plugs by the above method.
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IG-18 JLD-4G20/24 Ignition System –Ignition Coil
Ignition Coil
Component
Engine trim cover
IG
Ignition coil
Spark coil
Engine assembly
NL-3 01/2016
JLD-4G20/24 Ignition System –Ignition Coil IG-19
Removal
cover"
4. Remove the ignition coil
1) Disconnect the ignition coil harness connector.
IG
2) Remove the fixing bolts of ignition coil and

remove the ignition coil.
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IG-20 JLD-4G20/24 Ignition System –Ignition Coil
Installation
1) Apply a small amount of dielectric grease to the
ignition coil head, and install the ignition coil.
2) Tighten the ignition coil fixing bolt.
3) Connect spark plug coil connector.
IG
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JLD-4G20/24 Ignition System –Spark Plug IG-21
Spark Plug
Component
Engine trim cover
IG
Ignition coil
Spark coil
Engine assembly
NL-3 01/2016
IG-22 JLD-4G20/24 Ignition System –Spark Plug
Removal
cover"
4. Remove the ignition coil; refer to “Ignition coil”
5. Remove the spark plug
1) Remove the spark plug with a special tool for S16
spark plug
IG
Installation
1. Install the spark plugs.
1) Insert the spark plug, and tighten to the specified
torque with a special tool.
NL-3 01/2016
IG JLE-4G18TDB Ignition System –Contents IG-1
IG JLE-4G18TDB Ignition System
Ignition System ..............................................................................................................................IG-2

Component Position .............................................................................................................................. IG-2
On-board Check .................................................................................................................................... IG-3
No Power Output from Main Relay IGN after Starting .......................................................................... IG-4
Spark Plug No Arcing Fault ................................................................................................................... IG-8
Spark Plug Check and Diagnosis........................................................................................................ IG-13
Common Spark Plug Fault Phenomenon in Use ................................................................................ IG-15
The Ignition Coil Component ......................................................................................................IG-18
Component .......................................................................................................................................... IG-18 IG
Removal .............................................................................................................................................. IG-19
Installation ........................................................................................................................................... IG-19
Spark Plug ....................................................................................................................................IG-20
Component .......................................................................................................................................... IG-20
Removal .............................................................................................................................................. IG-21
Installation ........................................................................................................................................... IG-21
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IG-2 JLE-4G18TDB Ignition System –Ignition System
Ignition System
Component Position
Engine trim cover
Ignition coil
Spark coil
IG
NL-3 01/2016
JLE-4G18TDB Ignition System –Ignition System IG-3
On-board Check
3. Remove the engine trim cover. Refer to Engine trim
cover.
4. Remove the ignition coil component Refer to "Ignition
coil component"
5. Remove the spark plug Refer to "Spark plug"
6. Check the ignition coil component and perform the
spark test.
2) Install the tested spark plug to the ignition coil IG
component.
3) Ground the tested spark plug, and test in
sequence to see whether the spark plug gives
out any sparks when the engine is rotated.
4) After confirming that the spark plug is normal,
perform the spark plug test by the above method.
NL-3 01/2016
No Power Output from Main Relay IGN after Starting

Notice
First determine whether there is engine DTC when overhauling there is no power output of the ignition relay, whether the
signal transmissions between engine anti-theft passive entry passive start (PEPS), BCM, and engine control module are
normal, and they should be repaired first if not normal.
7. Circuit diagram:
Main
relay
ER05 Cylinder No.1 ignition coil Cylinder No.2 ignition coil Cylinder No.3 ignition coil Cylinder No.4 ignition coil
IG
Diagnostic steps:

with a multimeter.
value.
Yes
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Step 2 Check the conductivity of the power supply wire of the main relay ER05.

mode to OFF state.
(b) Remove the main relay ER05.
(c) Measure the voltage value between B+ and terminal 86
of main relay ER05.
(d) Measure the voltage value between B+ and terminal 30
of main relay ER05.
(e) Confirm whether the voltage value meets the standard
value.
No IG
Maintain or replace the harness.
Yes
Step 3 Check the circuit between main relay ER05 and EMS.

mode to OFF state.
(g) Disconnect the negative battery cable.
(h) Remove the main relay ER05.
(i) Disconnect the EMS harness connector CA01.
(j) Measure the resistance value between terminal 69 of
EMS harness connector CA01 and terminal 85 of main
relay ER05.
(k) Confirm whether the resistance value meets the
standard value.
CA01Engine
Enginecompartment
managementfuse,
system (plug-in
relay box part K) harness connector 2
Yes
Step 4 Replace the main relay ER05.
NL-3 01/2016

(b) Remove and replace the main relay ER05.
(c) Measure the output voltage value at terminal 30 of the
main relay ER05.
value.
No Replace the main relay ER05.
IG
Yes
Step 5 Check the fuse EF09 of EMS power.

with a multimeter.
value.
No Replace fuse EF09 after overhaul of

harness short circuit fault
Yes
OFF state.
(b) Measure the resistance value between B＋ of battery and
fuse EF09.
(c) Measure the resistance between fuse EF09 and terminals
3, 5 and 6 of EMS harness connector CA01.
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Yes

mode to OFF state.
(b) Measure the resistance between terminals 1, 2 and 4 of
EMS harness connector CA01 and reliable grounding
point.
No Repair or replace the harness IG
Next Step

Next Step
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Spark Plug No Arcing Fault

Notice
Before diagnosis of spark plug not arcing, make sure the engine anti-theft locking system is not activated and is working
properly.
Notice
When the ignition coil is under arcing test, it is prohibited to connect the ignition coil directly with grounding, which may
damage the ignition coil or engine control module. The correct method is to connect one end of a good spark plug to the
ignition coil, and the other end to the reliable grounding.
8. Circuit diagram:
IG
Main Cylinder No.1 ignition coil Cylinder No.2 ignition coil Cylinder No.3 ignition coil Cylinder No.4 ignition coil
relay
ER05
Diagnostic steps:
Notice
Before overhauling non-ignition of the spark plug, first determine whether the main relay has power output.
NL-3 01/2016

with a multimeter.
value.
IG
Yes
Step 2 Check the voltage on terminal 1 of ignition coil EN10

mode to OFF state.
EN10 Ignition coil 1 harness connector (b) Disconnect the negative battery cable, and disconnect
the harness connector EN10 of the cylinder No.1
ignition coil.
(c) Connect the negative battery cable, and connect the
harness connector EN10 of the cylinder No.1 ignition
coil.
(d) Operate the power switch to turn the power supply
mode to ON state.
(e) Measure the voltage between terminal 1 of the harness
connector EN10 of the cylinder No.1 ignition coil and a
reliable ground point.
value.
Yes
(a) Check the spark plug; refer to "Spark plug check and
diagnosis".
(b) Confirm whether the spark plug is working properly.
No Replace the spark plug.
Yes
Step 4 Check ignition coil control circuit
NL-3 01/2016

mode to OFF state.
EN10 Ignition coil 1 harness connector (d) Disconnect EMS harness connector EN35.
(e) Disconnect the ignition coil harness connector EN10.
EMS harness connector EN35 and terminal 2 of ignition
coil harness connector EN10.
(g) Measure the resistance value between terminal 2 of
ignition coil harness connector EN10 and reliable
grounding.
(h) Measure resistance value between terminal 2 of ignition
coil harness connectors EN10 and power supply.
IG Standard Resistance value: 10 kΩ or higher
(i) Confirm whether the resistance is normal.
Yes
Step 5 Check the ignition coil working performance.
(a) Replace with new ignition coils.

(b) Confirm if the system is working normally.
Notice
The time for starter switch in "ST" position should not be
longer than 5 seconds; otherwise it will damage the starter
motor.
Notice
It can also connect the fault diagnostic scanner, when the
starter switch is in the "ST" position, and observe the data
stream in the fault diagnostic scanner: Engine/Data
list/"Engine speed".
Yes Replace the ignition coil, and confirm the

system is working properly.
No
Step 6 Check the ignition coil grounding circuit.
NL-3 01/2016

mode to OFF state.
EN10 Ignition coil 1 harness connector (b) Disconnect the ignition coil harness connectors EN10
(c) Measure the resistance between terminal 3 of ignition
coil harness connectors EN10 and reliable grounding.
value.
IG
Yes
Step 7 Turn the starter switch to "ST" position, and observe whether the engine speed is displayed in the
instrument.
Yes Go to step 10
No
Step 8 Check speed sensor signal fault.
Next Step

mode to OFF state.
(b) Measure the resistance value between B＋ of battery
and fuse EF09.
Yes
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mode to OFF state.
(b) Measure the resistance between terminal 1/2/4 of EMS
IG
Next Step

Next Step
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Spark Plug Check and Diagnosis

1. Drawing of Spark Plug Structure:
IG
Diagnostic steps:
Step 1 Remove the spark plug; refer to "Spark plug".
Next Step
Step 2 Check whether terminal A is bent or broken, and inspect whether terminal A is loose through twisting
and pulling the terminal.
Next Step
Step 3 Check whether the insulator B has arcing or signs of leakage, which is due to discharging between
the two ends of terminal B which lies between terminal A and the grounding point.
Check whether there are the following situations:

(a) Check the ignition coil for damage.
(b) Check whether the cylinder head spark plug groove is
wet. Engine oil, engine coolant or water is not allowed.
Because damped spark plug sleeve will cause arc
discharge.
Next Step
Step 4 Check whether the insulator B has crack, or else, it may cause discharge.
NL-3 01/2016
Next Step
Step 5 Check whether there is any indication of abnormal discharge of the center electrode C, and measure
the clearance between the center electrodes.
(a) Check whether the spark plug torque is correct. The

spark plug tightening torque is30N.m (18.45 lb-ft). The
spark plug will not work properly due to insufficiency of
the torque, and insulator B cracking will be caused by
too large spark plug tightening torque.
(b) Check whether there is power loss in the insulator tip
instead of the center electrode D.
IG (c) Check for the electrode C-side fracture and worn.
(d) Check whether the center electrode D is broken, worn
or loosen by shaking spark plug. It means that the
internal parts are damaged if crackling sound is heard.
The loosen center electrode D will decrease the spark
strength.
(e) Check whether there is short circuit connection in
electrode C and D; the reduced deposit in electrode C
will reduce or even eliminate their clearance.
(f) Check whether the electrode is too dirty.
Next Step
Step 6 Check whether there is debris in the spark plug slot of the cylinder lid. Or else, it may damage the
spark plug during installation.
NL-3 01/2016
Common Spark Plug Fault Phenomenon in Use

Serious burn of the spark plug: the scar in the spark plug top, damage or electrode melting and burning indicate the spark plug
has been damaged. The same shall be replaced. During replacement, the symptom of ablation and color changes shall be
checked in order to analyze the cause of fault:
a. If the electrode is melting and the insulator becoming white, it indicates that the overtemperature occurs in combustion
chamber. This may be due to too much carbon residue in the combustion chamber, so that undersize valve clearance
causes overheating or undercooling of exhaust valve or poor operating condition of cooling device. Or the spark plug is
not tightened as specified torque.
b. The round electrode and insulator joint scar indicates the early combustion of the engine. It may be caused by earlier
ignition time, low octane value of the gasoline or over high spar plug's calorific value, etc.
c. Insulator top rupture. Knock combustion is the main reason of the insulator rupture. Premature ignition timing, lowoctane
gasoline or too high combustor temperature may lead to engine knocking combustion.
d. The insulator top has grey black stripe. Such stripe means that the spark plug has leakage. A new one shall be replaced.
Spark plug deposit: with respect to the sticky deposit between the spark plug insulator top and electrode, if the scenario is IG
severe, the engine will stop work; if the spark plug is cleaned, it may be temporarily remedied. In order to sustain good
performance, the fault root cause shall be determined.
a. Oily deposit. The oily deposit of the spark plug shows the lubricant has entered the combustion chamber. In case of
individual spark plug only, possibly, the valve tappet lute is damaged. If every cylinder spark plug has oily residue, it
indicates that there is cylinder channeling oil. Check whether the air filter and ventilation device is blocked.
b. Black deposit. There is black residue on the spark plug electrodes and inside the spark plug, indicating that the mixture is
too thick. Increase the engine running speed and retain for a few minutes to burn the layer of black soot on the electrode.
1. With normal spark plug, center electrode is gray or yellow.
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2. With excessive fuel combustion, spark plug center electrode has serious corrosion.
IG
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3. The incorrect calorific value of the spark plug or the fault phenomenon caused by the fault of engine fuel system, the
center electrode of spark plug and intermediate insulating magnet has very serious carbon deposit.
IG
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IG-18 JLE-4G18TDB Ignition System –The Ignition Coil Component
The Ignition Coil Component

Component
Engine trim cover
IG Ignition coil
Spark coil
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JLE-4G18TDB Ignition System –The Ignition Coil Component IG-19
Removal
cover"
4. Remove the ignition coil component
1) Disconnect the ignition coil component harness
connector.
2) Remove the fixing bolt of ignition coil component.
3) Take out the ignition coil component.
IG
Installation
1. Install the ignition coil component
1) Apply a small amount of dielectric grease to the
ignition coil head, and install the ignition coil
component.
2) Tighten the fixing bolt of ignition coil.
Torque: 8.5 N·m (Metric ) 6.27 lb-ft (English )
3) Connect spark plug coil connector.
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IG-20 JLE-4G18TDB Ignition System –Spark Plug
Spark Plug
Component
Engine trim cover
IG Ignition coil
Spark coil
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JLE-4G18TDB Ignition System –Spark Plug IG-21
Removal
cover"
4. Remove the ignition coil component; refer to "Ignition
coil component"
5. Remove the spark plug
1) Remove the spark plug with a special tool for S16
spark plug
IG
Installation
1. Install the spark plug.
1) Insert the spark plug, and tighten to the specified
torque with a special tool.
2. Install the ignition coil component
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IG-22 JLE-4G18TDB Ignition System –Spark Plug
IG
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JLD-4G20 Starter System –Contents ST-1
ST JLD-4G20 Starter System
Starter System ............................................................................................................................... ST-2

Component Position ............................................................................................................................. ST-2
Fault of No Stop of Starter Motor ......................................................................................................... ST-3
The Engine Is Unable to Start. ............................................................................................................. ST-7
Starting Motor Noise Diagnosis.......................................................................................................... ST-15
Jump Start Procedure ........................................................................................................................ ST-16
Starter Motor ............................................................................................................................... ST-18
Component ......................................................................................................................................... ST-18 ST
Removal ............................................................................................................................................. ST-21
Check ................................................................................................................................................. ST-22
Installation .......................................................................................................................................... ST-22
Starter Motor Relay ..................................................................................................................... ST-23
On-board Check ................................................................................................................................. ST-23
ST-2 JLD-4G20 Starter System – Starter System
Starter System
Component Position
ST
Starter motor
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JLD-4G20 Starter System – Starter System ST-3
Fault of No Stop of Starter Motor

Diagnostic steps:
Step 1 Access the engine management system with the scanner.
(a) Check whether DTC is output.
Yes Diagnose according to output DTCs
No
Step 2 Operate starter switch to change the power supply mode to OFF state.
ST
Next Step
Step 3 Whether the starter motor runs after removing the starter relay?
No Go to step 5.
Yes
Step 4 Disconnect the starter motor harness connector EG26.
(a) Disconnect the negative battery cable.

(b) Disconnect the starter motor harness connector EG26.
EG26 Starter motor excitation harness connector (c) Connect the negative battery cable.
(d) Whether the starter motor is still running?
Yes Replace the starter motor assembly, and

confirm the fault has been eliminated.
No
Step 5 Check the starter motor control circuit.
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mode to OFF state.
(b) Plug down the starter relay.
EG26 Starter motor excitation harness connector
(c) Measure the voltage between terminal 1 of starter
value.
ST
Yes
Step 6 Replace the starter motor relay ER10, and confirm whether the fault is eliminated.
(a) Replace the starter motor relay ER10.

Yes Replace the starter motor relay, and

No
Step 7 Measure the two control circuits of starter motor relay for short circuit.


(c) Disconnect the neutral switch harness connector
EG25.
(d) Disconnect (PEPS) control module harness connector
IP54.
(e) Measure the resistance value between the circuit
between terminal 3 of gear switch harness connector
EG25 and terminal 86 of starter relay ER10 and the
reliable grounding circuit.( MT model)
(f) Measure the resistance value between the circuit
between terminal 13 of passive entry passive start
(PEPS) control module harness connector IP54 and
terminal 85 of starter relay ER10 and the reliable
grounding.
(g) Measure the resistance between the circuit between
terminal 10 of passive entry passive start control
module harness connector IP54 and terminal 86 of
starter relay ER10 and the reliable power supply
circuit.
(h) Confirm whether the resistance value meets the
standard value.
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Engine compartment, relay box No Overhaul or replace the harness
ST
EG25 neutral switch harness connector
Yes
Step 8 Check the starter signal feedback circuit.
(a) Measure the resistance value between terminal 85 of

starter motor relay ER10 and terminal 13 of PEPS
control module harness connector IP54.
(b) Ensure whether the system is normal.
No Overhaul or replace the harness
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Engine compartment, relay box
ST
Yes
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The engine is unable to start.

Notice
Before performing this test procedure, it is necessary to check all fuses of the starting system, which helps eliminate the fault
quickly.
Diagnostic steps:
No
Step 2 Confirm the fault symptoms. ST
Next Step
Step 3 Does the engine run?
No Go to step 8
Yes
Step 4 Is the engine running normal?
No Go to step 6
Yes
Step 5 Check the ignition/fuel system.
(a) Troubleshoot the faults of fuel system and ignition system

(b) Confirm that there is no fault in the fuel system or
ignition system.
Next Step
Step 6 Check power supply situation of the starter motor.
Check the following contents:

(a) Whether the battery charging situation is normal and
the starting voltage is less than 10.5V, otherwise the
battery should be recharged.
(b) Check the battery binding post connections for
looseness and corrosion.
(c) Check the engine mechanical system to determine
whether there is abnormal noise and whether the
cylinder compression pressure is normal.
(d) Whether all these are normal?
Yes
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Step 7 Replace the starter motor.

(a) Replace the starter motor; refer to "Starter motor".
Next Step
Step 8 Does the starter motor rotate?
Yes Replace the starter motor
No
Step 9 Does the solenoid switch of starter motor work?
ST
No Go to step 15
Yes
Step 10 Check the engine and belt drive system for mechanical catching (engine catching, alternator catching).
Yes Repair the catching position.
No
Step 11 Check whether the resistance of cables between the battery and starter solenoid switch is too high.
Standard value: Less than 0.3 Ω
(a) Confirm whether the resistance value meets the
standard value.
No Check and repair the cable, and replace

the harness if necessary
Yes
Step 12 Check whether the grounding circuit resistance between the battery and the starter motor is too high.
standard value.

Yes
Step 13 Check whether the starter solenoid switch harness connection is normal.
No Treat abnormally connected parts
Yes

(a) Confirm whether the faults are eliminated?
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Yes Treat abnormally connected parts
No
Step 15 Check the starter motor control power supply.

mode to OFF state.
(b) Disconnect the starter motor harness connector EG26.
mode to ST state.
(d) Measure the voltage of terminal 1 of starter motor
ST
No
Step 16 Check the starter motor control power supply harness.

mode to OFF state.
(c) Measure the resistance value of terminal 87 of starter
relay ER10 and terminal 1 of starter motor harness
connector EG26.
standard value.

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Engine fuse relay box
ST
Yes
Step 17 Operate starter switch to put power supply mode in ST state, and check whether starter relay can be engaged.
No Go to step 21
Yes
Step 18 Measure the power supply of terminal 30 of starter motor relay ER10.
(a) Remove the starter motor relay.

Engine fuse relay box (b) Measure the voltage of terminal 30 of starter motor
relay ER10 in the fuse relay box of the engine
compartment.
(c) Confirm whether the voltage value meets the standard
value.
Yes Replace the starter motor relay ER10.
No
Step 19 Check the starter motor relay fuse IF14 and check for a short circuit.
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(a) Plug down the fuse IF14 and observe whether the fuse
Indoor fuse, relay box is blown out.
Replace the fuse, repair the short circuit

Yes
fault, and replace the harness if
necessary
ST
No
Step 20 Check the circuit between fuse IF14 and battery harness.

Indoor fuse, relay box mode to OFF state.
(c) Measure the resistance value between fuse IF14 and
terminal 1 of battery harness connector EG34.
standard value.
No Check and repair the harness, and

EG34 Front fuse box harness connector (B+)

`
Yes
Step 21 Check the voltage of the control line of the starter motor relay.
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(b) Remove the starter motor relay ER10.
mode to ST state.
(d) (Measure the voltage between terminals 85 and 86 of
starter motor relay ER10 respectively.
(e) Confirm whether the resistance value meets the
standard value.
Yes Replace the starter motor relay ER10.

ST
No
Step 22 Check the control harness of the starter motor relay.

mode to OFF state.
IP54 PEPS harness connector 1 (b) Remove the starter motor relay ER10.
(c) Disconnect the negative battery cable.
(d) Disconnect the harness connector IP54 of PEPS
control component and the harness connector EG25 of
neutral switch.
starter relay ER10 and terminal 10 of PEPS control
module harness connector IP54.
(f) Measure the resistance value of terminal 86 of starter
motor relay ER10 and terminal 3 of neutral switch
(g) Confirm whether the resistance value meets the
standard value?

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EG25 Neutral switch harness connector
ST
Yes
Step 23 Check the continuity between starter motor relay ER10 and PEPS.

mode to OFF state.
IP54 PEPS harness connector 1 (b) Disconnect the negative battery cable.
(c) Disconnect the PEPS harness connector IP54.
harness connector IP54.
(f) Confirm whether the resistance value is normal.

Yes
Step 24 Check the continuity between starter motor relay ER10 and neutral switch.
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mode to OFF state.
EG25 Neutral switch harness connector (b) Disconnect the negative battery cable.
(c) Disconnect the neutral switch harness connector EG25.
starter motor relay ER10 and terminal 3 of neutral
(e) Confirm whether the resistance is normal.

ST
Yes
Step 25 Replace the starting switch.
(a) Replace the starting switch.

(b) Check whether the system is normal.
No
Step 26 Check the PEPS control module.
(a) Check the PEPS control module.

Next Step
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Starting Motor Noise Diagnosis

Before starting the diagnosis, please refer to the system description and precautions, and perform necessary checking.
Diagnostic steps:
Step 1 Start the engine, and monitor whether the starter motor rotates.
a) When the engine starts and the starter remains at the

close position, any loud "sigh" (if the starter is at the
close position, the engine speed further increases,
does the sound seem to be the alarm)?
Yes Go to step 5
No ST
Step 2 When the engine starts, with the gradual stop of the starter, any "wuthering", "roaring" or "knock" sound
under certain circumstance?
Yes Go to step 4
No
Step 3 When the engine starts and the engine crankshaft turns and normally starts, any high frequency fluid wuthering?
Next Step
Step 4 Overhaul the starter motor.
(a) Check starter motor bushings and clutch gears, to see

whether clutch gears are cracking or worn or bushings
are worn.
Next Step
Step 5 Check the flywheel.
(a) Check whether the flywheel gear ring has the following
faults: gear rupture, gear miss, gear wear, flywheel
bend, or the gear damage. If necessary, replace the
flywheel
Yes Replace the flywheel.
Next Step
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Jump Start Procedure

Diagnostic steps:
Step 1 Park properly the vehicle capable of providing the jumping power supply so that the jumping cable
can connect the battery of the both vehicles.
Next Step
Step 2 Operate starter switch to put power supply mode of both vehicles in OFF state, and shut down
headlamps and all the accessory power equipment.
Next Step
Step 3 Press down the hazard alarm lamp switch and make the hazard alarm lamp on.
Next Step
ST
Step 4 Enable the two vehicle park brakes.
Next Step
Step 5 Determine the transmission is in the neutral position.

Warning!
The bridge connection cable must be intact without
exposed wires; otherwise it will cause unnecessary
personal injury or vehicle damage.
Next Step
Step 6 Connect one end of the red cable to the positive terminal of the battery capable of providing adequate
power and determine it is not connected with other metal pieces.
Next Step
Step 7 Connect the other end of the red cable to the positive terminal of the discharged batter; don't connect
the red cable to the negative terminal of the discharged battery.
Warning!
Do not connect the bridge connection cable directly to the
battery negative terminal to prevent the spark and possible
battery gas explosion.
Next Step
Step 8 Connect one end of the black cable to the negative terminal of the battery capable of providing
adequate power.
Next Step
Step 9 Finally, connect one end of the black cable to the fixed grounding point of the engine with battery, and
the distance to the battery is at least 500 mm (19.7 in).
Next Step
Step 10 Start the vehicle's engine with sufficient power provided by the battery, and make the engine runs at
medium speed for 3 min or more.
Next Step
Step 11 The startup is equipped with the vehicle engine with discharged battery.
Next Step
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Step 12 Remove the jumper cables in reverse order.
Next Step
Notice
During the removal procedure, if the other end of the cable has not been fully disconnected, avoid the cable clamp contact with
any metal objects.
Step 13 The operation is completed.
ST
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ST-18 JLD-4G20 Starter System – Starter Motor
Starter Motor
Component
ST
Engine trim cover
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JLD-4G20 Starter System – Starter Motor ST-19
Air filter element ST
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ST
Starter motor
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JLD-4G20 Starter System – Starter Motor ST-21
Removal
cover"
4. Remove the air filter intake pipe; refer to "Air filter
intake pipe"
5. Remove the upper shell air outlet flange plate; refer to
"Air filter"
6. Remove the air filter; refer to "Air filter"
7. Remove the starter motor
1) Disconnect the starter motor power cord (Label ST
1).
2) Disconnect the electromagnetic switch line
(Label 2) of the starter motor.
3) Remove 2 fixing bolts of the starter motor.

4) Take down the starter motor.
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Check
1. Check the starter motor
1) Clip the starter motor to a vise.
2) Connect the battery and ammeter to the starter
motor.
3) When the clutch pinion remains stretch out,
check and confirm whether the starter motor
rotates steadily. Check and confirm whether the
ammeter reading is in accordance with the
current value specified below.
Standard current
Starter motor (electromagnetic switch) holding
ST coil (at 12.2V) current: 36A
Starter motor (electromagnetic switch) suction
coil (at 12.2V) current: 13A
Installation
1) Install and tighten the starter motor and 2 fixing
bolts.
Torque: 60N·m (Metric) 44.28lb-ft(English)
2) Connect the starter motor power cord (Label 1)

and the electromagnetic switch line (Label 2) of
the starter motor.
3) Start the vehicle, and check whether the starter
motor operates normally.
2. Install the air filter.
3. Install the upper housing air outlet flange plate
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JLD-4G20 Starter System – Starter Motor Relay ST-23
Starter Motor Relay On-board Check

1. Check the starter motor relay
1) Apply DC 12V voltage to terminal 85 and terminal
86 of the starter relay, and a "click" from a pick-up
of the relay can be heard.
2) Measure the resistance between terminal 30 and
terminal 87 without applying DC 12V voltage to
terminal 85 and terminal 86 of the starter relay.
Standard value: More than 10kΩ
ST
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ST-24 JLD-4G20 Starter System – Starter Motor Relay
ST
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JLE-4G18TDB Starter System –Contents ST-1
ST JLE-4G18TDB Starter System
Starter System ............................................................................................................................... ST-2

Component Position ............................................................................................................................. ST-2
Fault of No Stop of Starter Motor ......................................................................................................... ST-4
The Engine Is Unable to Start. ............................................................................................................. ST-8
Starting Motor Noise Diagnosis.......................................................................................................... ST-18
Starter Motor MT ......................................................................................................................... ST-19
Component ......................................................................................................................................... ST-19
Removal ............................................................................................................................................. ST-21
Check ................................................................................................................................................. ST-22 ST
Installation .......................................................................................................................................... ST-22
Starter Motor AT .......................................................................................................................... ST-23
Component ......................................................................................................................................... ST-23
Removal ............................................................................................................................................. ST-25
Check ................................................................................................................................................. ST-26
Installation .......................................................................................................................................... ST-26
Starter Motor Relay ..................................................................................................................... ST-27
On-board Check ................................................................................................................................. ST-27
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ST-2 JLE-4G18TDB Starter System – Starter System
Starter System
Component Position
ST
MT starter
motor
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JLE-4G18TDB Starter System – Starter System ST-3
ST
AT starter
motor
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Fault of No Stop of Starter Motor

No
Step 2 Operate starter switch to change the power supply mode to OFF state.
ST
Next Step
Step 3 Whether the starter motor runs after removing the starter relay?
No Go to step 5
Yes
Step 4 Disconnect the starter motor harness connector EN26 (AT model) or EN43 (MT model).

(b) Disconnect the starter motor harness connector EN26
(AT model) or EN43 (MT model).
EN26 Starter motor excitation harness connector (AT model)
(d) Whether the starter motor is still running?
Yes Replace the starter motor assembly, and

EN43 Starter motor excitation harness connector (MT model)
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No
Step 5 Check the starter motor control circuit.

mode to OFF state.
(c) Measure the voltage between starter motor harness
connector N26 (AT model) or terminal 1 of EN43 (MT
model) and a reliable grounding.
value.
ST
EN43 Starter motor excitation harness connector (MT model)
Yes
Step 6 Replace the starter motor relay ER10, and confirm whether the fault has been eliminated.
(a) Replace the starter motor relay ER10.

Yes Replace the starter relay, and confirm

No
Step 7 Measure the two control circuits of starter motor relay for short circuit.
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EN31 Transmission position switch harness connector
(c) Disconnect the transmission position switch harness
connector EN31 (AT model) or disconnect the neutral
switch harness connector EN44 (MT model).
(d) Disconnect PEPS control module harness connector
IP54.
(e) Measure the resistance value between the circuit
EN31 and terminal 86 of starter relay ER10 and the
reliable grounding circuit.( AT model)
(f) Measure the resistance value between the circuit
between neutral switch 86 and the reliable grounding
ST (MT model).
(g) Measure the resistance value between the circuit
IP54 PEPS harness connector 1 EN31 and terminal 85 of starter relay ER10 and a
reliable power cord (AT model).
(h) Measure the resistance value between the circuit
between terminal 3 of neutral switch harness connector
EN44 and terminal 85 of starter relay ER10 and a
reliable power cord (MT model).
(i) Measure the resistance value between the circuit
between terminal 13 of PEPS control module harness
connector IP54 and terminal 86 of starter relay ER10
and the reliable grounding.
(j) Measure the resistance between the circuit between
terminal 13 of passive entry passive start control
module harness connector IP54 and terminal 86 of
starter relay ER10 and the reliable power supply circuit.
(k) Confirm whether the resistance value meets the
standard value.
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EN44 Neutral switch harness connector
ST
Yes
Step 8 Check the signal feedback line of the starter motor.
(a) Measure the resistance value between terminal 85 of

control component harness connector IP54.
Yes
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The Engine Is Unable to Start.

Notice
Before performing this test procedure, it is necessary to check all fuses of the starting system, which helps eliminate the fault
quickly.
Diagnostic steps:
No
ST
Next Step
Step 3 Does the engine run?
No Go to step 8
Yes
Step 4 Is the engine running normal?
No Go to step 6
Yes
Step 5 Check the ignition/fuel system.

(a) Perform troubleshooting of fuel system and ignition
system.
(b) Confirm that there is no fault in the fuel system or
ignition system.
Next Step
Step 6 Check power supply situation of the starter motor.

Check the following contents:
(a) Whether the battery charging situation is normal and
the starting voltage is less than 10.5V, otherwise the
battery should be recharged.
(b) Check the battery binding post connections for
looseness and corrosion.
(c) Check the engine mechanical system to determine
whether there is abnormal noise and whether the
cylinder compression pressure is normal.
(d) Whether all these are normal?
Yes
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(a) For replacement of starter motor; refer to "Starter motor
MT” or “starter motor AT".
Next Step
Step 8 Does the starter motor rotate?
No
Step 9 Does the solenoid switch of starter motor work?

ST
No Go to step 15
Yes
Step 10 Check the engine and belt drive system for mechanical catching (engine catching, alternator catching).
Yes Repair the catching position.
No
Step 11 Check whether the resistance of cables between the battery and starter solenoid switch is too high.
Standard value: Less than 0.3 Ω
standard value.

Yes
Step 12 Check whether the grounding circuit resistance between the battery and the starter motor is too high.
standard value.

Yes
Step 13 Check whether the starter solenoid switch harness connection is normal.
No Treat abnormally connected parts
Yes

(a) Confirm whether the faults are eliminated?
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Yes Treat abnormally connected parts
No
Step 15 Check the starter motor control power supply.

mode to OFF state.
EN26 Starter motor excitation harness connector (AT model) (b) Disconnect the starter motor harness connector EN26
(AT model) or EN43 (MT model).
mode to ST state.
ST
(d) Measure the voltage of terminal 1 of starter motor
EN43 Starter excitation harness connector (MT model)
No
Step 16 Check the starter motor control power supply harness.
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mode to OFF state.
(c) Measure the resistance value of terminal 87 of starter
relay ER10 and terminal 1 of starter motor harness
connector EN26.
standard value.

ST
EN43 Starter excitation harness connector (MT model)
Yes
Step 17 Operate starter switch to put power supply mode in ST state, and check whether starter relay can be engaged.
No Go to step 21
Yes
Step 18 Measure power supply at terminal 30 of the starter relay ER10.
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(a) Remove the starter relay.

(b) Measure the voltage of terminal 30 of starter motor
relay ER10 in the fuse relay box of the engine
compartment.
value.
Yes Replace the starter relay ER10.
ST
No
Step 19 Check starter relay fuse IF14 and check whether the circuit is in short circuit.
(a) Plug down the fuse IF14 and observe whether the fuse
Indoor fuse, relay box is blown out.
Yes Replace the fuse, repair the short circuit

fault, and replace the harness if
necessary
No
Step 20 Check the circuit between fuse IF14 and battery harness.

(c) Measure the resistance value between fuse IF14 and
terminal 1 of battery harness connector EN34.
standard value.
No Check the harness and replace it if

necessary
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EN34 Front fuse box harness connector (B+)
ST
Yes
Step 21 Check control circuit voltage of the starter relay.

(b) Remove the starter relay ER10.
mode to ST state.
(d) (Measure the voltage between terminals 85 and 86 of
starter motor relay ER10 respectively.
(e) Confirm whether the resistance value meets the
standard value.
Yes Replace the starter relay ER10.
No
Step 22 Check the control harness of the starter relay.
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mode to OFF state.

(b) Remove the starter motor relay ER10.
(c) Disconnect the negative battery cable.
(d) Disconnect the PEPS control component harness
connector IP54, transmission position switch harness
connector EN31 (AT model) and neutral switch harness
connector EN44 (MT model).
starter relay ER10 and terminal 13 of PEPS control
module harness connector IP54.
(f) Measure the resistance value of terminal 86 of starter
relay ER10 and terminal 3 of transmission position
ST switch harness connector EN31 (AT model).
(g) Measure the resistance value between the terminal 86
Engine compartment fuse, relay box of starter relay ER10 and terminal 3 of transmission
position switch harness connector EN44 (MT model)
Standard value: <1 Ω
(h) Confirm whether the resistance value meets the
standard value?

EN44 Neutral switch harness connector
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EN31 Transmission position switch harness connector
ST
Yes
Step 23 Check the conductivity between starter control relay ER10 and PEPS.

mode to OFF state.
IP54 PEPS harness connector 1 (b) Disconnect the negative battery cable.
(c) Disconnect the PEPS harness connector IP54.
(d) Measure the resistance value between the terminal 86
of starter control relay ER10 and the terminal 13 of
PEPS harness connector IP54.
(e) Measure the resistance value between the terminal 85
of starter motor control relay ER10 and the terminal 10
of PEPS harness connector IP54.

Yes
Step 24 Check the conductivity between starter motor control relay ER10 and transmission position switch
(AT model) or neutral switch (MT model).
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OFF state.
EN31 Transmission position switch harness connector (b) Disconnect the negative battery cable.
(c) Disconnect the transmission position switch harness
connector EN31 (AT model), disconnect the neutral switch
harness connector EN44 (MT model).
(d) Measure the resistance value between terminal 85 of starter
motor control relay ER10 and terminal 3 of transmission
position switch harness connector EN31 (AT model).
(e) Measure the resistance value between terminal 85 of starter
motor control relay ER10 and terminal 3 of neutral switch
ST
EN44 Neutral switch harness connector No Check and repair the harness, and
Yes
Step 25 Replace the starter switch.
(a) Replace the starting switch.

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No
Step 26 Check the PEPS control module.
(a) Check the passive entry passive start control module.

Next Step
ST
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Starting Motor Noise Diagnosis

Before starting the diagnosis, please refer to the system description and precautions, and perform necessary checking.
Diagnostic steps:
Step 1 Start the engine, and monitor whether the starter motor rotates.
a) When the engine starts and the starter remains at the

close position, any loud "sigh" (if the starter is at the
close position, the engine speed further increases,
does the sound seem to be the alarm)?
Yes
Go to step 5
ST No
Step 2 When the engine starts, with the gradual stop of the starter, any "wuthering", "roaring" or "knock" sound
under certain circumstance?
Yes Go to step 4
No
Step 3 When the engine starts and the engine crankshaft turns and normally starts, any high frequency fluid
wuthering?
Next Step
Step 4 Overhaul the starter motor.
(a) Check starter motor bushings and clutch gears, to see

whether clutch gears are cracking or worn or bushings are
worn.
Next Step
Step 5 Check the flywheel.
(a) Check whether the flywheel gear ring has the following
faults: gear rupture, gear miss, gear wear, flywheel
bend, or the gear damage. If necessary, replace the
flywheel
Yes
Replace the flywheel.
Next Step
NL-3 01/2016
JLE-4G18TDB Starter System – Starter Motor MT ST-19
Starter Motor MT
Component
Air flow meter
Engine intake hose

ST
Air filter element
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ST-20 JLE-4G18TDB Starter System – Starter Motor MT
ST
Starter motor MT
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JLE-4G18TDB Starter System – Starter Motor MT ST-21
Removal
cover"
intake pipe"
"Air filter"
1) Disconnect the starter motor power cord (Label ST
1).
2) Disconnect the electromagnetic switch line
(Label 2) of the starter motor.
3) Remove 2 fixing bolts of the starter motor.
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ST-22 JLE-4G18TDB Starter System – Starter Motor MT
Check
motor.
Ammeter
3) When the clutch pinion remains stretch out, check
and confirm whether the starter motor rotates
steadily. Check and confirm whether the ammeter
reading is in accordance with the current value
specified below.
Standard current:
Starter motor (electromagnetic switch) holding coil
ST (at 12.2V) current: 36A
Starter motor (electromagnetic switch) suction coil
(at 12.2V) current: 13A
Installation
1) Tighten the fixing bolt of starter motor.
2) Connect the starter motor power cord (Label 1) and

the electromagnetic switch harness connector
(Label 2).
3. Install the upper shell air outlet flange plate
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JLE-4G18TDB Starter System – Starter Motor AT ST-23
Starter Motor AT
Component
Air flow meter
Engine intake hose ST

Air filter element
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ST-24 JLE-4G18TDB Starter System – Starter Motor AT
ST
Starter (AT)
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JLE-4G18TDB Starter System – Starter Motor AT ST-25
Removal
cover"
intake pipe"
"Air filter"
1) Remove the gland nut of the electromagnetic ST
switch harness of the starter motor, and
disconnect the electromagnetic switch harness
connector of the starter motor.
2) Pull the dust cover of the starter motor power
cord, remove the gland nut, and disconnect the
starter motor power cord.
3) Remove 2 fixing bolts of the starter motor, and

take down the starter motor.
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ST-26 JLE-4G18TDB Starter System – Starter Motor AT
Check
motor.
Ammeter 3) When the clutch pinion remains stretch out,
check and confirm whether the starter motor
Terminal 30
rotates steadily. Check and confirm whether the
ammeter reading is in accordance with the
current value specified below.
Standard current:
Starter motor (electromagnetic switch) holding
ST coil (at 12.2V) current: 36A
Vehicle body Starter motor (electromagnetic switch) suction
Terminal 50
coil (at 12.2V) current: 13A
Installation
1) Align two locating pins on the starter motor with

the mounting holes in the gearbox, and install the
starter motor.
2) Install and fasten the fixing bolt of the starter
motor.
3) Connect the starter motor harness connector.

3. Install the upper shell air outlet flange plate
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JLE-4G18TDB Starter System – Starter Motor Relay ST-27
Starter Motor Relay
On-board Check
1. Check the starter motor relay
1) Apply DC 12V voltage to terminal 85 and terminal
86 of the starter relay, and a "click" from a pick-up
of the relay can be heard.
2) Measure the resistance between terminal 30 and
terminal 87 without applying DC 12V voltage to
terminal 85 and terminal 86 of the starter relay.
Standard value: More than 10kΩ
ST
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ST-28 JLE-4G18TDB Starter System – Starter Motor Relay
ST
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JLD-4G20/24 Charging System –Contents CH-1
CH JLD-4G20/24 Charging System
Charging System ......................................................................................................................... CH-2

Notices .................................................................................................................................................CH-2
Component Position .............................................................................................................................CH-3
System Diagram ...................................................................................................................................CH-4
Table of Fault Symptom .......................................................................................................................CH-5
On-board Check ...................................................................................................................................CH-6
Charging Indicator Lamp Always ON ...................................................................................................CH-9
Charging Indicator Lamp Always OFF ...............................................................................................CH-12
Alternator Noise Diagnosis ................................................................................................................CH-14 CH
Battery Discharging Current and Parasitic Load Test ........................................................................CH-16
Alternator.................................................................................................................................... CH-17
Component .........................................................................................................................................CH-17
Removal .............................................................................................................................................CH-21
Check .................................................................................................................................................CH-22
Installation ..........................................................................................................................................CH-22
Battery Cable .............................................................................................................................. CH-23
Battery Cable Disconnection..............................................................................................................CH-23
Battery Cable Connection ..................................................................................................................CH-24
Battery ........................................................................................................................................ CH-26
Component .........................................................................................................................................CH-26
Removal .............................................................................................................................................CH-27
Installation ..........................................................................................................................................CH-27
Battery Bracket .......................................................................................................................... CH-28
Component .........................................................................................................................................CH-28
Removal .............................................................................................................................................CH-29
Installation ..........................................................................................................................................CH-29
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CH-2 JLD-4G20/24 Charging System – Charging System
Charging System
Notices
1. Check and confirm that the battery cable is connected to the correct terminal.
2. During quick charging of battery, disconnect the battery cable.
3. Do not use a high voltage insulation resistance tester for testing.
4. When the engine is running, do not disconnect the battery cable.
5. Check and confirm that the charging cable nut is fastened to the alternator and engine compartment fuse relay box
terminal B+.
CH
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JLD-4G20/24 Charging System – Charging System CH-3
Component Position
CH
Alternator
Battery
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System Diagram
CH
Battery Alternator Combination

instrument
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Table of Fault Symptom
Symptoms Suspected Parts: Measures/References
Air conditioning clutch pulley CH-9

The charge warning lamp is on during
driving
Alternator -
Drive belt CH-10

When the engine is running, the
Air conditioning clutch pulley -
alternator makes a noise
Alternator -
CH
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On-board Check
1. Checking battery condition
Notice
If the battery power is low or the engine is difficult to
start, perform the following operating procedure.
1) Check the battery for damage and deformation. If
any serious damage, deformation or leakage is
detected, replace the battery.
2) Check the electrolyte level of each cell
(maintenance-free battery).
• If the electrolyte level is below the lower limit, replace
the battery.
CH • If the electrolyte level is above the lower limit, check
the battery voltage when starting the engine. If the
voltage is lower than 9.6 V, recharge or replace the
battery.
Notice
Before checking the battery voltage, shut down all the
electrical systems (headlamps, blower motor, rear
defogger, etc.).
2. Check the battery terminals
1) Check and confirm that the battery terminals are
not loose or corroded.
2) If any terminal is corroded, clean the terminal.
3. Check the fuse
1) Measure the resistance of the fuse.
2) If the measurement result is not in conformity
with the provisions, replace the fuse as required.
1) Check the belt for traces of wear, rupture or other
damages.
2) If any of the following defects is detected, replace
the drive belt.
• The belt is worn, ruptured or the cord is exposed.
• Larger ruptures appear in more than one position.
• The belt edge is severely damaged.
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3) Check and confirm that the belt is correctly

installed in the wedge groove.
Notice
Correct Wrong
Check by hand to confirm that the belt does not slip
from the groove at the bottom of the pulley.
4) If the belt has slipped out, the drive belt shall be
replaced. Install the new drive belt correctly.
CH
5. Check the alternator wiring

1) Visually check the alternator wiring. Check and
confirm that the wiring is in good condition.
6. Check for abnormal noise
1) Listen to the alternator and check for any
abnormal noise. When the engine is running,
check and confirm that there is no abnormal
noise from the alternator.
7. Check the charge warning lamp circuit
1) Place the starting switch in ON (IG) position.
Check and confirm that the charge warning lamp
is on.
2) Start the engine, then check and confirm that the
lamp has gone out.
3) If the working condition of the warning lamp does
not conform to the provisions, troubleshoot the
charge warning lamp circuit.
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8. Check the charging circuit without load

1) Disconnect the wiring from the alternator terminal
Disconnect the harness of terminal B. B+, and connect it to the negative (-) lead of the
ammeter.
2) Connect the positive (+) lead of the ammeter to the
terminal B+ of the alternator.
3) Connect the positive (+) lead of the voltmeter to the
positive (+) terminal of the battery.
4) Ground the negative (-) lead of the voltmeter.
5) Maintain the engine speed at 2,000 rpm, and check
the ammeter and voltmeter readings.
Standard amperage: 10A or less.
Standard voltage: 13.2~14.8 V
CH
6) If the result is not in conformity with the provisions,
replace the alternator.
Notice
If the battery is not fully charged, the ammeter reading
will sometimes be greater than standard amperes.
9. Check the charging circuit with load
1) Maintain the engine speed at 2,000 rpm, turn on
the high beam headlamps, and turn the heater
blower switch to the HI position.
2) Check the reading of ampere meter.
Standard current：30 A or more
3) If the ammeter reading is less than the standard
current, maintain the alternator.
Notice
If the battery is fully charged, the reading may be less
than the standard current. If so, increase the electrical
load (run the wiper, rear window defogger, etc.), and
recheck the reading on the ammeter.
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Charging Indicator Lamp Always ON

Diagnostic steps:
Step 1 Start the engine. After the starter is started, does the battery charging indicator lamp remains lit?
No Intermittent fault, refer to "Check of

Yes
Step 2 Measure whether battery terminal voltage is in the range from 11V to 14V.
CH
No Go to step 5.
Yes
Step 3 Check the charging indicator lamp control circuit.

mode to OFF state.
IP17 Combination instrument harness connector (c) Disconnect alternator harness connector EG20.
(d) Remove the instrument, and disconnect the instrument
of combination instrument harness connector IP17 and
the terminal 1 of alternator harness connector EG20.
alternator harness connector EG20 and reliable
grounding.
Standard resistance value:
Test item Standard value
IP17(27)-EG20(1) Less than 1 Ω
EG20(1) -reliable grounding circuit 10kΩ or higher

EG20 Alternator control harness connector

standard value.

Yes
Step 4 Check the power supply grounding of instrument.
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mode to ON state.
(b) Measure the voltage between terminals 1, 2 of
combination instrument harness connector IP17 and
IP17 Combination instrument harness connector
terminal 3, 4.
No Check the fuse, check and repair the

cable, and replace it if necessary
CH
Yes
Step 5 Check the alternator power supply wire.
(a) Check whether the fuse EF35 is blown out. If so,

Engine compartment fuse, relay box replace the fuse after the short circuit fault is repaired.
mode to OFF state.
(b) Disconnect the battery negative electrode
(d) Disconnect alternator harness connector EG19.
(e) Connect the battery negative electrode
(f) Measure the voltage between terminal 1 of alternator
(g) Confirm whether the voltage value meets standard
value.
Yes Repair or replace the harness
EG19 Alternator B+ harness connector
No
Step 6 Replace the alternator.
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(a) Replace the alternator.

Next Step
CH
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Charging Indicator Lamp Always OFF

Diagnostic steps:
Yes Intermittent fault, refer to "Check of

No

CH
mode to OFF state.
IP17 Combination instrument harness connector (c) Disconnect alternator harness connector EG20.
the terminal 1 of alternator harness connector EN20.
(f) Measure the resistance between terminal 1 of
alternator harness connector EG20 and reliable
grounding.
EG20 Alternator control harness connector EG20(1) - Reliable grounding

10kΩ or higher
circuit

standard value.
No Repair the fault position, and replace the

Yes

No
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mode to ON state.
terminals 3, 4.
value.

CH
Yes
Step 5 Replace combination instrument assembly.
(a) Replace the combination instrument.

Next Step
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Alternator Noise Diagnosis

Diagnosis tips:
The alternator noise may be caused by electrical or mechanical noise. The electric noise (magnetic wuthering) usually varies
with the electric load attached in the alternator, which are the normal operation characteristics of the alternator. Make a
differentiation during maintenance diagnosis. Or else, it will incur unnecessary customer complaint. When diagnosing the
alternator with mechanical noise, firstly check whether there are loose alternator components or mutual interference. In some
cases even if the sound in engine compartment is light, it can enter the passenger compartment. If this is the case, replacing
the alternator does not solve the fault, which leads to misjudgments.
Diagnostic steps:
Step 1 Make the alternator stop and determine whether the noise disappears
(a) Start the engine and determine whether noise

continues.
CH (b) Stop the engine.
(c) Disconnect alternator harness connector EN19.
(e) Determine whether the noise disappears.
Yes Go to Step 6
No
Step 2 Check the alternator shaft
(a) Stop the engine.

(b) Remove the drive belt.
(c) Rotate the alternator pulley by hand.
(d) Does the alternator rotate steady, free from catching or
grinding noise?
Yes Go to Step 6
No
Step 3 Reinstall the alternator.
(a) Reinstall the alternator, and fasten the alternator

mounting bolts to the specified torque
(b) Start the engine, does the noise disappear?
No
Step 4 Check whether there is loosening of the transmission belt?
Yes Go to Step 7
No
Step 5 Compare with a known intact vehicle. Is the noise the same?
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No
Notice
If a clear generator fault has not been found, make sure
that all other possible noise sources have been excluded
and then replace the alternator. If noise belongs to the
normal characteristics of the alternator, the replacement of
alternator will not make noise disappear.
Confirm the fault is eliminated. CH
Next Step
Step 7 Replace the drive belt or belt tensioner assembly.
Refer to "Belt tensioning mechanism subassembly".
Next Step
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Battery Discharging Current and Parasitic Load Test

Diagnosis tips:
In case of continuous power loss of the battery, it's required to execute the following test procedures to check whether the
battery has stray current.
Notice
Prior to performing the procedure, please firstly check whether there is after-sales installed device in the vehicle, such as DVD,
audio amplifier, trunk woofer and other non-original accessories, if so, please cut off these system to perform this test
procedure.
Diagnostic steps:
Step 1 Disconnect the negative battery cable
Next Step
CH
Step 2 One end of the digital multimeter connects with the negative cable of the battery; the other end is
connected to the negative pole of the battery.
Next Step
Step 3 Select the maximum range level of the "Current test" of the digital multimeter.
Next Step
Step 4 Open the front left door and observe the multimeter's readings
Notice
Do not carry out any other operations at this time; otherwise
it is likely to damage the multimeter.
Next Step
Step 5 If the multimeter has no reading, check whether it has been broken; if the multimeter has reading,
close the front left door and press down the engine compartment switch and the remote control door
lock button.
Next Step
Step 6 Observe the vehicle anti-theft system indicator lamp shows the system normally access the alert
mode.
Next Step
Step 7 Wait more than 10 min, observe the multimeter's reading (if the multimeter's reading is abnormal,
tune down the multimeter's level), the multimeter's reading shall be below 30 mA. In case of higher
than 30 mA, there may be stray current
Notice
When the system parasitic current cannot be confirmed, compare the vehicle with a known good vehicle to helping with
diagnosis.
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JLD-4G20/24 Charging System – Alternator CH-17
Alternator
Component
CH
Vehicle wheel nut
Wheel assembly
N·m (Ib-ft): specified torque
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CH-18 JLD-4G20/24 Charging System – Alternator
CH
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CH
Engine trim cover
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CH
Alternator
Drive belt
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Removal
cover"
4. Remove the right front wheel; refer to "Wheel and tire"
5. Lift the vehicle
6. Remove the engine right guard plate; refer to "Left and
9. Remove the alternator CH
1) Disconnect the alternator harness connector and

the power cord.
2) Remove 2 fixing bolts of the alternator.
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Check
1. Check the alternator
1) Check the alternator pulley groove for wear or
other defects.
CH
Installation
1. Install the alternator.
1) Install and tighten the fixing bolt of alternator
2) Connect the starter harness connector and the

power cord.
2. Lift the vehicle
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JLD-4G20/24 Charging System – Battery Cable CH-23
Battery Cable Battery Cable Disconnection.

compartment"
compartment"
5. Remove the battery heat shield
CH
1) Shut down all current-using equipment, and turn
off the starting switch.
2) Open the battery negative protection cover,

unscrew the battery negative cable nut, and take
down the negative battery cable.
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CH-24 JLD-4G20/24 Charging System – Battery Cable
7. Disconnect the positive battery cable

1) Open the battery positive protection cover,
unscrew the battery positive cable nut, and take
down the positive battery cable.
CH
Battery Cable Connection

1. Connect the positive battery cable.
1) Install the positive battery cable, tighten the
battery positive cable nut, and close the positive
protection cover.

1) Install the negative battery cable, tighten the
battery negative cable nut, and close the
negative protection cover.
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JLD-4G20/24 Charging System – Battery Cable CH-25
3. Install the battery heat shield.

CH
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CH-26 JLD-4G20/24 Charging System – Battery
Battery
Component
18 Positive cable
Negative cable
CH
Battery
Battery bracket
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JLD-4G20/24 Charging System – Battery CH-27
Removal
compartment"
compartment"
7. Disconnect the positive battery cable. CH
8. Remove the battery
1) Remove the fixing bolt of battery plate.

2) Take out the battery.
Installation
1) Put in the battery
2) Install and tighten the fixing bolt of battery
pressing plate.
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CH-28 JLD-4G20/24 Charging System – Battery Bracket
Battery Bracket
Component
18 Positive cable
Negative cable
CH
Battery
Battery bracket
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CH JLD-4G20/24 Charging System – Battery bracket CH-29
Removal
compartment"
compartment"
6. Disconnect the negative battery cable; refer to
"Battery cable" CH
7. Disconnect the positive battery cable; refer to "Battery
cable"
8. Remove the battery; refer to “Battery”
1) Remove 4 fixing bolts of the battery support, and

take down the battery support.
Installation
1) Install the battery support, install and tighten 4
fixing bolts of the battery support.
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CH-30 JLD-4G20/24 Charging System – Battery Bracket
CH
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JLE-4G18TDB Charging System –Contents CH-1
CH JLE-4G18TDB Charging System
Charging System ......................................................................................................................... CH-2

Notices .................................................................................................................................................CH-2
Component Position .............................................................................................................................CH-3
On-board Check ...................................................................................................................................CH-4
Table of Fault Symptoms .....................................................................................................................CH-7
Charging Indicator Lamp Always ON ...................................................................................................CH-8
Charging Indicator Lamp Always OFF ............................................................................................... CH-11
Alternator Noise Diagnosis ................................................................................................................CH-13 CH
Battery Discharging Current and Parasitic Load Test ........................................................................CH-15
Alternator.................................................................................................................................... CH-16
Component .........................................................................................................................................CH-16
Removal .............................................................................................................................................CH-17
Installation ..........................................................................................................................................CH-18
Battery Cable .............................................................................................................................. CH-20
Component .........................................................................................................................................CH-20
Removal of Battery Cable ..................................................................................................................CH-21
Install the Battery Cables ...................................................................................................................CH-23
Battery ........................................................................................................................................ CH-24
Removal .............................................................................................................................................CH-24
Installation ..........................................................................................................................................CH-25
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CH-2 JLE-4G18TDB Charging System – Charging System
Charging System
Notices
1. Check and confirm that the battery cable is connected to the correct terminal.
2. During quick charging of battery, disconnect the battery cable.
3. Do not use a high voltage insulation resistance tester for testing.
4. When the engine is running, do not disconnect the battery cable.
5. Check and confirm that the charging cable nut is fastened to the alternator and engine compartment relay box B+
terminal.
CH
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JLE-4G18TDB Charging System – Charging System CH-3
Component Position
CH
Alternator
Battery
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On-board Check
1. Checking battery condition
Notice
If the battery power is low or the engine is difficult to
start, perform the following operating procedure.
1) Check the battery for damage and deformation. If
any serious damage, deformation or leakage is
detected, replace the battery.
2) Check the electrolyte level of each cell
(maintenance-free battery).
• If the electrolyte level is below the lower limit, replace
the battery.
CH • If the electrolyte level is above the lower limit, check
the battery voltage when starting the engine. If the
voltage is lower than 9.6 V, recharge or replace the
battery.
Notice
Before checking the battery voltage, shut down all the
electrical systems (headlamps, blower motor, rear
defogger, etc.).
2. Check the battery terminals
1) Check and confirm that the battery terminals are
not loose or corroded.
2) If any terminal is corroded, clean the terminal.
3. Check the fuse
1) Measure the resistance of the fuse.
Notice
If the result is not in conformity with the provisions,
replace the fuse as required.
1) Check the belt for traces of wear, rupture or other
damages.
Notice
If any of the following defects is detected, replace the
drive belt.
• The belt is worn, ruptured or the cord is exposed.
• Deep and large ruptures appear in more than one
position.
• The belt edge is severely damaged.
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2) Check and confirm that the belt is correctly installed

in the wedge groove.
Notice
Check by hand to confirm that the belt does not slip
Correct Wrong from the groove at the bottom of the pulley.
3) If the belt has slipped out, the drive belt shall be
replaced. Install the new drive belt correctly.
CH
5. Check the alternator harness

1) Visually check the alternator wire harness. Check
and confirm that the harness is in good condition.
6. Check for abnormal noise
1) Listen to the alternator and check for any abnormal
noise. When the engine is running, check and
confirm that there is no abnormal noise from the
alternator.
7. Check the charge warning lamp circuit
1) Place the starting switch in ON (IG) position. Check
and confirm that the charge warning lamp is on.
2) Start the engine, then check and confirm that the
lamp has gone out.
3) If the working condition of the warning lamp does
not conform to the provisions, troubleshoot the
charge warning lamp circuit.
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8. Check the charging circuit without load

Disconnect the harness of terminal B. 1) Disconnect the harness from the alternator terminal
B+, and connect it to the ammeter negative (-) lead.
2) Connect the positive (+) lead of the ammeter to the
terminal B+ of the alternator.
3) Connect the positive (+) lead of the voltmeter to the
positive (+) terminal of the battery.
4) Ground the negative (-) lead of the voltmeter.
5) Maintain the engine speed at 2,000 rpm, and check
the ammeter and voltmeter readings.
Standard amperage: 10A or less.
Standard voltage: 13.2~14.8 V
CH 6) If the result is not in conformity with the provisions,
replace the alternator.
Notice
If the battery is not fully charged, the ammeter reading
will sometimes be greater than the standard current.
9. Check the charging circuit with load
1) Maintain the engine speed at 2,000 rpm, turn on
the high beam headlamps, and turn the heater
blower switch to the HI position.
2) Check the reading of ampere meter.
Standard current：30 A or more
3) If the ammeter reading is less than the standard
current, maintain the alternator.
Notice
If the battery is fully charged, the reading may be less
than the standard current. If so, increase the electrical
load (run the wiper, rear window defogger, etc.), and
recheck the reading on the ammeter.
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Symptoms Suspected Parts: Reference Page
Air conditioning clutch pulley CH-9

The charge warning lamp is on during driving
Alternator -
Drive belt CH-10

When the engine is running, the alternator
Air conditioning clutch pulley -
makes a noise
Alternator -
CH
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Charging Indicator Lamp Always ON

Diagnostic steps:
No Intermittent fault, refer to "Check of

Yes
Step 2 Measure whether battery terminal voltage is in the range from 11V to 14V.
CH No Go to step 5.
Yes

mode to OFF state.
IP17 Combination instrument harness connector (c) Disconnect alternator harness connector EN20.
alternator harness connector EN20 and reliable
grounding.
IP17(27)-EN20(1) Less than 1 Ω
EN20(1) and reliable grounding 10kΩ or higher

EN20 Alternator control harness connector

standard value.

Yes
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mode to ON state.
terminal 3, 4.
value.

CH
Yes
Step 5 Check the alternator power supply circuit.
(a) Check whether the fuse EF35 is blown out. If so,

Engine compartment fuse, relay box replace the fuse after the short circuit fault is repaired.
mode to OFF state.
(c) Disconnect the battery negative electrode
(d) Disconnect alternator harness connector EN19.
(e) Connect the battery negative electrode.
(f) Measure the voltage between terminal 1 of alternator
harness connector EN19 and reliable grounding.
(g) Confirm whether the voltage value meets standard
value.
Yes Maintain or replace the harness
EN19 Alternator B+ harness connector
No
Step 6 Replace alternator.
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Next Step
CH
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Charging Indicator Lamp Always OFF

Diagnostic steps:
Step 1 Start the engine. After the starter is started, does the battery charging indicator lamp remain lit?
Yes Intermittent fault, refer to "Check of

No

CH
mode to OFF state.
(d) Disconnect the battery negative electrode
(e) Disconnect alternator harness connector EN20.
(f) Remove the instrument, and disconnect the instrument
(g) Measure the resistance value between the terminal 27
(h) Measure the resistance value between terminal 1 of
alternator harness connector EN20 and reliable
grounding.

EN20 Alternator control harness connector
EN20(1) and reliable grounding 10kΩ or higher
(i) Confirm whether the resistance value meets the

standard value.

Yes

No
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mode to ON state.
terminal 3, 4.
value.

CH
Yes
Step 5 Replace combination instrument assembly.
(a) Replace the combination instrument.

Next Step
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Alternator Noise Diagnosis

Diagnosis tips:
The alternator noise may be caused by electrical or mechanical noise. The electric noise (magnetic wuthering) usually varies
with the electric load attached in the alternator, which are the normal operation characteristics of the alternator. Make a
differentiation during maintenance diagnosis. Or else, it will incur unnecessary customer complaint. When diagnosing the
alternator with mechanical noise, firstly check whether there are loose alternator components or mutual interference. In some
cases even if the sound in engine compartment is light, it can enter the passenger compartment. If this is the case, replacing
the alternator does not solve the fault, which leads to misjudgments.
Diagnostic steps:
Step 1 Make the alternator stop and determine whether the noise disappears
(a) Start the engine and determine whether noise continues.

(b) Stop the engine.
CH
(c) Disconnect alternator harness connector EN19.
(e) Determine whether the noise disappears.
Yes Go to Step 6
No
Step 2 Check alternator shaft
(a) Stop the engine.

(b) Remove the drive belt.
(c) Rotate the alternator pulley by hand.
(d) Does the alternator rotate steady, free from catching or
grinding noise?
Yes Go to Step 6
No
Step 3 Reinstall the alternator.
(a) Reinstall the alternator, and fasten the alternator

mounting bolts to the specified torque
(b) Start the engine, does the noise disappear?
No
Step 4 Check whether there is loosening of the transmission belt.
Yes
Go to Step 7
No
Step 5 Compare with a known intact vehicle. Is the noise the same?
NL-3 01/2016
No
Notice
If a clear generator fault has not been found, make sure
that all other possible noise sources have been excluded
and then replace the alternator. If noise belongs to the
normal characteristics of the alternator, the replacement of
alternator will not make noise disappear.
CH Confirm the fault is eliminated.
Next Step
Step 7 Replace the drive belt or belt tensioner assembly.
Refer to "Belt tensioner assembly"
Next Step
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Battery Discharging Current and Parasitic Load Test

Diagnosis tips:
In case of continuous power loss of the battery, it's required to execute the following test procedures to check whether the
battery has stray current.
Notice
Prior to performing the procedure, please firstly check whether there is after-sales installed device in the vehicle, such as DVD,
audio amplifier, trunk woofer and other non-original accessories, if so, please cut off these system to perform this test
procedure.
Diagnostic steps:
Step 1 Disconnect the negative battery cable.
Next Step
CH
Step 2 One end of the digital multimeter connects with the negative cable of the battery; the other end is
connected to the negative pole of the battery.
Next Step
Step 3 Select the maximum range level of the "Current test" of the digital multimeter.
Next Step
Step 4 Open the front left door and observe the multimeter's readings
Notice
Do not carry out any other operations at this time; otherwise
it is likely to damage the multimeter.
Next Step
Step 5 If the multimeter has no reading, check whether it has been broken; if the multimeter has reading,
close the front left door and press down the engine compartment switch and the remote control door
lock button.
Next Step
Step 6 Observe the vehicle anti-theft system indicator lamp, it shows the system normally access the alert
mode.
Next Step
Step 7 Wait for more than 10 min, observe the multimeter's reading (if the multimeter's reading is abnormal,
tune down the multimeter's level), the multimeter's reading shall be below 30 mA. In case of higher
than 30 mA, there may be stray current.
Notice
When the system parasitic current cannot be confirmed, compare the vehicle with a known good vehicle to helping with
diagnosis.
NL-3 01/2016
CH-16 JLE-4G18TDB Charging System – Alternator
Alternator
Component
CH
Alternator
Drive belt
NL-3 01/2016
JLE-4G18TDB Charging System – Alternator CH-17
Removal
cover"
4. Remove the right front wheel; refer to "Wheel and tire"
5. Lift the vehicle
6. Remove the engine right guard plate; refer to "Left and
9. Remove the alternator CH
1) Disconnect the alternator harness connector
2) Remove the fixing nut of generator charging

harness.
3) Disengage the alternator charging harness.
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CH-18 JLE-4G18TDB Charging System – Alternator
4) Remove 4 fixing bolts of the alternator diagonally.
CH
Installation
1. Install the alternator.
1) Install the alternator.
2) Install and fasten 4 fixing bolts of the alternator.
3) Connect the starter motor harness connector.
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JLE-4G18TDB Charging System – Alternator CH-19
4) Connect the starter charging harness.

5) Install and tighten the fixing bolts.
2. Lift the vehicle
CH
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CH-20 JLE-4G18TDB Charging System – Battery Cable
Battery Cable
Component
Negative battery
CH cable
Battery
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JLE-4G18TDB Charging System – Battery Cable CH-21
Removal of Battery Cable

compartment"
compartment"
6. Remove the negative battery cable
1) Shut down all current-using equipment, and turn CH
off the starting switch.
2) Remove the battery heat shield.
3) Open the battery negative protection cover.
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CH-22 JLE-4G18TDB Charging System – Battery Cable
4) Unscrew the battery negative cable nut.

5) Remove the negative battery cable.
CH
7. Remove the battery positive cable.

1) Open the battery positive protection cover.
2) Unscrew the battery positive cable nut.

3) Remove the battery positive cable.
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JLE-4G18TDB Charging System – Battery Cable CH-23
Install the Battery Cables
1. Install the positive battery cable.

1) Install the battery positive cable, tighten the
battery positive cable nut, and close the positive
protection cover.
CH
2. Install the battery negative cable

1) Install the battery negative cable, tighten the
battery negative cable nut, and close the
negative protection cover.
2) Close the battery positive and negative protection

covers.
NL-3 01/2016
CH-24 JLE-4G18TDB Charging System – Battery
Battery Removal
3. Disconnect the negative battery cable; refer to
"Battery cable"
4. Disconnect the positive battery cable; refer to "Battery
cable"
compartment"
CH 7. Remove the upper trim panel assembly of left fender;
compartment"
8. Remove the battery; refer to Battery cable.
1) Remove the fixing bolts of battery pressure plate,

and take out the battery.

1) Remove the fixing bolts of battery support, and
take down the battery support.
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JLE-4G18TDB Charging System – Battery CH-25
Installation
1) Install the battery support, and tighten the fixing
bolts of battery support.
CH

1) Install the battery, and tighten the fixing bolts of
battery pressing plate.
NL-3 01/2016
CH-26 JLE-4G18TDB Charging System – Battery
CH
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Transmission- Contents AT-1
AT Transmission
Automatic Transmission System ................................................................................................. AT-3

Internal Check ......................................................................................................................................AT-3
Component Position .............................................................................................................................AT-4
System Diagram...................................................................................................................................AT-6
System Description ..............................................................................................................................AT-7
How to Carry Out the Analysis for Elimination of Fault ........................................................................ AT-9
Initialization.........................................................................................................................................AT-10
Automatic Transmission Terminal ......................................................................................................AT-12
Table of DTCs ....................................................................................................................................AT-17
DTC P060336 P060456 P160431 U100016 U100017 U100021 U100022 ...................................... AT-20
DTC P070713 P070814 U010387 U040476 .....................................................................................AT-27
DTC P071154 .....................................................................................................................................AT-32
DTC P071253 P071354 .....................................................................................................................AT-34
DTC P160531 P161030 P161131 P09A304 .....................................................................................AT-38
AT
DTC P071608 P07170F.....................................................................................................................AT-42
DTC P072108 P07220F.....................................................................................................................AT-46
DTC P071D10 P071E00 P071F04 P09560F P095700 P095804 ..................................................... AT-50
DTC P072960 P073160 P073260 P073360 P073460 P073560 P073660 ....................................... AT-55
DTC P074163 P074262 P074464 .....................................................................................................AT-57
DTC P096200 P096304 .....................................................................................................................AT-59
DTC P096600 P096704 .....................................................................................................................AT-63
DTC P098500 P098604 .....................................................................................................................AT-67
DTC P099800 P099904 .....................................................................................................................AT-71
DTC P099B00 P099C04 ....................................................................................................................AT-75
DTC P099E00 P099F04 ....................................................................................................................AT-79
DTC P097300 P097404 .....................................................................................................................AT-83
DTC P097600 P097704 .....................................................................................................................AT-87
DTC P097900 P098004 .....................................................................................................................AT-91
DTC P098200 P098304 .....................................................................................................................AT-95
DTC U010082 U010083 U010087 U010187 U010287 U012187 U012282 U012283 U014482 U014483
P180100 U040476 U040176 U040276 U040376 U041576 U007300 .............................................. AT-99
DTC U160141 U160641 U160741 U160847 U160940 ...................................................................AT-103
DTC U160E30、U161247、U161347 .............................................................................................AT-105
Automatic Transmission Oil ..................................................................................................... AT-107
On-board Check ...............................................................................................................................AT-107
Replace ............................................................................................................................................AT-107
Automatic Transmission Oil Cooling System ......................................................................... AT-108
Clean ................................................................................................................................................AT-108
Gear Switch ............................................................................................................................... AT-109
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AT-2 Transmission- Contents
Component .......................................................................................................................................AT-109
Removal ........................................................................................................................................... AT-111
Installation ........................................................................................................................................ AT-112
Gearshift Flexible Shaft Assembly .......................................................................................... AT-114
Component ....................................................................................................................................... AT-114
Removal ...........................................................................................................................................AT-121
Installation ........................................................................................................................................AT-122
Automatic Gear Shifter Assembly ........................................................................................... AT-124
Component .......................................................................................................................................AT-124
Removal ...........................................................................................................................................AT-128
Disassembling ..................................................................................................................................AT-129
Assembling .......................................................................................................................................AT-129
Installation ........................................................................................................................................AT-130
Automatic Transmission .......................................................................................................... AT-131
Component .......................................................................................................................................AT-131
Removal ...........................................................................................................................................AT-147
Installation ........................................................................................................................................AT-149
AT
NL-3 01/2016
Transmission-Automatic Transmission System AT-3
Automatic Transmission System

Internal Check
• After disconnecting and reconnecting the negative (-) cable of the battery, initialize the following systems.
• When replacing the automatic transmission assembly, engine assembly or EMS, execute memory reset (AT
initialization).
• If EMS is replaced, register EMS communication ID in the shutdown system.
Tips:
Memory reset operation cannot be completed only when the battery cables are disconnected.
AT
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AT-4 Transmission-Automatic Transmission System
Component Position
Location of automatic transmission assembly
AT
Legend
1.Automatic transmission 2.TCU
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Oil inlet plug, oil drain plug, gear switch and crankshaft position sensor
AT
Legend
1. Oil drain plug 3. Oil inlet plug
2. Crankshaft position sensor 4. Gear switch
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System Diagram
DSI transmission TCU control system
Gearshift switch
Gateway
Reversing radar module
Suppressor switch
AT
Transmission module
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System Description
Overview of DSI Automatic Transmission
This transmission has the following characteristics:
– has six advance gears
– has one reverse gear
– has one hydraulic torque converter. This hydraulic torque converter contains one lock-up clutch
– adopts electronic gear shifting and pressure control
– has one single-planetary gear set
– has one dual-planetary gear set
– has one hydraulically controlled brake belt and one multi-disc brake
– has three multi-disc wet clutches
All hydraulic functions are controlled and managed by a solenoid valve:
– has engagement comfort adjustment
– has gear shifting comfort adjustment
– has gear shifting curve selection
– has hydraulic torque converter clutch adjustment
This automatic transmission uses synthesized automatic transmission fluid. To ensure the automatic transmission can
normally operate within its service life, you must replace the automatic transmission fluid per 60,000km traveled.
The engine power is transmitted to the automatic transmission through the hydraulic torque converter with the lockup clutch.
This automatic transmission realizes six advance gears and one reverse gear through the combination of one drive single-row AT
planet wheel and one driven double-row planetary gear. This gear device structure is usually called as LePelletier gear
combination.
DSI automatic transmission is electronically controlled and its control system is composed of the following parts:
– Input shaft and output shaft speed sensor
– Four switch solenoid valves and six variable flow solenoid valve units
– Hydraulic torque converter clutch (TCC)
– Automatic transmission control unit (TCU)
– Internal embedded memory module (EMM)
The internal clutch and brake belt of the transmission are operated by controlling the flow direction and pressure of automatic
transmission fluid (ATF) so as to realize gear selection. The transmission control unit (TCU) can control all electronic
components as well as the gear selection, gearshift pressure and trackslip of the hydraulic torque converter.
In case of any system fault, the transmission control unit (TCU) may maintain the performance maximization of the
transmission through fault mode effect control (FMEC). If the transmission control unit (TCU) is out of control or powered off,
the transmission can still maintain basic speed change functions (i.e. parking, reverse, neutral and limp modes). Both the
opening states of reverse gear and hydraulic torque converter clutch can be realized through the pure hydraulic system of the
transmission when there is no electronic control assist at all.
The transmission also contains one external (parking, reverse, neutral and driving) gear selector sensor (gear switch) and one
internal transmission fluid temperature sensor.
In the manual mode application program, the transmission control unit (TCU) also needs to acquire relevant signals from the
transmission gear shift to determine the time for the driver to open the manual mode function.
If the transmission has serious troubles or other components on the complete vehicle have troubles possibly affecting normal
operation of transmission, the transmission control unit (TCU) can automatically operate "limp home (trouble) mode" to ensure
the vehicle can travel to the authorized dealer for repair. In the "limp mode", engine malfunction (MIL) indicator light on the
instrument panel will be controlled to go on, and the transmission can continue to operate under functional limitation. The
limitation level of the functions depends on the severity of troubles detected by TCU.
If the transmission is too hot, the gear shift mode will automatically switch to a work state convenient for transmission cooling.
In an environment with extremely high temperature, the transmission control unit (TCU) will disable all gear shift functions of
the transmission in order to protect transmission hardware, so that the transmission is in neutral position until transmission
fluid temperature is cooled to safe level.
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The transmission control unit can also perform the transmission diagnosis and monitor all components that may affect the
emissions from the vehicle. The diagnostic protocol complies with the requirements of the on-board diagnosis protocol (OBD)
II. Also, it supports additional diagnostic function to make sure all faults are eliminated quickly in operating environment.
If the vehicle fails, it needs to be towed. Firstly, remove the main drive shaft or lift off the drive wheels, and then tow the vehicle.
If the vehicle is towed without removing the main drive shaft or lifting off the drive wheels, the transmission will fail because of
insufficient transmission bearing lubrication.
If the occurred trouble mode is occasional, press the start switch to IG OFF position to exit "limp home mode", and restart after
30 s. If the trouble still exists, the transmission will still enter "limp home mode" again. Whether the fault mode occurs again or
not, travel slowly to the nearest service station for repair immediately.
AT
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How to Carry Out the Analysis for Elimination of Fault

Diagnosis descriptions
Get familiar with the system functions and operation before starting system diagnosis, so that it will help to determine the
correct diagnostic procedures, more importantly, it will also help to determine whether the customer described situation is
normal.
Diagnostic introduction:
Mechanical fault of the automatic transmission includes any of the following symptoms: noise or vibration, automatic
transmission fluid leakage, the vehicle cannot move forward or backward. The reasons for these symptoms are: assembly
errors, less transmission fluid, a part of automatic transmission at fault.
The following are the reasons for a control system fault: EMS fault, switch fault and the harness connector fault.
Diagnostic fault finding strategy:
Please use the following steps to check your faults. If following these steps carefully, you will find most of the automatic
transmission faults.
1. Collect fault information from vehicle owner as much as possible.
2. Verify fault situations described by vehicle owner.
3. Check if vehicle has automatic transmission fault code (DTC).
4. If fault symptom only appears occasionally and no fault code (DTC) appears, it indicates that it is an intermittent fault.
Refer to “Intermittent fault check”.
5. Record the Diagnostic trouble code (DTC) if any.
6. Verify the fault conditions again after the road test is performed.
AT
7. If the diagnostic trouble code (DTC) occurs again, refer to "Diagnostic trouble code table".
8. If the diagnostic trouble code (DTC) is not reset, they are intermittent faults, refer to "Intermittent fault check".
9. After repair, conduct the road test again, to confirm that fault has been eliminated.
Stall test
Be capable of carrying our stall test to the DSI automatic transmission to ensure whether the transmission-clutch can bear all
torque of the engine, without sliding.
1. Time of stall test should not exceed 10s.
2. Tighten the parking brake.
3. Start the engine;
4. Depress and hold the brake pedal by left foot;
5. Shift to the "Forward gear" (gear D);
6. 100% depress (fully) and hold the accelerator pedal for 6s;
Notice: Keep stepping on the brake pedal in the whole process of stepping on the accelerator pedal.
7. Read out the engine speed, namely stall speed;
8. Release the accelerator pedal;
9. Shift to "reverse gear"(gear R);
10. Depress the accelerator pedal by 100% by right foot, and hold it for 6 s;
Notice: Keep stepping on the brake pedal in the whole process of stepping on the accelerator pedal.
11. Read the engine speed, namely stall speed.
Notice: If the engine speed is higher than 3,000rpm, the transmission has hardware fault.
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Initialization
Notice: After replacing the automatic transmission assembly or ECU, execute the following steps:
Step 1 Rematch the automatic transmission.

(b) Put the transmission gear shift lever in "P" position, do
not depress the brake pedal, and press "Start" button
(engine does not operate).
(c) Run "ResetAda PtiveData" program, and wait for
response.
Next Step
Step 2 Activate the original data.
(a) Connect the fault diagnostic scanner.

(c) Run "ActivateAda PtiveGreENOffset" program, and
wait for response.
Next Step
AT
Step 3 Reset the mileage.
(a) Connect the fault diagnostic scanner.

(c) Run "SetKmTravelled" program.
Notice: After replacing with a new transmission or
upon warranty period of the transmission, set the trip
distance as 0 km.
Next Step
Step 4 Re-debugging.
(a) Do not depress the brake pedal, press "Start" button

and power off the vehicle.
(b) Start the vehicle again, and check whether the
automatic transmission is operating properly.
(c) Check whether the automatic transmission operates
normally.
No
Step 5 Adapt quickly to adjust cycling program.
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(a) Through normal driving, the transmission temperature

is raised to the operating temperature (65℃ ~ 95°C).
Notice: The transmission fluid temperature must be
maintained between 65°C and 95°C, which is the
precondition for ensuring function adaptability of the
transmission.
(b) After the vehicle stops traveling, depress the brake
pedal, switch the gear shift lever from neutral position
(N) to 1st gear and back to neutral position (N), 15
cycles in total. Every time the gear shift lever is
switched to the neutral position, it shall stay in the
neutral position for 2 s.
(c) After the vehicle stops traveling, depress the brake
pedal, switch the gear shift lever from neutral position
(N) to R gear, 15 cycles in total. Every time the gear
shift lever is switched to the neutral position, it shall
stay in the neutral position for 2 s.
(d) Depress the accelerator pedal from 10% to 100%,
with each increase of 10 %, to achieve gear switching
from gear 1 to gear 6. Each pedal position should be
tested for at least 5 times, and pay attention to the
matching operation of the gearshift lever.
(e) Let the vehicle slip from gear 6 to gear 1, with a small
amount of braking force applied, which should be
carried out for at least 5 times.
(f) When the speed of the vehicle is at 20km/h~130km/h, AT
carry out the kickdown test with full throttle (WOT) at
various gears. In order to achieve the most realistic
results, during the kickdown, the accelerator pedal is
not depressed from 0% but from 20% to 100%.
Repeat this process for 5 times.
No
Step 6 Complete the matching.

(c) Run "SetKmTravelled" program.
Notice: After replacing with a new transmission or
upon warranty period of the transmission, set the trip
distance as 0 km.
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Automatic Transmission Terminal

S006 Automatic transmission control unit harness connector 1
SO06 Automatic transmission control unit harness connector 1
Terminal No. Terminal abbreviation Terminal description Normal working current
1 SOL 9 Solenoid valve VBS SOL9 1.1A

AT
Solenoid valve VBS SOL

7 VBS SOL RTN 4.7A
RETURN
8 GND Grounding 4A
Solenoid valve ON/OFF

9 ON/OFF SOL 2 760mA
SOL2

SOL1

SOL4

SOL3
13 -- -- --
14 -- -- --
Solenoid valve ON/OFF SOL

15 ON/OFF SOL RTN 2.28A
RETURN
16 IG Power 4A
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Terminal No. Terminal abbreviation Terminal Description Normal working current
1 -- -- --
2 -- -- --
3 -- -- --
4 TGS RANGE CTRL Gearshift gear control --

AT
5 -- -- --
6 -- -- --
7 -- -- --
8 -- -- --
9 -- -- --
10 RANGE ACTIVE Gearshift gear activation --
11 -- -- --
12 -- -- --
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Terminal No. Terminal abbreviation Terminal Description Normal working current
Output speed sensor of

1 OUTPUT SPEED 2mA
solenoid valve
Solenoid valve EMM/speed

2 SNR PWR 40mA
sensor signal
Solenoid valve input speed

AT 3 INPUT SPEED 2mA
sensor
4 EMM DATA Solenoid valve EMM data 5mA
5 -- -- --
6 -- -- --
7 GEAR LEVER Gear switch --
Solenoid valve oil

8 OIL TEMP 2mA
temperature sensor
9 -- -- --
10 P-CAN HI P-CAN HI --
11 -- -- --
Solenoid valve EMM/speed

12 SNR GND 50mA
sensor grounding
13 -- -- --
14 EMM CLOCK Solenoid valve EMM CLOCK 5mA
15 SW GND Gear shift grounding 50mA
16 -- -- --
17 GEAR LEVER GND Gears switch grounding --
Solenoid valve oil

18 OIL TEMP GND 2mA
temperature sensor
19 -- -- --
20 P-CAN LO P-CAN LO
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EN32 Automatic transmission harness connector
EN32 Automatic transmission harness connector
1 VBS SOL RTN VBS solenoid valve grounding 4.7A
2 SOL5 VBS solenoid valve 5 1.1A

AT
EMM message/speed sensor

8 SNR GND 50mA
grounding
EMM message/speed sensor

9 SNR PWR 40mA
power voltage
10 OUTPUT SPEED Output speed 2mA
11 INPUT SPEED Input speed 2mA
Embedded storage mode

12 EMM DATA 5mA
message
13 EMM CLOCK Embedded storage mode clock 5mA
14 -- --
15 -- --
16 -- --
17 -- --
18 -- --
19 -- --
20 ON/OFF VBS RTN On/Off solenoid valve grounding 2.28A
21 ON/OFF SOL1 On/Off solenoid valve 1 760mA
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22 ON/OFF SOL 2 On/Off solenoid valve 2 760mA
Solenoid valve oil

25 OIL TEMP GND 2mA
temperature sensor
Solenoid valve oil

26 OIL TEMP 2mA
temperature sensor
AT
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Table of DTCs
DTC Description
P05030F Instability of drive shaft speed sensor.
P050008 The drive shaft speed sensor value and the transmission output value are unmatched.
P060336 TCU adaptive data storage fault
P060456 TCU adaptive data reaches the limit
P070713 Gearshift lever position sensor trouble – too low voltage
P070066 TCU asks to illuminate MIL light
P070814 Gearshift lever position sensor trouble – too high voltage (open circuit)
P071154 Transmission fluid temperature too high
P071253 Transmission fluid temperature sensor trouble – too low
P071354 Transmission fluid temperature sensor trouble – too high (open circuit)
P071608 Input shaft /turbine speed value
P07170F Unstable input shaft/turbine speed sensor
P071B00 Short circuit in performance mode switch AT
P071C04 Open circuit in performance mode switch
P071D10 Jammed Upshifting/downshifting control in manual gear-shifting (TGS)
P071E00 Low upshifting/downshifting control signal in manual gear-shifting (TGS)
P071F04 High upshifting/downshifting control signal (open circuit) in manual gear-shifting (open circuit)
P072108 Output shaft speed in exact consistency with input shaft speed
P07220F Unstable output shaft speed sensor
P072960 6th gear speed ratio error
P073160 Automatic or manual 1st gear speed ratio error
P073260 2nd gear speed ratio error
P073360 3rd gear speed ratio error
P073660 Wrong speed ratio at R position
P074163 Common detachment of torque converter lockup clutch
P074262 Common combination of torque converter lockup clutch
P074464 Slide trouble in torque converter lockup clutch
P09560F Error manual mode switch value
P082610 Jammed upshifting/downshifting switch (on steering wheel) in manual gear-shifting
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DTC Description
P082700 Too low upshifting/downshifting switch (on steering wheel) signal (short circuit) in manual gear-shifting
P082804 Too high upshifting/downshifting switch (on steering wheel) signal (open circuit) in manual gear-shifting
P095700 Short circuit in manual mode switch
P095804 Open circuit in manual mode switch
P096200 Overcurrent (short circuit) in solenoid valve S9
P096304 Weak current (open circuit) in solenoid valve S9
P097300 Overcurrent (short circuit) in On/Off solenoid valve S1
P097404 Weak current (open circuit) in On/Off solenoid valve S1
AT P098004 Weak current (open circuit) in On/Off solenoid valve S3
P099B00 Overcurrent (short circuit) in solenoid coil S7
P099C04 Lower current (open circuit) in solenoid coil S8
P099E00 Current overload (short circuit) in solenoid coil S8
P099F04 Lower current (open circuit) in solenoid coil S8
P09A100 Overcurrent (short circuit) in solenoid coil S11
P09A204 ON/OFF solenoid valve S1 low current (open circuit)
P09A304 Short circuit of EMM and speed sensor.
P09A404 Short circuit of mode switch
P160431 TCU EMM data error
P160531 EMM data mismatch
P161030 EMM communication error
P161131 EMM data error
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DTC Description
P180100 EMS failure to respond to TCU’s torque reduction request in gear shifting
U007300 TCU bus Off error
U010082 Failure in engine speed signal rolling code counter
U010083 Failure in engine speed signal checksum
U010087 Loss of CAN messages offered by engine controller
U010187 Loss of CAN messages offered by body controller
U010287 Loss of periodic CAN messages offered by transfer case
U010387 Loss of communication with gearshift lever
U012187 Loss of CAN messages from ECU (ABS/ESP/TCS) brake system
U012282 Failure in ABS/ESP rolling code counter for wheel speed
U012283 Failure in ABS/ESP wheel speed checksum
U014482 Failure in EMS IUPR rolling code counter for denominator
U014483 Failure in EMS IUPR denominator checksum
U040176 EMS offered CAN signals out of range or unavailable AT
U040276 BMC offered CAN signals out of range or unavailable
U040376 Transfer case data bus signals out of range or ineffective
U040476 Failure in gear shift lever communication data
U041576 CAN signals from ABS/ESP out of range or ineffective
U100016 TCU supply voltage too low
U100017 TCU supply voltage too high
U100021 Too low TCU communication voltage
U100022 Too high TCU communication voltage
U160141 Missing or damage of TCU application software
U160641 Calibration data error – platform
U160741 Calibration data error – variable activation
U160847 TCU VIN (Vehicle Identification Number ) code error
U160940 TCU hardware (PCB) calibration error
U160E30 Low-version software message error (Bosch specific DTC)
U161247 2WD/4WD match error
U161347 Engine type match error
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DTC P060336 P060456 P160431 U100016 U100017 U100021 U100022

1. DTC description
DTC P060336 TCU adaptive data storage fault
DTC P060456 TCU adaptive data reaches the limit
DTC P160431 TCU EMM data error
DTC U100016 TCU power supply voltage low
DTC U100017 TCU power supply voltage high
DTC U100021 Too low TCU communication voltage
DTC U100022 Too high TCU communication voltage
The transmission control unit (TCU) controls the transmission through the variable flow solenoid valve and ON/OFF solenoid
valve. Voltage for the transmission control unit is 8~16V, and current consumption is typically less than 4A, but gearshift is
needed when the current reaches 10A.
Mechanical components of transmission will change due to wear, etc. The transmission control unit uses gear data to adapt to
these changes, maintaining the gear quality within vehicle life. When transmission components change into a point where the
transmission control unit (TCU) cannot adapt to changing data in maintaining its gear quality, the transmission control unit will
set a trouble code.

(control strategy)
AT
P060336 Hardware circuit check
P060456 Hardware circuit check

Start switch located in "ON"
position
EMM digital image stored in
P160431 the TCU was damaged or
lost.
1.Start switch located in open

position
System pressure is less than
2.Engine speed >300 r/min
U100016 working voltage of solenoid
valve. 3.Transmission control unit
power voltage < 8 V for 0.5
second
1.Start switch located in open 1.TCU

System voltage is higher position
2.TCU power supply circuit
U100017 than working voltage of 2.Transmission control unit
solenoid valve. 3.TCU grounding circuit
power voltage > 17 V for 60
seconds

position
System voltage lower than
2.Engine speed >300 r/min
U100021 voltage required for data
communication 3.Transmission control unit
power voltage < 8 V for 0.5
second

System voltage higher than position
U100022 voltage required for data 2.Transmission control unit
communication power voltage > 17 V for 60
seconds
NL-3 01/2016
3. Circuit diagram:
Gateway
AT
Notice: Prior to executing this diagnostic step, observe the data list of the fault diagnostic scanner and analyze data accuracy
for quick troubleshooting!
Step 1 Re-read after clearing DTC, and check whether the control system has any DTC other than DTC
P060336 P060456 P160431 U100016 U100017 U100021 U100022.
(a) Connect fault diagnostic scanner to "fault diagnosis

interface".
mode to ON state.
(c) Power on the fault diagnosis scanner.
(d) Eliminate the DTC.
(e) Re-read the DTC, and check whether the present
conforms to the following conditions.
Displayed DTC Go to step 2
DTC P060336
P060456 P160431
U100016 U100017
U100021 U100022 Yes
P060456 P160431
U100016 U100017
U100021 U100022
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Displayed DTC Go to step 2

DTC P060336
P060456 P160431
U100016 U100017
U100021 U100022
No
P060456 P160431
U100016 U100017
U100021 U100022 other
DTC
No Refer to “The table of DTCs.”
Yes
Step 2 Check power supply and charging system
(a) Check the battery positive and negative cables for

loose connection.
(b) Check the engine harness connector for damages or
looseness.
Yes Reconnect the harness connector or

replace the harness.
AT
No
Step 3 Check the TCU power supply circuit.

mode to OFF state.
(b) Disconnect TCU harness connector S006
SO06 Automatic transmission control unit harness connector 1 (c) Operate the starter switch to turn the power supply
mode to ON state.
the automatic transmission harness connector S006
(e) Measure voltage value between the terminal 16 of the
automatic transmission harness connector S006 and
reliable grounding.
SO06（16）-reliable grounding
10 kΩ or higher
resistance value
SO06（16）-reliable grounding
11~14V
voltage value
(f) Does the voltage meet the standard value?
No
Circuit fault, repair circuit.
Yes
Step 4 Check the TCU grounding circuit.
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OFF state.
(b) Disconnect TCU harness connector S006
(c) Operate the starter switch to turn the power supply mode to ON
state.
(d) Measure the resistance value between terminal 8 of the
automatic transmission harness connector S006 and reliable
grounding.
(e) Measure voltage value between the terminal 8 of the automatic
transmission harness connector S006 and reliable grounding.
SO06 （ 8 ） -reliable grounding

Less than 3 Ω
resistance value
SO06 （ 8 ） -reliable grounding

0V
voltage value
AT
No Circuit fault, repair circuit.
Yes
Step 5 Replace TCU., refer to "TCU" (automatic transmission control unit).
Next Step
Step 6 Perform automatic transmission re-matching program, refer to "Initialization".
Next Step
(a) Connect fault diagnostic scanner to diagnostic test interface.

(b) Operate the starter switch to turn the power supply mode to ON
state.
(c) Clear DTCs.
(d) Start the engine and idle warming up for at least 5 minutes.
No
Intermittent fault, refer to "Check of intermittent
fault for intermittent fault".
Yes
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DTC P071B00 P071C04 P09A404

DTC P071B00 Short circuit in performance mode switch
DTC P071C04 Open circuit in performance mode switch
DTC3 P09A404 Short circuit of mode switch
The middle switch assembly provides performance mode data to the transmission control unit (TCU). When the gear shift is in
non-neutral and non-parking positions, the motor of the gear switch operates. When the gearshift is in reverse gear position,
the gear switch sends a signal to the reverse gear light.
DTC No. DTC detection strategy DTC setting condition Fault position
(control strategy)
The middle switch sensor gives a 1. Middle switch

P071B00 P09A404
grounding short-circuit indicated value
Start switch located in "ON" 2. Middle switch circuit
position 3. Gateway circuit
The middle switch sensor gives a
P071C04
grounding open-circuit indicated value 4. TCU
3. Circuit diagram:
AT Middle switch
Automatic transmission control unit
Gateway
Transmission gear switch
Notice: Prior to executing these diagnostic steps, observe the data table of the fault diagnosis scanner and analyze data
Step 1 Read the DTC again after eliminating the DTCs, and check whether the control system has faults
except DTC P071B00 P071C04 P09A404.
NL-3 01/2016

interface".
mode to ON state.
(c) Power on the fault diagnosis scanner.
(e) Read DTC again, and check current setting condition of
DTC.

DTC P071B00 P071C04
Yes
P09A404
DTCs except DTC
P071B00, P071C04 and No
P09A404.
No Refer to “The table of DTCs".
Yes
Step 2 Check power supply and charging system
(a) Check whether the positive and negative cables of the AT

battery are loose.
(b) Check the engine harness connector for damages or
looseness.
Reconnect the harness connector or

Yes replace the harness.
No
Step 3 Check the middle switch power circuit.

mode to OFF state.
(b) Disconnect the middle combination switch harness
IP82 middle switch harness connector
connector IP82.
mode to ON state.
(d) Measure the resistance between the terminal No.10 of
middle switch box harness connector IP82 and reliable
grounding.
Standard resistant:10kΩ or higher
(e) Measure the resistance between the terminal No.10 of
middle switch harness connector IP82 and reliable
grounding
Standard resistance: 11~14 V
Yes
Step 4 Check the middle switch grounding circuit.
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mode to OFF state.
IP82 middle switch harness connector (b) Disconnect the middle combination switch harness
connector S006.
mode to ON state.
grounding.
grounding
Standard resistance: 11~14 V
Yes
Step 5 Replace the middle switch

AT
Yes
Step 6 Replace TCU, refer to "TCU (automatic transmission control unit)".
Next Step
Next Step

interface.
mode to ON state.
(c) Clear DTCs.
(e) Read the DTC of the control system again and confirm
the system has no DTC output.
No Intermittent fault, refer to "Intermittent

fault check".
Yes
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DTC P070713 P070814 U010387 U040476

1. DTC description:
Diagnostic trouble codes (DTC) Failure types
P070713 Gearshift lever position sensor trouble – too low voltage
P070814 Gearshift lever position sensor trouble – too high voltage
(open circuit)
U010387 Loss of communication with gearshift lever
U040476 Failure in gear shift lever communication data
Gear switch assembly provides gearshift position data to the transmission control unit (TCU), and the gear switch motor
runs when the gearshift is in the non-neutral and non-parking gears. When the gearshift is in reverse gear position, the gear
switch sends a signal to the reverse gear light.
The transmission control unit provides a 5V reference signal to the gear position control circuit (gear switch) to measure
the voltage of the circuit and thus measure the gear position. The resistances in different shift positions are different.
(control strategy)
Gearshift lever position
sensor (gear switch) gives a
P070713
grounding short circuit AT
indicated value.
Gearshift lever position
sensor (gear switch) gives a
P070814
grounding short circuit
1. Gear switch
indicated value. Start switch located in "ON"
2. Gear switch circuit
The gear shift lever position position
3. BCM
sensor (gear switch) gives an
U010387
indication of communication
failure
The gear shift lever position
sensor (gear switch) gives an
U040476
indication of data
communication failure
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3. Circuit diagram:
Middle switch

To IPEPS
IP 54-10
To BCM
IP67-45
Gateway
AT
Transmission gear switch
Notice: prior to executing these diagnostic steps, observe the data table of the fault diagnosis scanner and analyze data
Read the DTC again after eliminating the DTCs, and check whether the control system has faults
Step 1
except DTC P070713 P070814 U010387 U010387.

interface".
mode to ON state.
(c) Power on the fault diagnostic scanner.
(e) Read the DTC again, and check current setting
condition of DTC.
DTC P070713 P070814
Yes
U010387 U010387
DTCs except DTC
P070713, P070814, No
P0101387 and U010387.
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Refer to "The table of DTCs".

Yes
No
Step 2 Check the resistance of gearshift lever position sensor (gear switch) under the state of each gear.

mode to OFF state.
(b) Switch the gearshift sequentially to gears "P", "R", "N",
EN31 transmission position switch harness connector
"D" and "M", and measure the resistance between
terminals 4 and 5 of gear switch harness connector
EN31 at all gears.
standard
Gear position Measured items resistance
value
P EN31 (4)- EN31 (5) 16.789kΩ±8%
R EN31 (4)- EN31 (5) 8.953kΩ±8%
N EN31 (4)- EN31 (5) 5.036kΩ±8%
D EN31 (4)- EN31 (5) 2.686kΩ±8%
M(manual
EN31 (4)- EN31 (5) 1.119kΩ±8%
mode )
(c) W Does the voltage meet the standard value?
Notices: If resetting the step after replacing gears AT
switch, it doesn’t meet standard value; replace the
automatic transmission assembly.
No Replace the gear switch.
Yes
Step 3 Check the signal circuit of gearshift lever position sensor (gear switch).

mode to OFF state.
EN31 transmission position switch harness connector (b) Disconnect the harness connector EN31 of the gear
switch.
mode to ON state.
(d) Measure the voltage between terminals 4 and 5 of the
gear switch harness connector EN31.
Standard voltage: 4.9~5.1V
(e) Does the voltage meet the standard value?
Replace the TCU, refer to "TCU"

No (automatic transmission control unit).
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Yes
Step 4 Detect the circuits of terminals 4 and 5 of gearshift lever position sensor (gear switch).

mode to OFF state.
(b) Disconnect the harness connector EN31 of the gear
EN31 transmission position switch harness connector
switch.
(c) Measure the resistance between terminal 4 of the gear
switch harness connector EN31 and terminal 17 of the
automatic transmission control module S005.
(d) Measure the resistance between terminal 5 of the gear
switch harness connector EN31 and terminal 7 of the
automatic control module S005.
mode to ON state.
(f) Measure the voltage between terminal 4 of the gear
switch harness connector EN31 and reliable grounding.
(g) Measure the voltage between terminal 5 of the gear
switch harness connector EN31 and reliable grounding.
Test item Standard value:
EN31(4)-SO05(17) Less than 3 Ω
AT EN31(5)-SO05(7) Less than 3 Ω
S005 automatic transmission control unit harness connector 3 EN31(4)-reliable
0V
grounding voltage value
EN31(5)-reliable
0V
(h) Does the voltage meet the standard value?
No Overhaul the circuit.
Yes
Step 5 Replace the TCU, refer to "TCU (automatic transmission control unit)".
Next Step
Next Step

interface.
mode to ON state.
(c) Clear DTCs.
(e) Read DTC of the control system again and confirm the
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fault check".
Yes
AT
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DTC P071154
1. DTC description:
Transmission fluid temperature is too
DTC P071154
high.
The transmission control unit (TCU) monitors the temperature of the transmission fluid. In case of vehicle cooling system
fault, the automatic transmission cannot maintain a normal automatic transmission oil temperature, and the automatic
transmission control unit (TCU) will take preventive actions to prevent too high oil temperature from damaging other vehicle
parts such as automatic transmission. TCU also monitors temperature change rate according to present current operating
conditions (performance). If the temperature sensor performance is out of the predetermined normal value, set DTC as
P071154.
(control strategy)
1. Automatic transmission
1. The start switch is in ON
coolant
position.
P071154 Exceed the upper limit 2. Automatic transmission
2. Transmission fluid
cooling system
temperature > 130°C.
3. Engine cooling system
Notice: prior to executing these diagnostic steps, observe the data table of the fault diagnostic scanner and analyze data
Read DTC again after eliminating the DTCs, and check whether the control system has faults except
AT Step 1
DTC P071154.

interface".
mode to ON state.
condition of DTC.
DTC P071154 Yes
DTCs except P071154 No
Yes Refer to "The table of DTCs".
No
Step 2 Check whether the automatic transmission fluid level and oil quality meet the standard.
No Refill or replace automatic transmission

oil. Refer to "On-board check".
Yes
Step 3 Check whether the engine coolant meets the standard.
No Fill or replace the engine coolant, refer to

"Drain and filling of engine coolant"
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Yes
Check whether the automatic transmission cooling system leaks or is blocked or the pipeline is
Step 4
damaged.
No Repair or replace fault position.
Yes
Step 5 Check whether the engine cooling system leaks or is blocked or the pipeline is damaged.
No Repair or replace fault position.
Yes
AT
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DTC P071253 P071354

1. DTC description:
Transmission fluid temperature
DTC P071354
sensor voltage is high (open circuit).
Transmission fluid temperature
DTC P071253
sensor voltage is low (short circuit).
The automatic transmission fluid temperature (TFT) sensor is installed in the solenoid valve body tray. TFT sensor is a
thermal thermostat with negative coefficient. The transmission control unit (TCU) provides a 5V reference signal to the
automatic transmission fluid temperature sensor to measure the voltage drop in the circuit. When the automatic transmission
oil temperature rises, the resistance of the sensor is reduced. The resistance of the sensor is reduced as the temperature
rises.
(control strategy)
The transmission fluid
temperature sensor provides
P071253 1. Solenoid valve and
a grounding short circuit
harness assembly
indicative value. Start switch located in “ON”
2. TCU
The transmission fluid position
temperature sensor provides
P071354 assembly
an open circuit indicative
value.
3. Circuit diagram
AT
Gateway
Notice: Prior to executing these diagnostic steps, observe the data list of the fault diagnostic scanner and analyze data
NL-3 01/2016
Step 1
DTC P071253 and P071354.

interface".
mode to ON state.
condition of DTC.
DTC P071253、P071354 Yes
DTCs except DTC
No
P071253 and P071354.
No
AT
Step 2 Check the fluid temperature sensor resistance.

mode to OFF state.
EN32 automatic transmission harness connector

(b) Disconnect the solenoid valve harness connector EN32.
(c) Measure the resistance between terminals 25 and 26 of
the solenoid valve harness connector EN32.
Standard resistance (refer to “Relationship between
temperature of oil temperature sensor and resistance”):
20°C (68°F) 56.74 kΩ~65.86 kΩ
(d) Does the voltage meet the standard value?
Replace the automatic transmission

No
assembly.
Yes
Step 3 Check the signal voltage of fluid temperature sensor.
NL-3 01/2016

mode to OFF state.

mode to ON state.
solenoid valve harness connector EN32.
Replace the TCU. Refer to "TCU

No
(automatic transmission control unit)".
Yes
Step 4 Check the fluid temperature sensor circuit.

mode to OFF state.
AT EN32 automatic transmission harness connector
solenoid valve harness connector EN32 and terminal 18
of the automatic transmission control module SO05.
mode to ON state.
(f) Measure the voltage between terminal 25 of solenoid
valve harness connector EN32 and reliable grounding.
(g) Measure the voltage between terminal 26 of solenoid
S005 automatic transmission control unit harness connector 3 EN32 (25)-reliable
0V
EN32 (26)-reliable
0V
No Circuit fault, overhaul the circuit.
Yes
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Next Step
Step 6 Perform automatic transmission re-matching program, refer to “Initialization”.
Next Step

interface.
mode to ON state.
(c) Clear DTCs.

fault check".
AT
Yes
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DTC P160531 P161030 P161131 P09A304

1. DTC description:
DTC P161030 EMM communication error
DTC P161131 EMM data error
DTC P09A304 Short circuit of EMM and speed
sensor.
DTC P160531 EMM data mismatch
In the process of manufacture and design, the EMM module is matched with the transmission solenoid valve body. Hall-effect
sensor drive signal is low. 36 pulse signals are generated on the C1 clutch outer tooth hub per revolution when the
transmission control unit increases the resistance signal to 5V.
(control strategy)
Data stored in an Embedded
Memory Module (EMM) of
P160531
TCU cannot meet the EMM
1. Solenoid valve and
module in the transmission.
AT harness assembly
TCU cannot communicate
P161030 Start switch located in "ON" 2. TCM
with EMM.
position 3. Automatic transmission
Data stored in EMM is
assembly
P161131 damaged or lost or
unavailable.
EMM and speed sensor line
P09A304
feedback has short circuit
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3. Circuit diagram
AT
Step 1 Read DTC again after eliminating the DTCs, and check whether the control system has faults except
DTC P160531, P161030, P161131 and P09A304.

interface".
mode to ON state.
condition of DTC.
DTC P160531, P161030,
Yes
P161131 and P09A304
DTCs except P160531,
P161030, P161131 and No
P09A304.
NL-3 01/2016
Yes Please refer to "The table of DTCs".
No
Step 2 Detect EMM module line.

mode to OFF state.
(c) Measure the resistance between terminal 8 of solenoid
valve harness connector EN32 and terminal 12 of the
S005 automatic transmission control unit harness connector 3
automatic transmission control module SO05.
(d) Measure the resistance between terminal 9 of solenoid
(f) Measure the resistance between terminal 13 of solenoid
valve harness connector EN32 and terminal 14 of
(g) Operate the starter switch to put power supply mode in
ON state.
AT
(h) Measure the voltage between terminal 8 of solenoid
(i) Measure the voltage between terminal 9 of solenoid
(j) Measure the voltage between terminal 12 of solenoid
(k) Measure the voltage between terminal 13 of solenoid
EN32 (8)-reliable
0V
EN32 (9)-reliable
0V
EN32 (12)-reliable
0V
EN32 (13)-reliable
0V
(l) Does the voltage meet the standard value?
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Yes
Next Step
Next Step
Step 5 Test the vehicle on road after eliminating DTC, and reread the DTC.
(a) Test the vehicle on road after eliminating DTC, and

reread the DTC.
(b) Whether the fault still exists or not.
Yes Replace the automatic transmission

assembly.
No
AT

interface.
mode to ON state.
(c) Clear DTCs.
Intermittent fault, refer to "Intermittent

No
fault check".
Yes
NL-3 01/2016
DTC P071608 P07170F

1. DTC description:
DTC P071608 Input shaft /turbine speed value
The input shaft /turbine speed sensor
DTC P07170F
signal is unstable.
The ISS sensor is a Hall-effect sensor. The ISS sensor is integrated with the OSS sensor and installed on the main housing
of the automatic transmission (below the valve body). 40 pulse signals are generated on the C1 clutch outer tooth hub per
revolution when the transmission control unit (TCU) increases the resistance signal to 5V.
(control strategy)
Compared the input shaft
speed (ISS) with the engine
P071608 1. Solenoid valve and
speed, confirm the
authenticity 1. Start switch located in harness assembly
The input speed sensor "ON" position 2. TCM
receives the intermittent 2. Engine speed > 3000 rpm 3. Automatic transmission
pulse or interference pulse.
P07170F assembly
Conflict with signal of output
shaft
AT Unstable signal of input shaft
3. Circuit diagram:
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Step 1
DTC P071608 and P07170F.

interface".
mode to ON state.
condition of DTC.
P071608 and P07170F Yes
DTCs except P071608
No
and P07170F
Yes Refer to “The table of DTCs".
No AT
Step 2 Check the reference voltage of the input shaft speed sensor.

mode to OFF state.
EN32 automatic transmission harness connector (b) Disconnect the solenoid valve harness connector EN32.
mode to ON state.
Standard voltage value: >10V

No
(automatic transmission control unit)".
Yes
Step 3 Detect the signal voltage of input shaft speed sensor.
NL-3 01/2016

mode to OFF state.

mode to ON state.
No Replace the TCU. Refer to "TCU

(automatic transmission control unit)"
Yes
Step 4 Check the circuit of the input shaft speed sensor.

mode to OFF state.
AT automatic transmission control module S005.
of the automatic transmission control module S005.
(e) Measure the resistance between terminal 11 of solenoid
mode to ON state.
SO05 automatic transmission control unit harness connector 3
EN32 (8)-reliable 0V
grounding voltage v lue
(j) Does the voltage meet the standard value?
Yes
Step 5 Check the output waveform of the input shaft speed sensor.
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mode to OFF state.
(b) Connect an oscilloscope to terminal 3 and 12 of the
harness connector S005 of the automatic transmission
control module.
mode to ON state.
(d) Start the engine, increase the engine speed, and
observe whether the waveform of the oscilloscope
changes normally as the speed changes.
No
Step 6 Replace the TCU, refer to “TCU (automatic transmission control unit)".
Next Step
Next Step AT

interface.
mode to ON state.
(c) Clear DTCs.

fault check".
Yes
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DTC P072108 P07220F

1. DTC description:
Output shaft speed sensor signal is
DTC P07220F
unstable.
Output shaft speed sensor numerical
DTC P072108
value
The OSS sensor is a Hall-effect sensor. The ISS sensor is integrated with the OSS sensor and installed on the main housing
of the automatic transmission (below the valve body). While hall-effect sensor drive signal is low, 40 pulse signals are
generated on the automatic transmission drive gear per revolution when the transmission control unit (TCU) increases the
resistance signal to 5V.
(control strategy)
Compared the output shaft
speed (OSS) sensor with the 1. Solenoid valve and
P072108 external equivalent harness assembly
revolution speed signal, Start switch located in "ON"
2. TCM
verify the integrity thereof. position
The output speed sensor
P07220F receives the intermittent assembly
pulse or interference pulse
AT 3. Circuit diagram
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Step 1
DTC P072108 and P07220F.

interface".
mode to ON state.
condition of DTC.
P072108 and P07220F Yes
DTCs except DTC
No
P072108 and P07220F.
Refer to “The table of DTCs".

Yes
No
AT
Step 2 Check the reference voltage of the input shaft speed sensor.

mode to OFF state.
mode to ON state.
Standard voltage value: >10V

No
Yes
Step 3 Check the signal circuit of the output shaft speed sensor.
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mode to OFF state.
mode to ON state.
(d) Connect the oscilloscope to terminal 1 and 10 of the
harness connector SO05 of the automatic transmission
control module.

No
Yes
Step 4 Check the circuit of the output shaft speed sensor.

mode to OFF state.
EN32 automatic transmission harness connector (c) Measure the resistance between terminal 8 of solenoid
AT
(e) Measure the resistance between terminal 10 of solenoid
mode to ON state.
S005 automatic transmission control unit harness connector 3 Test item Standard value:
EN32 (8)-reliable
0V
EN32 (9)-reliable
0V
EN32 (10)-reliable
0V
Yes
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Step 5 Check the output waveform of the output shaft speed sensor.

mode to OFF state.
(b) Connect an oscilloscope to terminal 1 and 12 of the

harness connector S005 of the automatic transmission
control module.
mode to ON state.
(d) Start the engine, increase the engine speed, and
observe whether the waveform of the oscilloscope
changes normally as the speed changes.
No
Step 6 Replace the TCU, refer to “TCU (automatic transmission control unit)”.
Next Step
AT
Next Step

interface.
mode to ON state.
(c) Clear DTCs.

fault check".
Yes
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DTC P071D10 P071E00 P071F04 P09560F P095700 P095804

1. DTC description:
Manual gearshift control upper/ down
DTC P071D10
(TGS)stuck
Voltage of manual gearshift control
DTC P071E00 upper/ down (TGS) signal is too low
(short circuit)
High voltage of manual gearshift
DTC P071F04 control upper/down (TGS) signal
(open circuit)
DTC P09560F Error manual mode switch value
DTC P095700 Short circuit in manual mode switch
DTC P095804 Open circuit in manual mode switch
When the control lever is on “M”, the driver can define the maximum applicable speed ratio through the selection of “+” or “-”
on the gear selector. When initially moving the control lever to the manual “M”, the transmission will select the minimum
applicable speed ratio. When reaching the maximum of revolution per minute of the engine, the transmission will automatically
shift up no matter how the driver selects the limit. The manual mode gear control buttons “+” and “-” for manual mode are
installed on the gear shifter.
AT 2. DTC set and fault position:
(control strategy)
Press the manual gear
P071D10 shifting up/down switch
(TGS), and hold for 120 s.
Manual gearshift control
upper/ down (TGS) switch
P071E00
signal gives a short circuit
indicated value.
Manual gearshift control
upper/ down (TGS) switch 1. Gear shifter
P071F04 Start switch located in "ON"
signal give an open circuit 2. Gear shifter circuit
position
indicated value. 3. TCU
The manual mode switch
P09560F signal gives an indication of
wrong value.
P095700 signal gives an indication of
short circuit.
P095804 signal gives an indication of
open circuit.
NL-3 01/2016
3. Circuit diagram
To PEPS IP 54-14
To reverse radar
S061-1
Gateway
AT
Step 1
except DTC P071D10 P071E00 P071F04 P09560 FP095700 and P095804.

interface".
mode to ON state.
condition of DTC.
DTC P071D10 P071E00
P071F04 P09560F Yes
P095700 P095804
DTCs except DTC
P071D10 P071E00
No
P09560F P095700 and
P071F04.
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No
The gear shifter is used for switching various gears in sequence to check whether there is a
Step 2
mechanical fault.
Replace the gear shifter assembly. Refer

Yes
to “Gear shifter assembly".
No
Step 3 Check the resistance of the gear shifter in the manual mode.

mode to OFF state.
(b) Disconnect the automatic transmission control unit
S005 automatic transmission control unit harness connector 3 harness connectors SO07 and SO05.
(c) Control the gear shifter to perform the following actions
in the manual mode and measure resistance between
AT terminal 4 of the automatic transmission control module
harness connector SO07 and terminal 15 of the harness
connector SO05.
Measured items standard resistance value
Press down “+” button
under the manual mode 972~1188Ω
of the gear shifter.
Press down “-” button
under the manual mode 499~611Ω
S007 automatic transmission control unit harness connector 2 of the gear shifter.
Gear shifter under the
manual mode (Not press 2916~3564Ω
down any button)
Replace the gear shifter assembly. Refer

No
to "Gear shifter assembly".
Yes
Step 4 Detect the gear shifter circuit.
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mode to OFF state.
(b) Disconnect the gear shifter harness connector.
(c) Measure the resistance between the terminal No.2 of
S007 automatic transmission control unit harness connector 2 gear shifter harness connector SO08 and the terminal
No.4 of automatic transmission control unit SO07.
gear shifter harness connector SO08 and the terminal
gear shifter harness connector SO08 and the terminal
mode to ON state.
(g) Measure the voltage between terminal 2 of gear shifter
harness connector SO08 and reliable grounding.
(h) Measure the voltage between terminal 3 of gear shifter
(i) Measure the voltage between terminal 7 of gear shifter
S008 Transmission gear shifting switch harness connector
Measured items Standard value:
Gear shifter harness
connector SO08 (2) – Less than 3 Ω
SO07 (4)
Gear shifter harness AT
SO07 (10)
SO05 (15)
connector SO08 (2) –
0V
reliable grounding
voltage value
S005 automatic transmission control unit harness connector 3 0V
reliable grounding
voltage value
Less than 3 Ω
reliable grounding
voltage value
Yes
Step 5 Replace the TCU., refer to “TCU (automatic transmission control unit)".
Next Step
NL-3 01/2016
Next Step

interface.
mode to ON state.
(c) Clear DTCs.

No
fault check".
Yes

AT
NL-3 01/2016
DTC P072960 P073160 P073260 P073360 P073460 P073560 P073660

1. DTC description:
DTC P072960 6th gear drive ratio error
Automatic or manual 1st gear speed
DTC P073160
ratio error
DTC P073260 2nd gear speed ratio error
DTC P073360 3rd gear speed ratio error
DTC P073460 4th gear speed ratio error
DTC P073560 5th gear speed ratio error
DTC P073660 R gear speed ratio error
The transmission gear shift is controlled by the transmission control unit (TCU). The transmission control unit receives the
input information from the engine speed sensor and other vehicle sensors. During each gear shift, it selects the time to change
gear, controls the gear shift feel and the torque converter clutch (TCC).
(control strategy)
When not shifting gear, drive
ratio of gear 6 observed by
P072960
system is over the calibration
value.
P073160
value.
When not shifting gear, drive 1. Start switch located in
ratio of gear 2 observed by "ON" position AT
P073260
system is over the calibration 2. Engine speed > 300 rpm
value. 3. The engine is not in "limp" 1. Oil quality of automatic
When not shifting gear, drive mode. transmission
ratio of gear 3 observed by 4. Transmission fluid 2. Oil level of automatic
P073360
system is over the calibration temperature > 0°C. transmission
value. 5. Transmission output shaft 3. Automatic transmission
When not shifting gear, drive speed >300 rpm. assembly
ratio of gear 4 observed by 6. Transmission gearshift
P073460
system is over the calibration lever is not in gear N or
value. parking position.
P073560
value.
ratio of reverse gear
P073660
observed by system is over
the calibration value.
Step 1
except DTCP072960, P073160, P073260, P073360, P073460, P073560 and P073660.

interface".
mode to ON state.
condition of DTC.
NL-3 01/2016
No
Step 2 Check whether the automatic transmission leaks oil.
Yes Repair or replace fault position.
No
Check whether the oil quality and oil level of automatic transmission meet the standards. Refer to
Step 3
“Automatic transmission oil”.
Refill or replace the automatic

No transmission oil. Refer to "Automatic
transmission oil".
Yes
Step 4 Check whether the automatic transmission has obvious mechanical damage.
Yes Repair or replace the damaged part.

AT
No
Next Step
Next Step

interface.
mode to ON state.
(c) Clear DTCs.

No
fault check".
Yes
NL-3 01/2016
DTC P074163 P074262 P074464

1. DTC description:
Common detachment of torque
DTC P074163
converter lockup clutch
Common combination of torque
DTC P074262
converter lockup clutch
Slide trouble in torque converter
DTC P074464
lockup clutch
Automatic transmission releases the hydraulic torque converter lockup clutch through the hydraulic control system.
Hydraulic torque converter lockup clutch piston pressure is determined by the electronic variable control solenoid valve (VBS).
In operation process, the transmission control unit evaluates the speed of the torque converter slipping plate and compares it
with the expected one. If there is no predefined parameters for the torque converter slipping plate, DTC will set and display the
torque converter lockout problem.
(control strategy)
When locking is requested,
the hydraulic torque
converter always maintains
release state. After TCU
P074163
sends a locking request, the
slip speed is more than 50 1. Start switch located in
rpm and maintains more than "ON" position
0.5 s. 2. Engine speed > 300 rpm
1. Oil quality of automatic
When release is requested, 3. The engine is not in "limp"
transmission
the hydraulic torque mode. AT
2. Oil level of automatic
converter always maintains 4. Transmission fluid
transmission
locking state. After TCU temperature > 0°C.
P074262 sends a release request, the 5. Transmission does not in
assembly
slip speed is less than 150 gearshift process
rpm, and the engine torque is 6. Gearshift lever is on gear
more than 150 N·m and D.
maintains more than 0.5 s.
The slip speed of the
hydraulic torque converter is
P074464
out of control and maintains
more than 0.5 s.
Step 1
DTC P074163, P074262 and P074464.

interface".
mode to ON state.
condition of DTC.
DTC P074163, P074262
Yes
and P074464
DTCs except P074163,
No
P074262 and P074464
NL-3 01/2016
Yes Refer to “The table of DTCs"
No
Step 2 Check whether the automatic transmission leaks oil.
Yes Repair or replace fault position.
No
Check whether the automatic transmission fluid level and oil quality meet the standard. Refer to
Step 3
“Automatic transmission fluid”
Refill or replace the automatic

No transmission oil. Refer to “Automatic
transmission oil”.
Yes
Step 4 Check whether the automatic transmission has obvious mechanical damage.
Yes Repair or replace the damaged part.

AT
No
Step 5 Replace the automatic transmission assembly. Refer to “Automatic transmission oil”.
Next Step
Next Step

interface.
mode to ON state.
(c) Clear DTCs.

No
fault check".
Yes
NL-3 01/2016
DTC P096200 P096304

1. DTC description:
Too high current in solenoid valve S9
DTC P096200
(short circuit)
Too low current in solenoid valve S9
DTC P096304
(open circuit)
The transmission control unit (TCU) uses a variable pressure solenoid valve to regulate the hydraulic pressure. The
hydraulic pressure controls the torque flow through clutch element flow in the transmission. Transmission control unit (TCU)
controls the current of variable solenoid valve coil to differentiate torque through controlling and using different variables on the
clutch element. Clutch torque transmission components are directly related to the current applied to the solenoid valve. During
operation, the transmission control unit evaluates the current actually delivered to the solenoid valve and compares with the
expected. If there is no pre-defined parameter currently, the DTC is set to display abnormal load of the transmission control
unit.
(control strategy)
Feedback message of
P096200 solenoid valve S10 is short 1. Start switch located in
1. Solenoid valve
circuit. "ON" position
2. Solenoid valve circuit
Feedback information of 2. Power on solenoid valve 3. TCU
3. Voltage of TCU power
P096304 solenoid valve S10 is open
supply is normal.
circuit.
3. Circuit diagram AT
NL-3 01/2016
Step 1
DTC P096200 and P096304.

interface".
mode to ON state.
condition of DTC.
DTC P096200、P096304 Yes
DTCs except P096200
No
and P096304.
Refer to "The table of DTCs".

No
Yes
AT
Check the TCU power supply circuit. Refer to DTC P060336 P060456 P160431 U100016 U100017
Step 2
U100021 U100022
Next Step
Step 3 Check the S9 solenoid valve resistance.

mode to OFF state.

Standard resistance: 4.11~4.17 V

No assembly. Refer to “Automatic
transmission”.
Yes
Step 4 Test S9 solenoid circuit.
NL-3 01/2016

mode to OFF state.
EN32 automatic transmission harness connector (c) Measure the resistance between terminal 6 of the
mode to ON state.
EN32 (6)-reliable
0V
0V
AT
Yes
Next Step
Step 6 Perform automatic transmission re-matching program, refer to “Initialization".
Next Step

interface.
mode to ON state.
(c) Clear DTCs.

No
fault check".
Yes
NL-3 01/2016
AT
NL-3 01/2016
DTC P096600 P096704

1. DTC description:
The current of solenoid valve S10 is
DTC P096704
too low (open circuit)
DTC P096600
too high (short circuit)
unit.
(control strategy)
Feedback message of
1. Start switch located in
P096600 solenoid valve S10 is short 1. Solenoid valve
"ON" position
circuit. 2. Solenoid valve circuit
2. Power on solenoid valve
The feedback information of 3. TCU
3. Voltage of TCU power
P096704 solenoid valve S10 is open
supply is normal.
circuit.
3. Circuit diagram
AT
Notice: prior to executing these diagnostic steps, observe the data list of the fault diagnostic scanner and analyze data
NL-3 01/2016
Step 1
DTC P096600 and P096704.

interface".
mode to ON state.
condition of DTC.
DTC P096600、P096704 Yes
DTCs except P096600
No
and P0967044.
Please refer to "The table of diagnostic

No
DTCs".
AT Yes
Detect the TCU power circuit. Refer to “DTC P060336, P060456, P160431, U100016, U100017,
Step 2
U100021 and U100022”.
Next Step

mode to OFF state.


No assembly. Refer to "Automatic
transmission".
Yes
NL-3 01/2016

mode to OFF state.
mode to ON state.

AT
Yes
Next Step
Step 6 Perform automatic transmission re-matching program, refer to "Initialization"
Next Step
interface.
mode to ON state.
(c) Clear DTCs.

No
fault check".
Yes
NL-3 01/2016
AT
NL-3 01/2016
DTC P098500 P098604

1. DTC description:
DTC P098604
DTC P098500
unit.
(control strategy)
Feedback message of 1. Start switch located in
P098500 solenoid valve S5 exists
short circuit "ON" position 1. Solenoid valve
The feedback information of 2. Power on solenoid valve 2. Solenoid valve circuit
3. TCU
P098604 solenoid valve S5 is open 3. Voltage of TCU power
circuit. supply is normal.
3. Circuit diagram AT
NL-3 01/2016
Step 1
DTC P098500 and P098604.

interface".
mode to ON state.
condition of DTC.
DTC P098500, P098604 Yes
DTCs except P098500
No
and P098604
No Refer to "The table of DTCs".
AT Yes
Detect the TCU power supply circuit. Refer to “DTC P060336 P060456 P160431 U100016 U100017
Step 2
U100021 and U100022”.
Next Step

mode to OFF state.
No Replace the automatic transmission

assembly. Refer to "Automatic
transmission".
Yes
NL-3 01/2016

mode to OFF state.
mode to ON state.
EN32 (2)-reliable
0V
EN32 (1)-reliable
0V
AT
Yes
Next Step
Next Step

interface.
mode to ON state.
(c) Clear DTCs.

No fault check".
Yes
NL-3 01/2016
AT
NL-3 01/2016
DTC P099800 P099904

1. DTC description:
DTC P099904
too low(open circuit)
DTC P099800
unit.
(control strategy)
P099800 solenoid valve S6 is short
"ON" position 1. Solenoid valve
circuit.
2. Power on solenoid valve 2. Solenoid valve circuit
The feedback information of
3. TCU
P099904 solenoid valve S6 is open 3. Voltage of TCU power
3. Circuit diagram
AT
TCU Automatic transmission control
NL-3 01/2016
Step 1
DTC P099800 and P099904.

interface".
mode to ON state.
condition of DTC.
DTC P099800 and
Yes
P099904
DTCs except P099800
No
and P099904

AT
Yes
Detect the TCU power supply circuit. Refer to “DTC P060336, P060456, P160431, U100016,
Step 2
U100017, U100021 and U100022”.
Next Step

mode to OFF state.

Standard resistance value: 4.11~4.17 V

transmission".
Yes
NL-3 01/2016

mode to OFF state.
EN32 automatic transmission harness connector solenoid valve harness connector EN32 and terminal 6
mode to ON state.
EN32 (3)-reliable
0V
EN32 (1)-reliable
0V
S006 automatic transmission control unit harness connector 1 grounding voltage value
AT
Yes
Next Step
Next Step
interface.
mode to ON state.
(c) Clear DTCs.

No fault check".
Yes
NL-3 01/2016
AT
NL-3 01/2016
DTC P099B00 P099C04

1. DTC description:
DTC P099C04
DTC P099B00
unit.
DTC No DTC detection strategy Fault position
(control strategy)
Feedback message of 1. The start switch is in "ON"
P099B00 solenoid valve S7 exists
position 1. Solenoid valve
short circuit
2. The solenoid valve is on 2. Solenoid valve circuit
3. TCU
P099C04 solenoid valve S7 is open 3. The TCU power voltage is
circuit. normal.
3. Circuit diagram
AT
TCU Automatic transmission control unit
NL-3 01/2016
Step 1
DTC P099B00 and P099C04.

interface".
mode to ON state.
condition of DTC.
DTC P099B00 P099C04 Yes
DTCs except DTC
No
P099B00 and P099C04.
No Refer to "The table of diagnostic DTCs".
AT Yes
Step 2 Detect the TCU power circuit. Refer to “DTC P060336, P060456, P160431, U100016, U100017,
U100021 and U100022”.
Next Step

mode to OFF state.


transmission".
Yes
NL-3 01/2016

mode to OFF state.
mode to ON state.
EN32 (4)-reliable
0V
0V
AT
Yes
Next Step
Next Step

interface.
mode to ON state.
(c) Clear DTCs.

No fault check".
Yes
NL-3 01/2016
AT
NL-3 01/2016
DTC P099E00 P099F04

1. DTC description:
DTC P099F04
DTC P099E00
overloaded (short circuit)
unit.
(control strategy)
P099E00 solenoid valve S8 exists
short circuit
3. TCU
P099F04 solenoid valve S8 is open 3. Voltage of TCU power
3. Circuit diagram
AT
NL-3 01/2016
Step 1
DTC P099E00 and P099F04.

interface".
mode to ON state.
condition of DTC.
DTC P099E00 and
Yes
P099F04
DTCs except
DTCP099E00 and No
P099F04.
AT No Refer to "The table of DTCs".
Yes
Step 2
U100021 and U100022”.
Next Step
Step 3 Test the S8 solenoid valve resistance.

mode to OFF state.


transmission".
Yes
NL-3 01/2016

mode to OFF state.
mode to ON state.
EN32 (5)-reliable
0V
0V
AT
Yes
Next Step
Next Step

interface.
mode to ON state.
(c) Clear DTCs.

No fault check".
Yes
NL-3 01/2016
AT
NL-3 01/2016
DTC P097300 P097404

1. DTC description:
Too low circuit in on/off solenoid valve
DTC P097404
S1 (open circuit)
Too high circuit in on/off solenoid valve
DTC P097300
S1 (short circuit)
The transmission control unit (TCU) uses an ON/OFF solenoid valve to select among different clutch elements within the
transmission. During operation, the transmission control unit evaluates the current actually-delivered current to open/close the
solenoid valve and compares with the expected. If the current is not in the pre-defined parameter, the DTC is set to display
abnormal load of the transmission control unit.
(control strategy)
Feedback information of 1. Start switch located in
P097300 ON/OFF solenoid valve S1 is
short circuit.
Feedback information of
3. TCU
P097404 ON/OFF solenoid valve S1 is 3. Voltage of TCU power
open circuit. supply is normal.
3. Circuit diagram
AT
NL-3 01/2016
Step 1
DTC P097300 and P097404.

interface".
mode to ON state.
condition of DTC.
DTC P097300 and
Yes
P097404
DTCs except DTC
No
P097300 and P097404.

AT
Yes
Detect the TCU power circuit. Refer to “DTC P060336 P060456 P160431 U100016 U100017
Step 2
U100021 and U100022”.
Next Step
Step 3 Check resistance of ON/OFF solenoid valve S1.

mode to OFF state.


transmission".
Yes
Step 4 Check circuit of ON/OFF solenoid valve S1.
NL-3 01/2016

mode to OFF state.
mode to ON state.
EN32 (21)-reliable
0V
0V
AT
Yes
Next Step
Next Step

interface.
mode to ON state.
(c) Clear DTCs.

No fault check".
Yes
NL-3 01/2016
AT
NL-3 01/2016
DTC P097600 P097704

1. DTC description:
The circuit of on/off solenoid valve S2
DTC P097704
is too low (short circuit)
The circuit of on/off solenoid valve S2
DTC P097600
is too high (short circuit)
(control strategy)
The feedback information of 1. Start switch located in
short circuit.
Feedback information of
3. TCU
P097704 ON/OFF solenoid valve S2 is 3. Voltage of TCU power
open circuit. supply is normal.
3. Circuit diagram
AT
NL-3 01/2016
Step 1
DTC P097600 and P097704.

interface".
mode to ON state.
condition of DTC.
DTC P097600 and
Yes
P097704
DTCs except DTC
No
P097600 and P097704.

AT
Yes
Step 2
U100021 and U100022”.
Next Step

mode to OFF state.


transmission".
Yes
NL-3 01/2016

mode to OFF state.
mode to ON state.
EN32 (22)-reliable
0V
0V
AT
Yes
Next Step
Next Step

interface.
mode to ON state.
(c) Clear DTCs.

No fault check".
Yes
NL-3 01/2016
AT
NL-3 01/2016
DTC P097900 P098004

1. DTC description:
The circuit of on/off solenoid valve S3 is too low
DTC P098004
(open circuit)
The circuit of on/off solenoid valve S3 is too high
DTC P097900
(short circuit)
strategy)
1. Start switch located in "ON"
position 1. Solenoid valve
short circuit.
3. Voltage of TCU power supply is 3. TCU
normal.
open circuit. AT
3. Circuit diagram
TCU Automatic transmission control
Notice: Prior to executing these diagnostic steps, observe the data list of the fault diagnostic scanner and analyze
NL-3 01/2016
Step 1 Read DTC again after eliminating the DTCs, and check whether the control system has faults except DTC
P097900 and P098004.
interface".
to ON state.
(e) Read the DTC again, and check current setting condition
of DTC.
DTC P097900 and
Yes
P098004
DTCs except DTC P097900
No
and P098004
Yes
AT
Step 2
U100021 and U100022”.
Next Step

mode to OFF state.


transmission".
Yes
NL-3 01/2016
to OFF state.
to ON state.

0V
EN32 (20)-reliable
0V AT
Yes
Step 5 Replace TCU, refer to “TCU” (automatic transmission control unit).
Next Step
Next Step

interface.
mode to ON state.
(c) Clear DTCs.

No fault check".
Yes
NL-3 01/2016
AT
NL-3 01/2016
DTC P098200 P098304

1. DTC description:
DTC P098304 The circuit of on/off solenoid valve S4 is too low (open circuit)
DTC P098304 The circuit of on/off solenoid valve S4 is too high (short circuit)
DTC No. DTC detection strategy DTC setting condition (control strategy) Fault position
The feedback information of 1. Start switch located in "ON" position 1. Solenoid valve
P098200 ON/OFF solenoid valve S4 is 2. Power on solenoid valve 2. Solenoid valve circuit
short circuit. 3. Voltage of TCU power supply is 3. TCU
The feedback information of normal.
open circuit.
3. Circuit diagram
AT
Automatic Transmission
NL-3 01/2016
Read DTC again after eliminating the DTCs, and check whether the control system has faults except DTC
Step 1
P098200 and P098304
interface".
to ON state.
of DTC.
DTC P098200 and
Yes
P098304
DTCs except DTC P098200
No
and P098304.
AT Yes
Step 2
U100021 and U100022”.
Next Step

mode to OFF state.


transmission".
Yes
NL-3 01/2016
to OFF state.
to ON state.

0V
EN32 (20)-reliable
0V AT
Yes
Step 5 Replace TCU, refer to "TCU (automatic transmission control unit)".
Next Step
Next Step
interface.
mode to ON state.
(c) Clear DTCs.

No
fault check".
Yes
NL-3 01/2016
AT
NL-3 01/2016
DTC U010082 U010083 U010087 U010187 U010287 U012187 U012282 U012283 U014482 U014483
P180100 U040476 U040176 U040276 U040376 U041576 U007300
1. DTC description:
DTC U010082 Failure in engine speed signal rolling code counter
DTC U010083 Failure in engine speed signal checksum
DTC U010087 Loss of CAN messages offered by engine controller
DTC U010187 Loss of CAN messages offered by body controller
DTC U010287 Loss of periodic CAN messages offered by transfer case
DTC U012187 Loss of CAN messages from ECU (ABS/ESP/TCS) brake system
DTC U012282 Failure in ABS/ESP rolling code counter for wheel speed
DTC U012283 Failure in ABS/ESP wheel speed checksum
DTC U014482 Failure in EMS IUPR rolling code counter for denominator
DTC U014483 Failure in EMS IUPR denominator checksum
DTC P180100 EMS failure to respond to TCU’s torque reduction request in gear shifting
DTC U040476 Failure in gear shift lever communication data
DTC U040376 Transfer case data bus signals out of range or ineffective
DTC U040176 EMS offered CAN signals out of range or unavailable
DTC U040276 BMC offered CAN signals out of range or unavailable
DTC U041576 CAN signals from ABS/ESP out of range or ineffective AT
DTC U007300 TCU bus Off error

Control area network (CAN) bus is used for sharing the vehicle system information in the control unit which is connected
with the bus. If the information passes through the network, the transmission control unit will get a majority. If the transmission
control unit does not regularly receive specific information sent to the bus through the electronic control unit, the transmission
control unit will trigger a DTC with respect to communication.
NL-3 01/2016

DTC No. DTC detection strategy DTC setting condition (control Fault position
strategy)
U010082
U010083
U010083
U010187 1. The start switch is in "ON"
U010287 position for more than 1 s.
U012187 2. When the battery voltage is
U012282 more than 8 V, the static
U012283 speed of engine is greater 1、ECU, TCU, ABS, BCM, 4WD
U014482 -Check the circuit of hardware than 500 rpm or the battery and EMS
U014483 voltage is lower than 8 V and 2. CAN Bus
P180100 the gear is not in P/N
U040476 position, no CAN message
U040176 from relevant units is
U040276 received within 5 cycles.
U040376
AT U041576
U007300
NL-3 01/2016
Re-read after clearing trouble codes, and check whether the control system has any trouble code other than
Step 1 U010082 U010083 U010087 U010187 U010287 U012187 U012282 U012283 U014482 U014483
P180100 U040476 U040176 U040276 U040376 U041576 and U007300

interface".
to ON state.
of DTC.
DTC U010082 U010083 U010087
U010187 U010287 U012187 U012282
U012283 U014482 U014483 P180100 Yes AT
U040476 U040176 U040276 U040376
U041576 U007300
DTCs except DTC U010082 U010083
U010087 U010187 U010287 U012187
U012282 U012283 U014482 U014483 No
P180100 U040476 U040176 U040276
U040376 U041576 U007300
No Diagnostic trouble code (DTC) table
Yes
Step 2 Detect the CAN bus line of TCU. Refer to "The table of DTCs".
(a) Whether the CAN bus line has open circuit and short
circuit?
Yes Repair the circuit fault.
No
Step 3 Replace the TCU. TCU (automatic transmission control unit).
Next Step
Next Step
NL-3 01/2016

interface.
to ON state.
(c) Clear DTCs.
No
fault check".
Yes
AT
NL-3 01/2016
DTC U160141 U160641 U160741 U160847 U160940

1. DTC description:
DTC U160141 Missing or damage of TCU application software
DTC U160641 Calibration data error – platform
DTC U160741 Calibration data error – variable activation
DTC U160847 TCU VIN (Vehicle Identification Number ) code error
DTC U160940 TCU hardware (PCB) calibration error
The transmission control unit software or calibration software can be upgraded. These DTCs protect the transmission
control unit from loading damaged documents to the transmission control unit. They further ensure only the correct calibration
parameter and software version can be loaded into the current transmission control unit (TCU) for use.
U160141
1. Start switch located in "ON" position
U160641
2. CRC unavailable
U160741
U160847 Check the circuit of 1. Start switch located in "ON" position
1. TCU
hardware 2. VIN does not meet calibrated content.
U160940 1. Start switch located in "ON" position
AT
2. TCU made information does not
exist.
Step 1
DTC U160141, U160641, U160741, U160847 and U160940
interface".
to ON state.
of DTC.
DTC U160141, U160641, U160741,
Yes
U160847 and U160940
DTCs except DTC U160141,
U160641, U160741, U160847 and No
U160940
No Refer to "The table of DTCs"
NL-3 01/2016
Yes
Step 2 Update TCU calibration software.
Next Step

interface.
to ON state.
(c) Clear DTCs.
The fault is eliminated.
Yes
AT
No
Step 4 Replace TCU, refer to “TCU (automatic transmission control unit)".
Next Step
Next Step
interface.
to ON state.
(c) Clear DTCs.
No Intermittent fault, refer to "Intermittent fault
check".
Yes
NL-3 01/2016
DTC U160E30、U161247、U161347
1. DTC description:
DTC U160E30 Low-version software message error (Bosch specific DTC)
DTC U161247 2WD/4WD match error
DTC U161347 Engine type match error
U160E30 - Start switch located in "ON" position 1. TCU
Step 1
DTC U160E30.

interface".
to ON state.
AT
of DTC.
DTC U160E30, U161247
Yes
and U161347
DTCs except DTC
U160E30, U161247 and No
U161347
No Refer to "The table of DTCs"
Yes
Step 2 Check the fluid temperature sensor resistance.
Next Step
Step 3 The start switch is turned OFF/ON twice.

(a) Whether DTC U160E30, U161247 and U161347 still exist
or not.
No Troubleshooting
Yes
Step 4 Replace TCU, refer to “TCU” (automatic transmission control unit).
NL-3 01/2016
Next Step
Step 5 Conduct the automatic transmission rematching procedure. Refer to "Initialization".
Next Step

interface.
to ON state.
(c) Clear DTCs.
No
fault check".
AT Yes
NL-3 01/2016
Transmission-Automatic Transmission Oil AT-107
Automatic Transmission Oil

On-board Check
Notice
When checking oil level, make sure that the vehicle keeps
horizontal position.
Automatic transmission oil FuchsFES209-3292 must be used.
Completely dry transmission needs 7 L (JLE-4G18TDB)/7.5 L
(JLD-4G24) automatic transmission oil. (including oil cooling
system).
1. Lift the vehicle
2. Remove the bottom engine guard and small side engine
guards. Refer to "Left and right bottom engine guards".
3. Place an oil collecting container below the transmission oil
filler plug.
4. Remove the transmission oil filler plug.
5. Refill the transmission oil. When the transmission oil starts
to flow out from the oil drain hole, stop refilling
transmission oil.
6. Put the gear shift lever in the neutral (N) position. Start
AT
and idle the engine.
7. Refill the transmission oil again until it flows out of the oil
filler, and then tighten the oil rain plug.
9. Drive the vehicle for about 5 min.
10. Connect the fault diagnostic scanner of the vehicle with
the vehicle diagnostic interface, and read oil temperature
data from TCU.
11. Put the gear shift lever in neutral (N) position, keep the
engine running until the transmission oil temperature
reaches 50°C, and turn off the engine.
13. Place an oil collecting container below the transmission
oil filler plug. Remove the transmission oil filler plug, and
drain transmission oil continuously for 50 s.
14. Install and tighten the oil filler plug.
Replace
Notice
When checking oil level, make sure that the vehicle keeps
Automatic transmission oil FuchsFES209-3292 must be used.
Completely dry transmission needs 7 L (JLE-4G18TDB)/7.5 L
(JLD-4G24) automatic transmission oil. (including oil cooling
system).
NL-3 01/2016
AT-108 Transmission-Automatic Transmission Oil Cooling System
1. Lift the vehicle

2. Place an oil collecting container below the transmission
oil drain plug.
3. Remove the transmission oil drain plug, and drain
transmission oil.
4. Install and tighten the oil drain plug.
5. Remove the oil filler plug.

6. Fill transmission oil from the oil filler hole. When the
transmission oil starts to flow out of the oil filler hole, stop
filling and tighten the oil filler plug.
7. Check the oil level of the transmission. Refer to "Automatic
transmission fluid"
AT
Notice
Every time the transmission oil is replaced, about 5 L new
automatic transmission oil FuchsFES209-3292 is needed.
8. Recheck and tighten the oil filler plug and oil drain plug.
Automatic Transmission Oil Cooling

System
Clean
1. Lift the vehicle
3. Remove the bolt of the automatic transmission oil inlet
hose at the transmission side, and put the hose end into
the oil collecting container.
4. Start and idle the engine, and collect transmission oil
drained from the automatic transmission oil inlet hose. Fill
transmission oil at the same time.
5. Stop operating the engine when about 2.5 L oil is drained.
6. Install and tighten the bolt of the automatic transmission
oil inlet hose at the transmission side.
Torque:13N·m (Metric) 9.6lb-ft (English)
7. Check and fill the transmission oil. Refer to "Automatic
transmission fluid”.
8. Install the transmission oil filler plug.
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Transmission-Gear Switch AT-109
Gear Switch
Component
Engine trim cover
AT
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AT-110 Transmission-Gear Switch
AT
N·m (lb-ft): specified torque
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Removal
compartment"
compartment"
5 Disconnect the negative battery cable
6. Remove the gearshift rocker arm subassembly
1) Disconnect the gear shifting flexible shaft assembly
from the gear shifting rocker subassembly.
AT
2) Remove the nuts connecting the gear shifting rocker

subassembly and the gear switch.
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AT-112 Transmission-Gear Switch
7. Remove the gear switch.

1). Disconnect the harness connector of gear switch.
2) Remove 2 fixing bolts the gear switch, and take

down the gear switch.
AT
Installation
1. Install the gear switch.
1). Install and tighten 2 fixing bolts of gear switch.
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2). Connect the harness connector of gear switch.
2. Install the gear shifting rocker subassembly.

1) Install the nuts connecting the gear shifting rocker
subassembly and the gear switch.
AT
2) Push the gear shifting flexible shaft assembly into

the gear shifting rocker subassembly fixing ball joint.
a. Make sure the lock button is in the uppermost
end when the cable is at the gear shifting rocker
end.
b. Press the ball joint into the gear shifting rocker
when the cable is at the gear shifting rocker
end.
c. Finally press the lock button to the end.
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AT-114 Transmission-Gearshift Flexible Shaft Assembly
Gearshift Flexible Shaft Assembly

Component
Engine trim cover
AT
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Transmission-Gearshift Flexible Shaft Assembly AT-115
Air flowmeter
Engine intakeintake
Engine hosehose
Air filter element
AT
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AT
A/C control panel assembly (automatic single zone)
A/C control panel assembly (automatic dual zones)
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A/C control panel assembly
Air purifier assembly
AT

Auxiliary instrument panel assembly
rear panel assembly
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Front oxygen sensor
Rear oxygen sensor
AT
Three-Way Catalytic
Converter Assembly
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Engine ECU (4G24_6AT)
Engine ECU (4G18TD)
Engine ECU bracket assembly (4G24)
AT
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Automatic gear shifter assembly
AT
Gear shifting flexible shaft assembly
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Removal
compartment"
compartment"
6. Remove the A/C control panel. Refer to "A/C control
panel assembly".
7. Remove the auxiliary instrument panel. Refer to
"Auxiliary instrument panel"
intake pipe"
10. Remove the engine ECU. Refer to "Engine ECU".
12. Remove the three-way catalytic cleaner assembly (this
step is only for engine 18TD). AT
14. Remove the gear shifting flexible shaft assembly.
from the gear shifting rocker subassembly.
from the gear shifting flexible shaft fixing support.
3) Remove one nut connecting the gear shifting
flexible shaft assembly and the body.
4) Remove two nuts connecting the cable support and

the bottom of the body front wall.
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from the automatic gear shifter assembly.
6) Remove two bolts connecting the gear shifting

flexible shaft assembly and the floor.
7) Press the gear shifting flexible shaft assembly
clamp seat, and pull out the gear shifting flexible
shaft.
AT 8) Pull out the gear shifting flexible shaft from the body.
Installation
1. Install the gear-shifting flexible shaft assembly.
1) Install the gear-shifting flexible shaft assembly on
the body.
2) Install and tighten two bolts connecting the gear
shifting flexible shaft assembly and the floor.
3) Fix the gear shifting flexible shaft assembly on the
automatic gear shifter assembly.
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4) Connect the gear shifting flexible shaft assembly

with the automatic gear shifter assembly.
5) Install and tighten one nut connecting the gear
shifting flexible shaft assembly with the body.
Notice
The saw-toothed feature of flexible shaft joint must face
upwards.
6) Install two nuts connecting the cable support with

the bottom of the body front wall.
AT
7) Clamp the gear shifting flexible shaft assembly onto

the gear shifting flexible shaft fixing support.
8) Make sure both the automatic shift lever and the
transmission gear shifting rocker are in P position,
connect the mounting support and the gear shifting
rocker subassembly.
Pay attention to connecting steps:
a. Make sure the lock button is in the uppermost
end when the cable is at the gear shifting rocker
end.
b. Press the ball joint into the gear shifting rocker
when the cable is at the gear shifting rocker
end.
c. Pull out the safety pin, and finally press the lock
button to the end.
2. Install the exhaust pipe heat shield.
3. Install the three-way catalytic cleaner assembly (this
step is only for engine 18TD).
4. Lift the vehicle
5. Install the auxiliary instrument panel
6. Install the A/C control panel.
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AT-124 Transmission-Automatic Gear Shifter Assembly
Automatic Gear Shifter Assembly

Component
Engine trim cover
AT
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Transmission-Automatic Gear Shifter Assembly AT-125
AT
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AT
Auxiliary instrument panel assembly Auxiliary instrument panel
rear panel assembly
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Manual gearshift
assembly
AT
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Removal
Refer to “Decorative covering parts of engine
compartment"
compartment"
6. Remove the A/C control panel. Refer to "A/C control
panel assembly".
"Auxiliary instrument panel"
8. Remove the automatic gear shifter assembly and TCU.
1) Remove the bolts at A/C duct support fixing points.
AT
2) Remove the connection between the gear shifter

and the gear shifting flexible shaft.
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3) Remove the gear shifter control harness and the

harness buckle.
4) Remove four fixing bolts of the gear shifter.
5) Take down the gear shifter assembly and TCU.
Disassembling
1. Remove the TCU
1) Remove four fixing bolts of TCU.
2) Take down TCU from the automatic gear shifter
assembly.
AT
Assembling
1. Install the TCU
1) Install TCU on the bottom of the automatic gear
shifter assembly.
2) Install and tighten four fixing bolts.
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Installation
1. Install the gear shifter assembly and TCU.
1) Install four fixing bolts of the gear shifter.
2) Install the gear shifter control harness and the
harness buckle.
3) Install the connection between the gear shifter and

the gear shifting flexible shaft.
AT
4) Install the bolts at the A/C duct support fixing points.

4 Connect the negative battery cable.
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Transmission-Automatic Transmission AT-131
Component
Engine trim cover
AT
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AT-132 Transmission-Automatic Transmission
Air flowmeter
Engine intake hose

Air filter element
AT
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Battery
AT
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Engine ECU
Engine ECU
AT
Engine ECU bracket assembly（4G18TD）
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AT
Vehicle wheel nut
Wheel assembly
Specified torque
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AT

Right engine guard
assembly
assembly
assembly
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Protective sleeve of control
Carbon canister
hose
Canister breather
paste
AT
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Right front brake
assembly

（4G18TD_6AT）
（4G24_6AT）
shaft assembly (AT)
AT
Engine assembly (18TD)
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Power takeoff value
Power takeoff
Right front constant velocity Middle shaft
bracket
AT
assembly
Engine assembly （4G24_6AT）
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Front suspension right longitudinal
beam assembly
AT
Front suspension left
longitudinal beam assembly
Front suspension
crossbeam assembly
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Right reinforcement plate of Left longitudinal
front suspension beam assembly
AT
Left reinforcement plate
of front suspension
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Front oxygen sensor
Rear oxygen sensor
AT
Three-way catalytic
converter assembly
N m (lb-ft): Specified torque
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Front suspension crossbeam AT

assembly
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（4G18TD）
AT
Engine assembly (4G18TD
Engine rear bracket
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AT
Starter (AT)
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AT
Starter (AT)
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Removal
5. Remove the upper trim panel assembly of the right fender.
Refer to "Decorative covering parts of engine compartment".
7. Release the pressure in fuel system. Refer to "Check procedure
for fuel pressure".
8. Refer to "A/C refrigerant recovery and filling" to recover the A/C
refrigerant.
9. Remove the air filter intake pipe. Refer to "Air filter intake pipe"
11. Remove the battery. Refer to "Battery cable".
12. Remove battery bracket
13. Remove the engine ECU. Refer to "Engine ECU".
14. Remove the engine ECU support assembly.
15. Remove the radiator cover. Refer to AT
18. Remove the protective plate on bottom of engine. Refer to
19. Remove the engine left/right guard plate .Refer to "Left and right
engine bottom guard plates"
20. Drain the engine oil. Refer to "Drainage and filling of engine oil"
engine coolant"
22. Drain transmission gear oil. Refer to "Automatic transmission
oil".
23. Remove the carbon canister solenoid valve. Refer to "Canister
control valve".
24. Remove the front constant velocity drive shaft. Refer to "Front
constant velocity drive shaft".
25. Remove the propeller shaft (four-wheel drive model). Refer to
"Propeller shaft assembly (4WD)".
26. Remove power take-off (four-wheel drive model). Refer to
"Power take-off".
27. Remove the front suspension side rail. Refer to "Front
suspension side rail assembly".
28. Remove the front suspension reinforcing plate. Refer to "Front
suspension reinforcing plate"
30. Remove the three-way catalytic converter assembly. Refer to"
Exhaust manifold".
31. Remove the front suspension cross beam. Refer to “Front
suspension cross beam assembly".
32. Remove the power assembly. Refer to "Engine assembly".
33. Remove the starter motor. Refer to "Starter motor AT".
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34. Remove the automatic transmission assembly.

1) Remove the rubber stopper of engine cylinder block.
2) Rotate the damping pulley component, and

successively expose 6 connecting bolts between
flywheel and hydraulic torque converter.
3) Lock the crankshaft flywheel assembly, and
successively remove 6 bolts connecting the torque
converter.
AT

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assembly and the lower end of the engine.

assembly and the middle part of the engine.
assembly.
AT
Notice
Clean the oil cooler during replacement with a new
transmission. Cleaning steps
1) Remove the oil cooler, and pour out oil.
2) Add the fresh transmission oil.
3) Shake and pour out transmission oil.
4) Repeat steps 2 and 3 for 2-3 times.
5) Restore.
Notice: Avoid old gear oil from affecting the new transmission.
If the impurity content is found to be high during transmission
oil drain check, replace with new oil cooler and pipeline.
If not, clean the oil cooler.
Installation
1. Install the transmission assembly.MT
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engine assembly and the upper end of the
transmission.
Torque:

transmission assembly and the lower end of the
engine.
Torque:
AT

engine assembly and the middle part of the
transmission.
Torque:
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5) Rotate the damping pulley component, and

successively install 6 bolts connecting the hydraulic
torque converter.
AT
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3. Install the power assembly.
4. Install the front suspension cross beam.
9. Install the power take-off (four-wheel drive model).
10. Install the propeller shaft (four-wheel drive model).
11. Install the front constant-speed drive shaft.
19. Fill the transmission gear oil
AT
22. Install the engine ECU.
35. Conduct automatic transmission matching procedure
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Transmission - Contents MT-1
MT Transmission
Fault Symptoms Table ....................................................................................................................................................... 2
Transmission Oil ................................................................................................................................................................ 3
On-board Check................................................................................................................................................................. 3
Replace.............................................................................................................................................................................. 3
Reverse Lamp Switch ........................................................................................................................................................ 5
Component ........................................................................................................................................................................ 5
Removal............................................................................................................................................................................. 7
Installation.......................................................................................................................................................................... 8
Neutral Switch .................................................................................................................................................................. 9
Component ........................................................................................................................................................................ 9
Removal........................................................................................................................................................................... 13
Installation........................................................................................................................................................................ 14
Gearshift Flexible Shaft Assembly................................................................................................................................... 15
Component ...................................................................................................................................................................... 15
Removal........................................................................................................................................................................... 20
Installation........................................................................................................................................................................ 21
Manual Gear Shifter Assembly ....................................................................................................................................... 24
Component ...................................................................................................................................................................... 24 MT
Removal........................................................................................................................................................................... 27
Installation........................................................................................................................................................................ 28
Transmission Assembly ................................................................................................................................................... 29
Component ...................................................................................................................................................................... 29
Removal........................................................................................................................................................................... 42
Installation........................................................................................................................................................................ 45
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MT-2 Transmission -Fault Symptoms Table
Fault Symptoms Table

Tips:
• The table below can help identify the cause of fault. The descending sequence is used to indicate the possibility of
causes of fault. Check every suspected location in accordance with the sequence. If necessary, repair, replace or
adjust the part which has failed.
• Before checking the following suspected locations, please check the fuses and relays relating to the system.
Symptoms Suspected Parts: Maintenance plan

Trip stop Gear shift fork is worn Replace with a new gear shift fork
The clearance between the synchronizer gear Replace the synchronizer gear hub or
hub and the gear sleeve spline is too large the gear sleeve
The shifting is hard. The cable support is defective Replace the cable support
The synchronizer ring and the gear cone have Adjust or replace
poor contact or are damaged
The synchronizer ring is excessively worn Replace the synchronizer ring
Non-designated lubricating oil is used Replace with designated lubricating oil
Vibration noise The stroke of shift level is incorrect Correct the stroke
The gears are worn and damaged Replace the relevant gears
Non-designated lubricating oil is used Replace with designated lubricating oil
MT
The lubricating oil is insufficient Refill the designated lubricating oil
Oil leakage Too much oil Check the oil level
The oil seal or seal ring is damaged Replace the oil seal or seal ring
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Transmission -Transmission Oil MT-3
Transmission Oil
On-board Check
Notice
When checking fluid level, make sure that the vehicle keeps
1. Lift the vehicle
2. Place an oil collecting container below the transmission oil
filler plug.
4. Fill the transmission oil. When the transmission oil starts
to flow out of the oil drain hole, stop filling the transmission
oil.
5. Install and tighten the oil filler plug.

Replace
1. Lift the vehicle
MT
2. Drain the transmission oil
1) Place an oil collecting container below the
transmission oil drain plug.
2) Remove the transmission oil drain plug, and drain
transmission oil.
3. Install the oil drain plug.
1) Install and tighten the oil drain plug.
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MT-4 Transmission -Transmission Oil
4. Remove the oil filler plug

1) Fill the transmission oil from the oil filler hole. When
the transmission oil starts to flow out of the oil filler
hole, stop filling and tighten the oil filler plug.
2) Check the oil level of the transmission. Refer to
“Transmission oil”.
Every time the transmission oil is replaced, about 1.6 L
new transmission oil is needed.
3) Recheck and tighten the oil filler plug and oil drain
plug.
MT
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Transmission -Reverse Lamp Switch MT-5
Reverse Lamp Switch

Component
Engine trim cover
MT
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MT-6 Transmission -Reverse Lamp Switch
Reverse lamp switch
MT
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Transmission -Reverse Lamp Switch MT-7
Removal
Refer to “Decorative covering parts of engine compartment"
7. Remove the air filter intake pipe. Refer to "Air filter intake
pipe"
8. Remove the air filter assembly. Refer to" Air filter"
9. Remove the backup light switch
1). Disconnect the reverse lamp switch harness connector.
MT
2) Remove the backup lamp switch.
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MT-8 Transmission -Reverse Lamp Switch
Installation
1. Install the backup lamp switch
1) Install and tighten the backup lamp switch.
2). Connect the reverse lamp switch harness connector.

MT 6. Install the upper trim panel of left fender
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Transmission -Neutral Switch MT-9
Neutral Switch
Component
Engine trim cover
MT
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MT-10 Transmission -Neutral Switch
MT
NL-3 01/2016
MT
Auxiliary instrument panel Auxiliary instrument panel rear

assembly panel assembly
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Neutral switch
MT
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Removal
2. Remove the upper trim panel of front bumper.
compartment"
fender. Please refer to "Decorative covering parts of
engine compartment"
4. Remove the upper trim panel assembly of left
fender. Please refer to "Decorative covering parts of
engine compartment"
6. Remove the engine trim cover. Please refer to
Engine trim cover.
7. Remove the air filter intake pipe. Please refer to "Air
filter intake pipe"
8. Remove the air filter assembly. Please refer to "Air
filter"
9. Remove the neutral switch
1) Disconnect the neutral switch harness connector.
MT
2) Remove the fixing bolts of neutral switch, and take

down the neutral switch.
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Installation
1. Install the neutral switch
1) Press the neutral switch locating pin into the
transmission hole, and install the fixing bolts of
neutral switch.
2) Connect the neutral switch harness connector.

MT 7. Install the upper trim panel connecting plate of
fender.
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Transmission -Gearshift Flexible Shaft Assembly MT-15
Gearshift Flexible Shaft Assembly

Component
Engine trim cover
MT
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MT-16 Transmission -Gearshift Flexible Shaft Assembly
MT
A/C control panel assembly (automatic

single zone)

dual zones)
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MT

Auxiliary instrument rear panel assembly
panel assembly
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Air flowmeter

Engine intake hose
Air filter element
MT
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Gear shifting handle

assembly
Manual gearshift assembly
Gearshift flexible shaft

assembly
MT
Manual transmission
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Removal
compartment"
compartment"
6. Remove the A/C control panel. Refer to “A/C control
panel assembly”.
“Auxiliary instrument panel”
pipe"
10. Remove the three-way catalytic cleaner assembly (this
step is only for engine 18TD).
11. Remove the front exhaust pipe (this step is only for
engine 20).
MT 13. Remove the gearshift flexible shaft assembly.
1) Disconnect the gear selecting flexible shaft 1 and
gear selecting flexible shaft 2 from the manual gear
shifter assembly.
2) Disconnect the gear shifting flexible shaft assembly 1

from the shift lever component.
3) Disconnect the gear selecting flexible shaft assembly
2 from the shift lever component.
4) Disconnect the gear selecting flexible shaft assembly
from the cable bracket assembly.
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5) Remove two bolts connecting the gearshift flexible

shaft assembly and the floor bottom.
6) Remove two fixing nuts connecting the gearshift

flexible shaft assembly support and the floor front.
7) Take down the gearshift flexible shaft assembly.
MT
Installation
1. Install the gearshift flexible shaft assembly.
1) Install and tighten two bolts connecting the gearshift
flexible shaft assembly and the floor bottom.
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2) Remove two fixing nuts connecting the gearshift

flexible shaft assembly support and the floor front.
3) Install the shift lever flexible shaft in the manual shift

lever assembly clamp slot.
MT
4) Connect the gear shifting flexible shaft assembly 1

and the gear lever component.
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5) Connect the gear shifting flexible shaft assembly and

the cable bracket assembly.
6) Install the gear shifting flexible shaft assembly 2 and

the gear shift lever component.
Notice: Before installing the flexible shaft joint, make sure the
flexible shaft length adjustment clip is loose.
MT
7) Make sure to press the adjustment clip and lock it

when the shift lever and the transmission are in
Locking neutral position.
Notice: If it is not installed and adjusted as required, it will be
difficult to engage to the 1st and 2nd gears.
2. Install the exhaust pipe heat shield.
Release
3. Install the front exhaust pipe (this step is only for
engine 20).
4. Install the three-way catalytic cleaner assembly
(this step is only for engine 18TD).
5. Install the air filter assembly. Refer to “Air filter”.
6. Install the intake pipe of air filter. Please refer to
“Intake pipe of air filter”
11. Install the upper trim panel connecting plate of
fender.
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MT-24 Transmission -Manual Gear Shifter Assembly
Manual Gear Shifter Assembly

Component
MT

single zone)
A/C control panel assembly (automatic dual

zones)
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Transmission -Manual Gear Shifter Assembly MT-25
MT

Auxiliary instrument rear panel assembly
panel assembly
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Gear shifting handle

assembly
Manual gearshift
assembly
Gearshift flexible shaft

assembly
MT
Manual transmission
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Transmission -Manual Gear Shifter Assembly MT-27
Removal
1. Remove the A/C control panel. Refer to “A/C control
panel assembly”.
2. Remove the auxiliary instrument panel. Refer to “Auxiliary
instrument panel”
3. Remove the gear shifting handle assembly.
1) Pry up the gear shifting sheath panel.

2) Slide up and loosen the gear shifting handle lock
ring, and loosen the buckle of the reverse gear draw
bar and reverse gear stop slide block.
4. Remove the connection between the gear

selecting/shifting flexible shaft and the shift lever. Refer to
“Gearshift flexible shaft assembly”. MT
5. Remove the manual gear shifter assembly.
1) Remove 4 fixing bolts of gear shifter.
2) Take out the gear shifter assembly.
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Installation
1. Install the manual gear shifter assembly.
1) Install the manual gear shifter assembly.
2) Install and tighten 4 fixing bolts of manual gear
shifter assembly.
2. Install the gearshift flexible shaft assembly (B6).
3. Install the gear shifting handle assembly.
MT
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Transmission -Transmission Assembly MT-29
Transmission Assembly
Component
Engine trim cover
MT
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MT-30 Transmission -Transmission Assembly
Air flowmeter
Engine intake hose Upper cover of air filter
Air filter element

MT
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Battery

Battery bracket MT
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Engine ECU (4G24_6AT)
Engine ECU (4G18TD)

MT (4G18TD)
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MT
Stuck type balance block
Radial tire (225/65 R17)
Aluminum alloy wheel (17×7J)

Hub trim cover (Emgrand)
Tire valve assembly
Vehicle wheel nut
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MT Engine right
assembly
guard plate
assembly

assembly
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Left constant velocity drive shaft assembly (4G20_6MT)
MT
Manual transmission
assembly
Right constant velocity drive shaft

assembly (4G18TD_6MT)
Right constant velocity drive shaft
assembly (4G20_6MT)
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assembly
Front suspension right

MT


assembly
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reinforcing plate Left longitudinal beam
assembly
MT

reinforcing plate
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Front oxygen sensor
Rear oxygen sensor
MT
Three-way catalytic
converter assembly
Catalytic converter
bracket
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Front suspension
crossbeam assembly
MT
Front bumper
assembly
Engine bottom guard

plate
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（4G18TD）

assembly（4G18TD）
Left engine support (4G18+6MT)
MT
Engine rear bracket

（4G18TD）
Engine rear vibration isolator assembly

（4G18TD）
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Manual transmission
assembly
MT
Starter motor （6MT）
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Removal
compartment"
fender. Refer to "Decorative covering parts of
engine compartment"
4. Remove the upper trim panel assembly of left
fender. Refer to "Decorative covering parts of
engine compartment"
5. Remove the engine trim cover. Refer to “Engine
trim cover”.
intake pipe"
9. Remove the battery tray. Refer to “Battery cable”.
11. Remove the engine ECU bracket assembly. Refer
to “Engine ECU”
12. Remove the front wheel. Refer to "Wheel and tire"
MT 14. Remove the engine bottom guard plate. Refer to
15. Remove the engine left/right guard plate Refer to
16. Drain transmission gear oil. Refer to “Automatic
transmission oil”.
17. Remove the front constant velocity drive shaft.
Refer to "Front constant velocity drive shaft"
18. Remove the front suspension longitudinal beam.
Refer to "Front suspension longitudinal beam
assembly"
19. Remove the front suspension reinforcing plate.
Refer to "Front suspension reinforcing plate"
20. Remove the auxiliary frame. Refer to "Front
auxiliary frame"
21. Remove the starter motor (6MT). Refer to “Starter
motor MT”.
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22. Remove the transmission assembly [power

assembly (JLD-4G20_6MT)].
1) Disconnect the transmission reverse gear switch
harness connector.
2) Disconnect the transmission reverse gear switch
harness from the support.
3) Remove 3 connecting bolts between the

transmission assembly and the upper end of the
engine.
MT

engine.
assembly.
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23. Remove the transmission assembly [power

assembly (JLE-4G18TDB_6MT)].
transmission assembly and the upper end of the
engine.
2) Remove one bolt connecting the transmission

assembly and the engine from the starter mounting
hole.
MT
3) Remove one bolt connecting the transmission

assembly and the middle rear end of the engine.
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transmission assembly and the lower part of the
engine.
assembly.
Installation
1. Install the transmission assembly [power assembly
(JLD-4G20_6MT)].
transmission.
MT

engine assembly and the lower end of the
transmission.
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4) Connect the transmission reverse switch harness

connector.
5) Fix the connection between the transmission reverse
switch harness and the support.
2. Install the transmission assembly [power assembly

(JLE-4G18TD_6MT)].
transmission.
Torque:
M12: 60N·m (Metric) 43.8lb-ft(English)
MT M10: 50N·m (Metric) 36.5lb-ft(English)

engine.
Torque:
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4) Install and tighten 1 connecting bolt between the

engine assembly and the middle rear end of the
transmission.
Torque:
5) Install and tighten 1 connecting bolt between the

engine assembly and the transmission from the
starter mounting hole.
Torque:
MT
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3. Install the starter motor (6MT)

5. Install the front suspension reinforcing plate
MT
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Clutch System-Contents CL-1
CL Clutch System
Clutch Hydraulic Fluid .......................................................................................................................... 2

Exhaust ................................................................................................................................................... 2
Clutch Pedal and Clutch Master Cylinder Assembly ........................................................................ 3
Component .............................................................................................................................................. 3
Removal .................................................................................................................................................. 4
Disassembling ......................................................................................................................................... 5
Assembling .............................................................................................................................................. 5
Installation ............................................................................................................................................... 6
Clutch Assembly ................................................................................................................................... 7
Component .............................................................................................................................................. 7
Removal ................................................................................................................................................ 18
Installation ............................................................................................................................................. 18
Release Bearing .................................................................................................................................. 20
Component ............................................................................................................................................ 20
Removal ................................................................................................................................................ 33
Installation ............................................................................................................................................. 34
CL
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CL-2 Clutch System -Clutch Hydraulic Fluid
Clutch Hydraulic Fluid

Exhaust
Notice
Clutch hydraulic fluid is corrosive and will damage electrical
joints and paint surfaces. Use appropriate container and
fender covers to prevent hydraulic fluid from touching these
parts. Use cotton cloth to timely wipe splashed hydraulic fluid.
Do not refill fluid drained from the system into the brake fluid
reservoir, because used hydraulic fluid may be mixed with air,
impurities and moisture.
compartment"
compartment"
5. Drain the hydraulic clutch air.
1) Check the clutch/brake fluid level in the fluid reservoir.

Notice
During hydraulic system exhaust, you must make the fluid
CL level in clutch/brake fluid reservoir is maintained at a position
between the minimum (MIN) and the maximum (MAX) marks.
2). Connect one end of the vinyl plastic hose to the

exhaust port plug, and insert the other end of the hose
into the container with half capacity of the brake fluid.
3). Slowly depress the clutch pedal for several times.
4). When depressing the clutch pedal, loose the exhaust
port screw, tighten the exhaust port screw till oil flows
out.
5). Repeat Step 3 until the oil in the container has no
bubbles.
Open Close
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Clutch System -Clutch Pedal and Clutch Master Cylinder Assembly CL-3
Clutch Pedal and Clutch Master Cylinder Assembly

Component
CL
Clutch switch
Clutch pedal
N·m(Ib-ft): specified torque
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CL-4 Clutch System -Clutch Pedal and Clutch Master Cylinder Assembly
Removal
compartment"
compartment"
6. Drain clutch hydraulic fluid.
7. Remove the instrument panel lower guard plate. Refer to
“Instrument panel”
8. Remove the clutch switch. Refer to “Clutch switch”.
9. Remove the clutch pedal with clutch master cylinder
assembly.
1) Disconnect the harness connector of the clutch
master cylinder.
CL
2) Remove the clutch hydraulic hose and master cylinder

oil inlet hose.
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Clutch System -Clutch Pedal and Clutch Master Cylinder Assembly CL-5
3) Remove 3 nuts at the connection between the clutch

pedal assembly and the body.
4) Take down the clutch pedal and clutch master cylinder
assembly.
Disassembling
1. Disassemble clutch master cylinder assembly
1) Remove the clutch pedal lock pin and pin shaft.
2) Take down the clutch master cylinder.
Notice: Rotate the clutch master cylinder clockwise to certain
angle and then take it out.
CL
Assembling
1. Assemble clutch master cylinder assembly
1) Install the clutch master cylinder on the clutch pedal.
2) Install the clutch pedal lock pin and pin shaft.
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CL-6 Clutch System -Clutch Pedal and Clutch Master Cylinder Assembly
Installation
1. Clutch pedal with clutch master cylinder assembly
1) Install 3 nuts at the connection between the clutch
pedal and the body.
Torque: 25 N·m (Metric) 18.4 lb-ft(English)
2) Connect the harness connector of the clutch master

cylinder.
CL
3) Connect the clutch master cylinder oil inlet hose and

the clutch hydraulic hose.
2. Install the clutch switch.
3. Install the instrument panel lower guard plate
4. Fill the clutch hydraulic fluid.
9. Close the engine negative hood.
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Clutch System -Clutch Assembly CL-7
Clutch Assembly
Component
Engine trim cover
CL
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CL-8 Clutch System -Clutch Assembly
Air flowmeter
Upper cover of air

Engine intake hose filter
Air filter element
Lower cover of air

filter

CL
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Engine ECU(4G20_6MT)
Engine ECU(4G18TD)

(4G18TD)
CL
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Vehicle wheel nut
CL
Wheel assembly
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CL
Engine right guard plate Engine left guard plate
assembly assembly

assembly
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assembly

longitudinal beam
assembly

longitudinal beam
CL assembly
Front suspension
crossbeam assembly
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CL
Front bumper
assembly
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(4G18TD_6MT)
(4G20 6MT)
Left front brake

assembly
Left constant velocity drive assembly

(4G18TD_6MT)
(4G20_6MT)
CL
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Engine front vibration isolator

assembly

assembly
Engine（4G20）
CL
Engine rear bracket

assembly
Engine rear vibration isolator

assembly
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Manual transmission
assembly
Engine（4G20）
CL
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(4G18)
Clutch driven plate

assembly (4G18)

(4G20)
Clutch driven plate

assembly (4G20)
CL
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Removal
compartment"
compartment"
cover”.
pipe"
11. Remove the engine ECU bracket assembly.
14. Remove the engine bottom guard plate. Refer to "Left and
15. Remove the engine left/right guard plate Refer to "Left
CL and right engine bottom guard plates"
16. Drain the transmission oil. Refer to “Oil drainage and
filling”.
19. Remove the front suspension reinforcing plate. Refer to
20. Remove the starter. Refer to “Starter motor MT”.
21. Remove the transmission assembly MT. Refer to
“Transmission assembly”.
22. Remove the clutch assembly.
Warning!
Replace the driven plate and the pressure plate at the same
time when the clutch 4G18TD is replaced.
1) Remove 6 bolts of clutch pressure plate assembly.
2) Take down the clutch pressure plate assembly.
3) Take down the clutch driven plate assembly.
Installation
1. Install the clutch assembly
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1) Apply the multifunctional grease to clutch driven plate

hub.
Notice: Apply appropriate amount of grease and do not
accumulate.
2) Align the clutch pressure plate and clutch driven plate
with the flywheel by using a special tool.
3) Install and tighten 6 bolts of the pressure plate
assembly.
Notice
Install the bolts in diagonal sequence.
4) Take down the special tool.
2. Install the transmission assembly MT
3. Install the starter MT.
6. Install the front constant velocity drive shaft.
CL
12. Install the engine ECU bracket assembly.
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CL-20 Clutch System -Release Bearing
Release Bearing
Component
Engine trim cover
CL
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Clutch System -Release Bearing CL-21
Air flowmeter

Engine intake hose
Air filter element

CL
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Negative battery
cable
Battery
Battery bracket
CL
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Engine ECU(4G20_6MT)
Engine ECU(4G18TD)

(4G20)

(4G18TD)
CL
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Vehicle wheel nut
CL
Wheel assembly
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CL
Engine right guard plate Engine left guard plate
assembly assembly

assembly
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assembly

CL

assembly
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CL
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(4G18TD_6MT)
(4G20_6MT)
Manual transmission
assembly
CL
Left front brake
assembly

(4G18TD_6MT)
(4G20_6MT)
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Engine front vibration isolator

assembly

assembly
Engine（4G20）
CL
Engine rear bracket

assembly
Engine rear vibration isolator

assembly
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Manual transmission
assembly
Engine（4G20）
CL
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Clutch pressure plate

assembly (4G18)
Clutch driven plate

assembly (4G18)
Clutch pressure plate

assembly (4G20)
Clutch driven plate

assembly (4G20)
CL
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Manual transmission
assembly
Release bearing
CL
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Removal
compartment"
compartment"
cover”.
pipe"
11. Remove the engine ECU bracket assembly.
12. Remove the front wheel. Refer to "Wheel and tire"
CL
15. Remove the engine left/right guard plate Refer to "Left
16. Drain the transmission oil. Refer to “Oil drainage and
filling”.
19. Remove the front suspension reinforcing plate. Refer to
20. Remove the starter. Refer to “Starter motor MT”.
21. Remove the transmission assembly MT. Refer to
“Transmission assembly”.
22. Remove the release bearing.
1) Remove 2 fixing bolts between release bearing and

transmission.
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2) Remove the U-clip connecting the release bearing

and the hydraulic hose, and disconnect the release
bearing from the hydraulic hose.
Installation
1. Install the release bearing.
1) Connect the U-clip connecting the release bearing
and the hydraulic hose, and disconnect the release
bearing from the hydraulic hose.
CL
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2) Install two fixing bolts connecting the release bearing

and the transmission.
2. Install the transmission assembly MT
3. Install the starter MT.
6. Install the front constant velocity drive shaft.
12. Install the engine ECU bracket assembly.
CL
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CL
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Brake System - Contents BR-1
BR Brake System
Brake System .......................................................................................................................................... BR - 4

Notices .............................................................................................................................................. BR - 4
Component Position .......................................................................................................................... BR - 6
Table of Fault Symptoms .................................................................................................................. BR - 7
Brake Fluid .............................................................................................................................................. BR - 8
On-board Check ................................................................................................................................ BR - 8
Fill the Brake Fluid. ........................................................................................................................... BR - 9
Exhaust Brake System .................................................................................................................... BR - 10
Drain the Brake Fluid ...................................................................................................................... BR - 12
Brake Pedal ........................................................................................................................................... BR - 13
Component ...................................................................................................................................... BR - 13
Removal .......................................................................................................................................... BR - 15
Disassembling ................................................................................................................................. BR - 16
Assembling ...................................................................................................................................... BR - 17 BR
Installation ....................................................................................................................................... BR - 18
Adjustment ...................................................................................................................................... BR - 20
Vacuum Booster Assembly ................................................................................................................. BR - 21
Component ...................................................................................................................................... BR - 21
On-board Check .............................................................................................................................. BR - 23
Removal .......................................................................................................................................... BR - 24
Installation ....................................................................................................................................... BR - 25
Brake Master Cylinder Assembly with Liquid Storage Tank ........................................................... BR - 27
Component ...................................................................................................................................... BR - 27
Removal .......................................................................................................................................... BR - 29
Installation ....................................................................................................................................... BR - 31
Brake Caliper Assembly ...................................................................................................................... BR - 33
Component ...................................................................................................................................... BR - 33
Removal .......................................................................................................................................... BR - 36
Check .............................................................................................................................................. BR - 40
Assembling ...................................................................................................................................... BR - 42
Installation ....................................................................................................................................... BR - 43
BR-2 Brake system - Contents
Front Brake Hose ................................................................................................................................. BR - 46

Component ...................................................................................................................................... BR - 46
Removal .......................................................................................................................................... BR - 48
Installation ....................................................................................................................................... BR - 49
Rear EPB Integrated Caliper Assembly ............................................................................................. BR - 51
Component ...................................................................................................................................... BR - 51
Removal .......................................................................................................................................... BR - 54
Check .............................................................................................................................................. BR - 59
Assembling ...................................................................................................................................... BR - 61
Installation ....................................................................................................................................... BR - 63
Rear Brake Hose ................................................................................................................................... BR - 66
Component ...................................................................................................................................... BR - 66
Removal .......................................................................................................................................... BR - 68
Installation ....................................................................................................................................... BR - 69
No.1 Brake Pipe Assembly of Brake Master Cylinder (ESP) ........................................................... BR - 71
BR Component ...................................................................................................................................... BR - 71
Removal .......................................................................................................................................... BR - 73
Installation ....................................................................................................................................... BR - 74
No.2 Brake Pipe Assembly of Brake Master Cylinder (ESP) ........................................................... BR - 75
Component ...................................................................................................................................... BR - 75
Removal .......................................................................................................................................... BR - 77
Installation ....................................................................................................................................... BR - 77
Left Front Brake Pipe Assembly ......................................................................................................... BR - 79
Component ...................................................................................................................................... BR - 79
Removal .......................................................................................................................................... BR - 82
Installation ....................................................................................................................................... BR - 82
Right Front Brake Pipe Assembly ...................................................................................................... BR - 84
Component ...................................................................................................................................... BR - 84
Removal .......................................................................................................................................... BR - 87
Installation ....................................................................................................................................... BR - 88
Left Rear No.1 Brake Pipe Assembly ................................................................................................. BR - 89
Component ...................................................................................................................................... BR - 89
Removal .......................................................................................................................................... BR - 91
Installation ....................................................................................................................................... BR - 92
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Brake System - Contents BR-3
Right Rear No.1 Brake Pipe Assembly............................................................................................... BR - 93

Component ...................................................................................................................................... BR - 93
Removal .......................................................................................................................................... BR - 95
Installation ....................................................................................................................................... BR - 96
Left Rear No.1 Brake Pipe Assembly ................................................................................................. BR - 98
Component ...................................................................................................................................... BR - 98
Removal ........................................................................................................................................ BR - 100
Installation ..................................................................................................................................... BR - 102
Right Rear No.2 Brake Pipe Assembly............................................................................................. BR - 105
Component .................................................................................................................................... BR - 105
Removal ........................................................................................................................................ BR - 107
Installation ..................................................................................................................................... BR - 109
Vacuum Booster Connecting Pipe (4G20) ....................................................................................... BR - 112
Component .................................................................................................................................... BR - 112
Component .................................................................................................................................... BR - 113
BR
Removal ........................................................................................................................................ BR - 114
Installation ..................................................................................................................................... BR - 115
BR-4 Brake System - Brake System
Brake System
Notices
Notice
− Each part shall be replaced correctly, otherwise the performance of brake system will be affected and driving safety may
be threatened. The failed part must be replaced by the one with the same part No. or an equivalent product.
− While repairing the brake system, keep parts and maintenance location clean, which is very important.
− Magnets must be used cautiously, because they may affect the performance of the speed sensor.
− Since the brake pipeline is a key part related to safety. In case of brake fluid leakage, the part must be disassembled and
checked. In case of any abnormity, replace the failed part with a new one.
− When removing brake components, cover the brake pipe junction to prevent dust or dross, etc. from falling into the pipe.
− Remove or install the brake pipe with caution to prevent damage or deformation.
− When installing the sealing gasket, ensure the brake pipe pass through the center of the sealing gasket.
− When installing the brake pipe or flexible hose, ensure it is free of twist or bend.
− If the flexible hose cap is unmatched with the notch on the bracket, twist the hose slightly to insert it into the notch.
− The flexible hose shall not contact the shock absorber oil and lubricating grease, etc.
− When installing the brake pipe into the plastic clamp, ensure the brake pipe is not loose or stuck.
− Do not reuse the clip or plastic clamp removed from the flexible hose.
− After installing the brake pipe and flexible hose, ensure they will not interfere with any other part.
BR
− The brake fluid shall not be stuck on paint surface, such as body paint. If brake fluid leaks onto the painted surface, you
should remove it immediately.
− When disconnecting the brake hose and brake pipeline,
1) Steady the brake hose with a wrench, and disconnect the brake pipe with the union nut wrench. Pay attention to not
deforming the pipe.
2) Remove the clip. 1
3) Install a new clip.
4) Connect the brake pipe with the union nut wrench, and pay attention to not deforming the pipeline.
Disconnect Connect:
Rotate
Rotate
Fix Fix
− When connecting the brake hose and brake pipeline:

1) Support the pipeline to prevent the brake pipe from deforming, and connect the brake pipe to the pipeline with the
union nut wrench.
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Brake System - Brake System BR-5
2) Support the pipeline to prevent the brake pipe from deforming, and install the bolts to fix the pipeline to body.
Fix
Rotate
Assistant driving warning

Warning!
An assistant should drive the vehicle while the technician checks for the location of the reported fault position. Otherwise, it
may cause personal injury.
Battery disconnection warning
Warning!
Before repairing any electrical component, the ignition key must be in the OFF position and all electrical loads must be "OFF" BR
unless otherwise specified in the procedure. If the tool or equipment is easily to contact with exposed electrical terminal, the
negative battery cable should be disconnected. Failure to follow these precautions may result in personal injury and/or
damage to the vehicle or its components.
Road test warning
Warning!
Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any operation that could jeopardize
vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage.
ABS components handling warning
Warning!
Certain components in Anti-lock Brake System (ABS) are unable to be repaired individually. Attempting to remove or
disconnect certain system components may result in personal injury and/or improper system operation. Only those
components with approved removing and installing procedures can be repaired.
Warning of brake dust
Warning!
Some models or after-sales optional brake components may contain fibers which can become airborne in dust. Inhaling dust
with fibers may cause serious personal injury, so please clean up any dust on the brake components with a damp cloth.
Brake fluid warning
Warning!
The brake fluid is easy to absorb the moisture. Do not use brake fluid from an open container that may be contaminated with
water. Incorrect or contaminated brake fluid could result in system fault, loss of vehicle control and personal injury.
Brake fluid irritant warning
Warning!
Brake fluid may be irritating to the skin or eyes. In case of contact, take the following measures:
Eye contact - Flush completely with clean water
Skin contact – Wash skin with soap and water
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BR-6 Brake System - Brake System
Component Position
Right rear brake assembly
Brake pedal assembly.
Right front brake

assembly
BR
Left rear brake assembly
Vacuum booster with brake master

cylinder assembly
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Brake System - Brake System BR-7

Symptoms Suspected Parts: measure/
1. Brake fluid level
Refer to “ABS or EBD or ESP warning
Brake warning lamp always on 2. Brake fluid level sensor
lamp is always lit”
3. Brake fluid level sensor harness
Refer to “Front brake caliper assembly”
1. Brake pad (broken, twisted, dirty,
“Rear EPB integrated caliper assembly
smooth)
of front brake caliper assembly”
2. Brake caliper bracket retaining bolts Check the fixing bolts for brake caliper
Brake system noise (loose) bracket.
3. Brake caliper fixing bolts (loose) Check the brake caliper fixing bolts.
4. Brake disc (with injury pattern) (front) Refer to “Front brake caliper assembly”
5. Brake disc guide plate (loose) “Rear EPB integrated caliper assembly
6. Brake caliper floating pin (worn) of front brake caliper assembly”
1. Pistons (fixed, stuck)
2. Brake disc (with crack and oil stain)
3. Brake pad (broken, twisted or oil
Brake deviation of front brake caliper assembly”
stains)
4. Brake hard pipe, hose (distortion, BR
Check the brake hard pipe and hose.
deformation)
1. Hydraulic brake booster system
Check the hydraulic vacuum booster.
(vacuum leaks, ineffective)
Brake pedal too hard
2. Brake hard pipe, hose ( distortion,
Check the brake hard pipe and hose.
deformation)
Check the brake system for brake fluid
1. Brake system brake fluid leak
leakage.
2. Air exists in the brake system Refer to “Exhaust brake system”
3. Brake disc (with injury pattern) “Rear EPB integrated caliper assembly
Brake pedal too soft and brake
shortage
4. Brake pad (broken, twisted,
excessive worn or oil stains)
5. Brake master cylinder (interior
Check the brake master cylinder.
leakage)
1. Brake pedal free travel (too short)
2. Brake pad (catching) Refer to “Front brake caliper assembly”
3. Floating pin of brake caliper “Rear EPB integrated caliper assembly
Brake dragging (corrosion) of front brake caliper assembly”
4. Pistons (fixed, catching)
5. Vacuum booster catching Check the vacuum booster.
6. Brake master cylinder (fault) Check the brake master cylinder.
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BR-8 Brake System –Brake Fluid
Brake Fluid
On-board Check
1. Check the brake fluid level
If the brake fluid level is lower than MIN line, check for
leakage and check the disc brake pads. Refill the brake fluid
to the fluid storage tank to MAX line after maintenance or
replacement if necessary.
Notice
When filling brake fluid to the brake master cylinder reservoir,
only use Super DOT4 brake fluid from a clean, sealed brake
fluid container. The use of any type of brake fluid other than
BR
the recommended type may cause contamination which
could damage to the rubber seal and/or rubber gasket inside
hydraulic brake system components.
Notice
If the air enters the ABS hydraulic brake regulator or the
mounted ABS hydraulic brake regulator is not fully filled with
fluid, use a fault diagnostic scanner to exhaust brake system
air instead of manually exhaust. Before the vehicle leaves the
factory, the ABS hydraulic brake regulator is fully filled with
fluid and exhausted, air will not enter the ABS hydraulic brake
regulator during the normal maintenance procedures
involving the regulator. In this case, use manual exhaust
procedures.
Notice
Avoid the spattering brake fluid onto painted surfaces,
electrical connectors, wires, or cables. Brake fluid will
damage painted surfaces and cause corrosion to electrical
components. If any brake fluid comes in contact with painted
surfaces, immediately flush the area with water. If any brake
fluid comes in contact with electrical connectors, wires, or
cables, use a clean cloth to wipe away the fluid.
Notice
Start carrying out exhaust procedure from Step 3 - "exhaust
air in the brake pipeline" if there is no doubt about air entering
the brake master cylinder. If the air is doubted of entering into
brake master cylinder, it needs to discharge air of brake
master cylinder from step 2.
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Brake System –Brake Fluid BR-9
1. Preparatory Works
1). Keep the flameout of engine , depress the brake pedal
several times until the completely eliminate the booster
pressure
Fill the Brake Fluid

3. Depress the brake pedal for several times until the
pressure in the vacuum booster is completely eliminated.
BR
4. Open the brake fluid filler cap.

5. Fill the brake fluid.
Before opening the fluid storage tank cap, please clean it up.
It is allowed to use the DOT4 brake fluid stored in the sealed
vessel only.
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Exhaust Brake System

Notice
Exhaust air in the master cylinder if the master cylinder is
reinstalled or the fluid tank is empty.
Notice
In the exhaust process, leave the master cylinder fluid
reservoir level at least more than half.
1. Preparatory Works
1). Slowly depress the brake pedal to the end, and hold the
position.
BR
2). Loosen one brake master cylinder pipe, tighten the

connection when the brake fluid flows out.
3). Loosen the other brake master cylinder pipe, tighten the
connection when the brake fluid flows out.
Notice
Cover the paint surface with a rag or cloth to prevent brake
fluid adhesion.
4). Repeat Step 1 to Step 3 for three to four times.
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Brake System –Brake Fluid BR-11
2. Exhaust air in the brake pipeline

Notice
Exhaust the air in the brake pipeline of the wheel farthest to
the master cylinder firstly
1) Remove the exhaust screw dust cover.
2). Connect a transparent tube to the vent screw on right
rear brake caliper, and extend the tube into the brake fluid
in the transparent container.
3) Press the brake pedal slowly for several times, and keep
the pedal at the bottom position.
Notice
Do not depress the brake pedal urgently.
BR
4). Depress the brake pedal, at the same time, loosen the
air drain screw, and drain the air in the brake caliper.
5) Tighten the exhaust screw when the brake fluid is no
longer overflowed; slowly release the brake pedal.
6) Repeat Step 3 to Step 5 until the air in brake fluid is
completely exhausted.
7). Loosen the air drain screw; if the bubble no longer
appears in the container, this indicates that the air has
been fully drained.
Notice
In the drain process, leave the master cylinder fluid reservoir
level at least more than half.
8) Tighten the exhaust screw.
9) Operate as the procedures in Steps 1 to –Steps 8.
Exhaust the air in other brake calipers.
10). After draining all the brake caliper air, check whether
the brake pedal is soft. If the brake pedal is soft, repeat the
entire drain process, until the pedal is normal.
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Drain the Brake Fluid

3. Depress the brake pedal for several times until the
pressure in the vacuum booster is completely eliminated.
4. Drain the brake fluid
1) Open the brake fluid filler cap.
2) Place a fluid collection tray.
3) Drain the brake fluid
4) Install the brake fluid filler cap.
Cover the paint surface with a rag or cloth to prevent brake
fluid adhesion.
BR
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Brake System - Brake Pedal BR-13
Brake Pedal
Component
BR
Instrument panel lower
guard plate assembly
Instrument panel left lower

guard plate cover plate
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BR-14 Brake System - Brake Pedal
BR
Brake pedal
N·m (Ib-ft) specified torque
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Removal
4. Remove the brake lamp switch. Refer to “Brake lamp
switch”
5. Remove the brake pedal
1) Loosen the harness clips on the brake pedal assembly.
BR
2) Remove the axis pin and disconnect the U-shaped clip

of vacuum booster connecting rod.
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3) Remove 2 fixing bolts connecting the brake pedal upper

part and body.
4) Remove 4 connecting nuts between the brake pedal

lower part and the vacuum booster.
5) Take out the brake pedal.
BR
Disassembling
1. Remove the brake pedal subassembly
1) Loosen the clips.
2) Remove the brake pedal rotating shaft, and lubricate the
shaft sleeve
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3) Remove the buffering cushion.
4) Remove the brake pedal cushion from the brake pedal

subassembly.
BR
Assembling
1. Assemble the brake pedal
1) Install the brake pedal cushion.
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2) Install the buffering cushion.
3) Apply the lubricant onto 2 new brake pedal shaft

sleeves.
4) Install 2 brake pedal shaft sleeves to the brake pedal
subassembly.
BR
Installation
1. Install the brake pedal bracket subassembly
1) Tighten 4 fixing nuts at the bottom of brake pedal.
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2) Tighten 2 fixing bolts at the top of brake pedal.

3) Connect the U-shaped clip of the vacuum booster

connecting rod and install it to the axis pin.
BR
4) Install the brake pedal assembly upper harness buckles.

2. Check and adjust the brake pedal height. Refer to
“On-board check”
3. Check the brake pedal for free stroke
4. Check the brake pedal for stroke allowance
5. Install the brake lamp switch.
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Adjustment
1. Check and adjust the brake pedal height
1) Check the brake pedal height.
a. Turn the carpet over.
b. Measure the minimum distance between brake pedal
surface and floor.
Minimum distance: 150mm
2) Adjust the brake pedal height.

a. Remove the brake lamp switch assembly.
b. Loosen the nuts of the vacuum booster connecting
rod U-shaped clip.
c. Rotate the connecting rod to adjust the brake pedal
height.
BR d. Fasten the U-shaped clip of connecting rod and lock
its nuts.
Torque: 25.5 N·m (Metric) 18.9lb-ft(English)
e. Pull out the front push rod of brake lamp switch
maximally. Depress the brake pedal; meanwhile
install the brake lamp switch to the pedal. Finally
loosen the brake pedal to adjust the switch to a
proper position automatically.
f. Connect the brake lamp switch harness connector.
2. Check the brake pedal for free stroke
Notice
Measure the distance at the same point for checking the
brake pedal height.
1) Shut down the engine Depress the pedal for several
times until there is no vacuum inside the brake booster.
Slowly release the brake pedal
Free travel of brake 2) Depress the pedal until a slight resistance is felt. As
pedal shown in the figure, measure the distance.
Free stroke: ≤25mm
Notice
If the free stroke does not meet the specification, troubleshoot
the brake system.
NL-3 01/2016
Brake System - Vacuum Booster Assembly BR-21
Vacuum Booster Assembly

Component
Air filter
BR
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BR-22 Brake System - Vacuum Booster Assembly
Instrument panel lower

BR guard plate assembly
Vacuum booster
connecting hard pipe
Vacuum booster
assembly2.0+MT
Vacuum booster
assembly1.8+AT
NL-3 01/2016
On-board Check
1. Airtightness check.
Correct Wrong 1) Start the engine and shut it down 1 to 2min later.
Depress the brake pedal slowly for several times.
Notice
Operate in the order of gears while pressing the brake pedal.
Do not depress it to the end once.
2) Depress the brake pedal to shut down the engine when
First gear Second Third gear
the engine is operating.
gear
Notice
Depress the pedal for 30s. The pedal stroke allowance does
not change, showing the booster airtightness is good.
2. Operation check
1) When placing the start switch at flameout position,
depress the brake pedal for several times to check the
pedal stroke allowance for change.
BR
2) Keep depressing the pedal and start the engine.

Notice
It is normal for the pedal to move down slightly.
NL-3 01/2016
Removal
3. Remove the air filter assembly. Refer to “Intake pipe of air
filter”
5. Drain the brake fluid. Refer to “Brake fluid”
6. Remove the brake master cylinder assembly with liquid
storage tank. Refer to “Brake master cylinder assembly with
liquid storage tank”
7. Remove the vacuum booster assembly
1) Remove the clamp of the vacuum booster connecting
hose 1, and disconnect the vacuum booster connecting
hose and vacuum booster.
BR
2) Remove the axis pin between the vacuum booster and

brake pedal bracket assembly to disconnect them.
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3) Remove 4 nuts connecting the vacuum booster with

brake master cylinder assembly to body.
4) Pull out the vacuum booster with brake master cylinder
assembly from engine compartment side.
Notice
Do not damage the brake pipeline.
Installation
1. Install the vacuum booster.

1) Install 4 nuts connecting the vacuum booster assembly
to body.
BR
2) Install the pin shaft connecting the vacuum booster to

the brake pedal.
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3) Connect the clamp of the vacuum booster connecting

hose 1.
4) Connect the harness connector of the oil sensor.

5. Exhaust brake system
BR 7. Close the engine hood
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Brake System - Brake Master Cylinder Assembly with Liquid Storage Tank BR-27
Brake Master Cylinder Assembly with Liquid Storage Tank

Component
Air filter
BR
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BR-28 Brake System - Brake Master Cylinder Assembly with Liquid Storage Tank
Vacuum booster
Vacuum
booster
Liquid
storage tank
cover
Fluid reservoir
BR
Brake master cylinder
Clutch slave cylinder

connecting hose (MT)
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Removal
filter”
5. Remove the brake master cylinder assembly with liquid
storage tank
1) Disconnect the harness connector of the oil sensor.
BR
2) Disconnect No.1 pipe assembly of vacuum booster

brake master cylinder and No.2 pipe assembly of brake
cylinder.
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3) Disconnect and remove the hose connecting the brake

master cylinder assembly with liquid storage tank to clutch
master cylinder (MT model).
4) Remove the 2 nuts connecting the brake master cylinder

assembly with liquid storage tank to vacuum booster.
5) Remove the brake master cylinder assembly with liquid
storage tank.
BR
Disassembling
1. Disassemble the brake master cylinder assembly with
liquid storage tank
1) Remove the pin connecting the brake master cylinder to
the liquid storage tank.
Assembling
1. Reassemble the brake master cylinder assembly with
liquid storage tank
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1) Install the pin connecting the brake master cylinder to

the liquid storage tank.
Installation
1. Install the brake master cylinder assembly with liquid

storage tank
1) Install the brake master cylinder assembly with liquid
storage tank.
2) Install the 2 nuts connecting the brake master cylinder
assembly with liquid storage tank to vacuum booster.
BR
3) Connect the hose connecting the brake master cylinder

assembly with liquid storage tank to clutch master cylinder
(MT model).
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4) Connect No.1 and No.2 pipe assemblies of brake

master cylinder.
5) Connect the harness connector of the oil sensor.

4. Check whether the brake fluid leaks.
BR 7. Close the engine hood
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Brake System - Front Brake Caliper Assembly BR-33
Brake Caliper Assembly

Component
BR
Vehicle wheel nut
Wheel assembly
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BR-34 Brake System - Front Brake Caliper Assembly
Brake hose assembly
Steering Knuckle
BR
Left front brake caliper
assembly
Left front dust cover
Brake disc
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Front brake caliper

Bleed screws
Piston seal ring
Brake caliper piston dust cover
Exhaust screw dust

cover (front)
Front disc brake caliper piston Bracket mounting

bolt
Sliding pin dust
cover
Sliding pin
Sliding pin rubber sleeve
BR
Brake friction pad

Snap spring
Brake friction pad
Brake caliper bracket

Snap spring
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Removal
Notice
Front left and right brake calipers have similar installation and
removal methods.
Warning!
To avoid any vehicle damage, serious personal injury even
death when major components are removed from the vehicle
and the vehicle is supported by a hoist, support with jack the
components standing at the opposite end from which the
components are being removed of the vehicle.
Warning!
The brake fluid is easy to absorb the moisture. Do not use
brake fluid from an open container that may be contaminated
with water. Incorrect or contaminated brake fluid could result
in system fault, loss of vehicle control and personal injury.
Warning!
Brake fluid may be irritating to the skin or eyes. In case of
contact, take the following measures:
BR
 Eye contact - Flush completely with water
 Skin contact – wash skin with soap and water.
1. Remove the front wheel. Refer to “Wheel and tire”.
3. Remove left front brake caliper assembly
1) Remove the bolts and copper gaskets at the junction
between the left front brake hose assembly and the left
front brake caliper assembly.
2) Disconnect the left front brake hose assembly and the
left front brake caliper assembly.
Notice
If brake fluid is leaked to the vehicle paint surface, clean the
surface completely.
NL-3 01/2016
3) Remove the 2 fixing bolts connecting the left front brake

caliper body to bracket, and remove the left front brake
caliper assemblies.
4) Remove the brake pads.

Notice
Front disc brake pads are different from each other. Ensure
each disc brake pad is marked with an identifying mark, so as
to reinstall them to original positions respectively.
BR
5) Remove the 2 fixing bolts connecting the bracket

assemblies and knuckle, and remove the bracket
assemblies.
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4. Remove the front brake disc.

Notice
Before removal, make assembling marks on the brake disc
and axle hub.
Disassembling
1. Disassemble the bracket assemblies

1) Remove the clamp springs of bracket assemblies
BR
2) Remove 2 sliding pins of bracket assemblies
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3) Remove the rubber sleeves from the sliding pins with a

screwdriver.
Notice
Do not damage the sliding pins of the brake caliper assembly.
Notice
Before using the screwdriver, please wrap the head of
screwdriver with adhesive tape.
4) Remove 2 dust covers for sliding pins.
BR
2. Disassemble the caliper components

1) Place a wood block in front of brake caliper piston to
prevent the piston from bumping the brake caliper body
when blown out.
2) Blow out the piston from the brake caliper exhaust
screw mounting hole with compressed air.
Notice
Do not put fingers in front of the brake caliper piston when
using compressed air.
Notice
Do not spill the brake fluid.
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3) Remove the brake caliper piston dust cover with a

screwdriver.
Notice
Pay attention to not damaging the brake caliper cylinder hole.
Notice
4) Remove the piston seal ring with a screwdriver.

Notice
Do not damage the brake caliper cylinder hole.
Notice
BR
5) Remove the front disc brake caliper exhaust screw dust

cover.
6) Remove the front disc brake caliper exhaust screw.
Check
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1. Check each rubber part for damage and aging

2. Check the disc brake pad guide plate for missing, serious
corrosion and bending of installing lug.
Ruler 3. Check whether or not the friction surface of brake pad has
been cracked, broken or damaged.
4. Check the brake pad for thickness
1) Measure the thickness of pad with a ruler.
Standard thickness: 11mm
Wear limit thickness: 2mm
Replace the brake pad if its thickness is less than the
minimum.
Notice
The new brake pad must be matched with the axle.
The seal parts must be replaced at the time of assembly.
Notice
After the new brake pad is installed, be sure to check the front
brake disc for abrasion.
5. Check the brake disc.
1) Check the surface of brake disc for abrasion
a. Clean the brake disc brake friction surface with industrial BR
alcohol or a permitted equivalent detergent.
b. Check the brake disc friction surface for the following
conditions:
 Serious rust corrosion and/or pitting corrosion
 Minor surface rust
 Cracking and/or born spot
 Serious color changing blue
 Deep scratches on the brake disc friction surface
If one or several conditions above occur on the friction
surface of the brake disc, repair or replace the brake disc
surface.
Notice
Brake pad shall be replaced as well after surface repair or
replacement of brake disc.
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2). Check the thickness of brake disc.

a. Use micrometer to measure and record minimum thickness
of 4 or more than 4 position points uniformly distributed along
the circumference of brake disc. Make sure that the
measurement is only limited in brake pad contact surface
area, and the distance between micrometer and exterior edge
of brake disc during each measurement must be equal.
Standard thickness: 28mm
Limit abrasion thickness: 26mm
6. Measure the end face run-out after brake disc assembly

Notice
When the brake disc is removed from the hub/axle flange,
eliminate rust or dirt on the matching surface of the hub/axle
flange and the brake disc; otherwise, it may result in
oversized end face run-out after the brake disc is assembled
to result in brake pulsation.
BR 1). Clean the brake disc friction surface with industrial
alcohol or similar cleaning agent.
2). Install the brake disc to the wheel brake disc / axle
flange.
3) Install the proper gaskets to the hub bolts, install wheel
nuts, and tighten the nuts with a wrench.
4). Install the dial gauge base to the steering knuckle and
place the dial gauge measuring head, so that it contacts
with the brake disc friction surface and is at 90°, and is
from the brake disc outer edge about 10mm (Metric) 0.5in
(English).
5). Rotate the brake disc, until the dial gauge reading
reaches the minimum, and then dial the dial gauge to zero.
reaches the maximum.
7). Mark and record the face run out.
8). After assembly of the brake disc, compare the face run
out with the specifications.
9) Maximum brake disc radial run-out: 0.08mm (Metric)
Notice
Irons of the dial indicator shall be kept away from axle hub
and speed sensor.
10). If run-out of rear end face exceeds specification after
assembly of brake disc, it is necessary to check bearing axial
clearance and run-out of axle wheel hub. If axial clearance
and run-out of axle wheel hub are normal and brake disc
thickness is within specified range, it is necessary to repair
the surface of brake disc to ensure correct levelness.
Assembling
1. Assemble the caliper component
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1) Fasten the bleed screw of brake caliper.

2) Install the dust cover for the bleed screw of front disc
brake.
3) Apply grease to the new piston seal ring.
4) Install the piston seal ring on the piston of disc brake
caliper.
5) Install the dust cover for brake caliper piston on the brake
caliper piston.
6) Install the brake caliper piston in the cylinder hole of brake
caliper.
2. Assemble the bracket component

1) Install the dust cover for sliding pin on the bracket
component.
BR
2) Install the rubber boot for sliding pin.

3) Install the sliding pin.
Installation
1. Install the front brake caliper assembly
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1) Install the front brake disc by aligning with the assembly

mark.
Notice
If a new brake disc is used for replacement, it shall be
installed at a position with the smallest run-out of the front
brake disc.
2) Install the bolt at the junction between the bracket

component and the steering knuckle.
Torque: 110N·m (Metric ) or 81.4lb-ft (English )
BR
3) Install the front brake pad
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4) Install 2 bolts connecting the front brake caliper

component and the bracket component.
Torque: 42N·m (Metric) 31lb-ft (English)
5) Install the bolt and copper washer at the junction

between the front brake hose assembly and the brake
caliper assembly.
Torque 31N·m (Metric) 22.9lb-ft (English)
Notice
Replace with a new copper washer.
3. Exhaust brake system BR
4. Check the brake fluid leakage
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BR-46 Brake System - Front Brake Hose
Front Brake Hose

Component
BR
Vehicle wheel nut
Wheel assembly
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Brake System - Front Brake Hose BR-47
Right front brake pipe assembly
Right front brake

hose assembly
Left front brake pipe assembly
BR
Front suspension device
Left front brake hose assembly
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Removal
Notice
The assembly and disassembly methods for left front and
right front brake hoses are similar.
Notice
If the left and right hoses are disconnected in the meantime,
be sure to make identification marks to indicate the positions
of hoses on both sides.
The positions of hoses on both sides are indicated.
Warning!
Carefully install and fix when replacing the brake pipes.
Always use the correct fasteners. Otherwise, it may cause
damage to the brake pipes and brake system resulting in
personal injury.
1. Drain the brake fluid
3. Remove the front brake hose.
1) Remove the connecting nut between brake hose and
BR
brake pipe.
2) Pull out the L-shaped spring buckle, and disconnect the
brake hose from the fixed mount.
3) Remove the bolt and copper washer at the junction

between the brake hose and the brake caliper assembly.
NL-3 01/2016
Brake System - Front Brake Hose BR-49
4) Remove the bolt at the junction between the brake hose

and the front pillar assembly.
5) Remove the fixing bolt on the No.2 bracket of left front

wheel speed sensor.
6) Take down the front brake hose.
BR
Installation
1. Install the front brake hose

1) Install the fixing bolt on the No.2 bracket of left front
wheel speed sensor.
Torque: 23N·m (Metric) 17lb-ft(English)
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2) Install the bolt at the junction between the brake hose

and the front pillar assembly.

between the brake hose and the brake subassembly.
Notice
BR
4) Snap in the L-shaped spring buckle.

5) Connect the brake hose and the brake pipe, and fasten
the nut.
2. Install front wheels.
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Brake System - Rear EPB Integrated Caliper Assembly BR-51
Rear EPB Integrated Caliper Assembly

Component
Vehicle wheel nut

BR
Wheel assembly
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BR-52 Brake System - Rear EPB Integrated Caliper Assembly
Rear brake hose assembly

Rear axle head seat
Left rear EPB integrated

caliper assembly
BR
Rear brake baseplate
Rear brake disc
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Dust cover for bleed screw of brake caliper

Bleed screw of brake caliper
Brake caliper piston

Brake caliper piston dust cover
Sliding pin
EPB control module. Sliding pin dust
cover
Brake caliper
Snap spring
Piston seal ring
Brake pad
BR
Brake pad
Brake caliper bracket
Snap spring
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Removal
Notice
The assembly and disassembly methods for left and right rear
EPB integrated caliper assemblies are similar. The operator
shall pull up the button of EPB (release) when switching the
power mode to OFF state. At the moment, since EPB is in a
release state after powered off, the operator can directly
remove the EPB.
Warning!
Vehicle will lose parking function when EPB is released; to
avoid vehicle damages, serious personal injuries and even
fatal accidents, do not implement this operation on road with
gradient.
Warning!
To avoid any vehicle damage, serious personal injury even
death when major components are dismantled from the
vehicle and the vehicle is supported by a hoist, support with
jack the components standing at the opposite end from which
the components are being removal of the vehicle.
Warning!
BR
The brake fluid is easy to absorb the moisture. Do not use
brake fluid from an open container that may be contaminated
with water. Incorrect or contaminated brake fluid could result
in system fault, loss of vehicle control and personal injury.
Warning!
Brake fluid may be irritating to the skin or eyes. In case of
contact, take the following measures:
 Eye contact - Flush completely with water
 Skin contact – Wash skin with soap and water.
2. Shut down battery negative cable
3. Remove the rear wheel. Refer to “Wheel and tire”
5. Remove rear EPB integrated caliper assembly
1) Disconnect the harness connector of rear EPB
integrated caliper assembly.
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2) Remove the bolt at the junction between the rear brake

hose assembly and the rear EPB integrated caliper
assembly.
3) Disconnect the left rear brake hose assembly.
Notice
If brake fluid is leaked to the vehicle paint surface, clean the
surface completely.
4) Remove 2 internal hexagonal fixing bolts and washers

at the junction between the EPB control module and the
brake caliper.
5) Take down the EPB control module.
BR
6) Remove 2 fixing bolts connecting the brake caliper and

the bracket.
7) Take down the left rear brake caliper component.
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8) Take down the brake pad.

Notice
Brake pads are all different from each other. Be sure to make
the identification mark on each pad, so as to re-install all the
pads in their original positions respectively.
9) Remove 2 fixing bolts connecting the bracket and the

rear axle end support, and take down the bracket
component.
BR
6. Remove the rear brake disc

1) Take down the rear brake disc.
Notice
Assembly marks shall be made on the brake disc and the
axle hub.
Disassembling
1. Disassemble the bracket assemblies
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1) Take down the snap ring from the bracket component.
2) Remove 2 sliding pins of bracket assemblies
BR
3) Remove the rubber sleeves from the sliding pins with a

screwdriver.
Notice
Do not damage the sliding pin.
Notice
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4) Remove 2 dust covers for sliding pins.
2. Disassemble the caliper assemblies

1) Place a wood block in front of brake caliper piston to
prevent the piston from bumping the brake caliper body
when blown out.
2) Blow out the piston from the brake caliper exhaust
screw mounting hole with compressed air.
BR Notice
Do not put fingers in front of the brake caliper piston when
using compressed air.
Notice
Do not spill the brake fluid.
3) Remove the brake caliper piston dust cover with a

screwdriver.
Notice
Pay attention to not damaging the brake caliper cylinder hole.
Notice
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4) Remove the piston seal ring from the brake caliper

subassembly with a screwdriver.
Notice
Do not damage the brake caliper cylinder hole.
Notice
5) Remove the dust cover for bleed screw of brake caliper.

6) Remove the bleed screw of brake caliper.
BR
Check
1. Check each rubber part for damage and aging

2. Check the disc brake pad guide plate for missing, serious
Ruler corrosion and bending of installing lug.
3. Check whether or not the friction surface of brake pad has
been cracked, broken or damaged.
4. Check the brake pad for thickness
1) Measure the pad thickness with a ruler.
Standard thickness:10mm
Wear limit thickness:2mm
Replace the brake pad if its thickness is less than the
minimum.
Notice
The disc brake pad must be replaced in the whole set
according to the axle.
Notice
After the new brake pad is installed, be sure to check the front
brake disc for abrasion.
NL-3 01/2016
5. Check the thickness of brake disc.

1) Check the surface of brake disc for abrasion
a. Clean the brake disc brake friction surface with industrial
alcohol or a permitted equivalent detergent.
b. Check the brake disc friction surface for the following
conditions:
 Serious rust corrosion and/or pitting corrosion
 Minor surface rust
 Cracking and/or born spot
 Serious color changing blue
 Deep scratches on the brake disc friction surface
If one or several conditions above occur on the friction
surface of the brake disc, repair or replace the brake disc
surface.
Notice
Brake pad shall be replaced as well after surface repair or
replacement of brake disc.
2). Check the thickness of brake disc.
BR a. Use micrometer to measure and record minimum
thickness of 4 or more than 4 position points uniformly
distributed along the circumference of brake disc. Make
sure that the measurement is only limited in brake pad
contact surface area, and the distance between
micrometer and exterior edge of brake disc during each
measurement must be equal.
Standard thickness:11mm
Wear limit thickness: 9mm
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6. Measure the end face run-out after brake disc assembly

Notice
When the brake disc is removed from the hub/axle flange,
eliminate rust or dirt on the matching surface of the hub/axle
flange and the brake disc; otherwise, it may result in
oversized end face run-out after the brake disc is assembled
to result in brake pulsation.
1). Clean the brake disc friction surface with industrial
alcohol or similar cleaning agent.
2). Install the brake disc to the wheel brake disc / axle
flange.
3) Install the proper gaskets to the hub bolts, install wheel
nuts, and tighten the nuts with a wrench.
4). Install the dial gauge base to the steering knuckle and
place the dial gauge measuring head, so that it contacts
with the brake disc friction surface and is at 90°, and is
from the brake disc outer edge about 10mm (Metric) 0.5in
(English).
reaches the minimum, and then dial the dial gauge to zero.
reaches the maximum. BR
7). Mark and record the face run out.
8). After assembly of the brake disc, compare the face run
out with the specifications.
9) Maximum brake disc radial run-out: 0.08mm (Metric)
Notice
Irons of the dial indicator shall be kept away from axle hub
and speed sensor.
10). If run-out of rear end face exceeds specification after
assembly of brake disc, it is necessary to check bearing
axial clearance and run-out of axle wheel hub. If axial
clearance and run-out of axle wheel hub are normal and
brake disc thickness is within specified range, it is
necessary to repair the surface of brake disc to ensure
correct levelness.
Assembling
1. Assemble the caliper component

1) Fasten the bleed screw of brake caliper.
2) Install the dust cover for bleed screw of brake caliper.
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3) Apply grease to the new piston seal ring.

4) Install the piston seal ring on the piston.
5) Install the dust cover for piston on the brake caliper piston.
6) Install the brake caliper piston in the cylinder hole of brake
caliper, and ensure upper and lower notches of the piston are
in a vertical direction.
BR
2. Assemble the bracket component

1) Install the dust cover for sliding pin on the bracket
component.
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2) Install the rubber boot for sliding pin.

3) Install the sliding pin.
Installation
1. Install the rear brake disc assembly

1) Install the rear brake disc by aligning with the assembly
mark.
Notice
If a new brake disc is used for replacement, it shall be
installed at a position with the smallest radial run-out of the
BR
front brake disc.
2. Install the EPB integrated caliper assembly

1) Tighten 2 bolts at the junction between the rear bracket
component and the rear axle end support.
Torque: 110N·m (Metric ) or 81.4lb-ft (English )
NL-3 01/2016
2) Install the rear brake pad.
3) Install 2 fixing bolts connecting the brake caliper and the

bracket.
4) Rotate the brake pad to make it fit with the brake disc
with the No.5 internal hexagonal wrench.
BR
Notice
Re-confirm that notches of the piston are in vertical direction.
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between the rear brake hose assembly and the rear EPB
integrated caliper assembly.
Notice
3. Install 2 internal hexagonal fixing bolts and washers at the

junction between the EPB control module and the brake.
Torque 9.5N·m (Metric) 7.1lb-ft (English)
BR
6) Connect the harness connector of rear EPB integrated

caliper assembly.
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BR-66 Brake System - Rear Brake Hose
Rear Brake Hose

Component
BR
Vehicle wheel nut
Wheel assembly
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Brake System - Rear Brake Hose BR-67
Right rear brake hose

assembly (EPB)
Right rear No.2 brake pipe assembly
Left rear No.2brake pipe assembly
Left rear brake hose

assembly
Rear suspension device
BR
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Removal
Notice
The installation and removal methods for right and left rear
brake hoses are similar.
Notice
If the left and right hoses are disconnected in the meantime,
be sure to make identification marks to indicate the positions
of hoses on both sides.
Warning!
personal injury.
3. Remove the rear brake hose.
1) Remove the bolt at the junction between the rear brake
hose and the brake caliper assembly.
BR
2) Remove the connecting nut between brake hose and

brake pipe, and disconnect brake hose and brake pipe.
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Brake System - Rear Brake Hose BR-69
3) Pull out the brake hose from the L-shaped spring

buckle.
Installation
1. Install the rear brake hose assembly

1) Pass the brake hose through the L-shaped spring
buckle.
BR
2) Connect the brake hose and the brake pipe, and fasten
the bolt.
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between the brake hose and the brake caliper assembly.
Notice
Replace with a new copper washer
2. Install the rear wheel
BR
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Brake System - No.1 Brake Pipe Assembly of Brake Master Cylinder (ESP) BR-71
No.1 Brake Pipe Assembly of Brake Master Cylinder (ESP)

Component
Air filter
BR
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BR-72 Brake System - No.1 Brake Pipe Assembly of Brake Master Cylinder (ESP)
Vacuum booster with brake master cylinder

assembly
ESC control module (integrated EPB

controller)
BR
No.1 brake pipe assembly of brake

master cylinder
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Removal

personal injury.
filter”
4. Remove No.1 brake pipe assembly of brake master
cylinder (ESP)
1) Remove the tubing nut connecting the No.1 brake pipe
assembly of brake master cylinder and the brake master
cylinder.
BR

assembly of brake master cylinder and the ESP control
module.
3) Take down the No.1 brake pipe assembly of brake
master cylinder.
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Installation
1. Install the No.1 brake pipe assembly of brake master

cylinder.
1) Install the tubing nut connecting the No.1 brake pipe
module.

cylinder.
BR 4. Check the brake fluid leakage
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No.2 Brake Pipe Assembly of Brake Master Cylinder (ESP)

Component
Air filter
BR
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Vacuum booster with brake

master cylinder assembly
ESC control module (integrated

EPB controller)
BR
No.2 brake pipe assembly of

brake master cylinder
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Removal

personal injury.
filter”
4. Remove No.2 brake pipe assembly of brake master
cylinder (ESP)
cylinder.
BR

module.
3) Take down the No.2 brake pipe assembly of brake
master cylinder.
Installation
1. Install the No.2 brake pipe assembly of brake master

cylinder.
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module.

cylinder.
BR 4. Check the brake fluid leakage
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Brake System - Left Front Brake Pipe Assembly BR-79
Left Front Brake Pipe Assembly

Component
BR
Vehicle wheel nut
Wheel assembly
NL-3 01/2016
BR-80 Brake System - Left Front Brake Pipe Assembly
Air filter
BR
NL-3 01/2016
Left front brake pipe

assembly

controller)
BR
Left front brake hose

assembly
NL-3 01/2016
BR-82 Brake System - Left Front Brake Pipe Assembly
Removal

personal injury.
2. Remove wheels. Refer to “Wheel and tire”
5. Remove the left front brake pipe assembly
1) Remove the tubing nut connecting the left front brake
pipe assembly and the ESP control module.
BR
2) Remove the tubing nut connecting the left front brake

pipe assembly and the left front brake hose assembly.
3) Take down the right front brake pipe assembly from the
wheel side.
Installation
1. Install the left front brake pipe assembly
NL-3 01/2016
1) Install the tubing nut connecting the left front brake pipe
assembly and the ESP control module.
2) Install the nut connecting the left front brake pipe

assembly and the left front brake hose assembly.
5. Install wheels.
6. Close the engine hood BR
NL-3 01/2016
BR-84 Brake System - Right Front Brake Pipe Assembly
Right Front Brake Pipe Assembly

Component
BR
Vehicle wheel nut
Wheel assembly
NL-3 01/2016
Brake System - Right Front Brake Pipe Assembly BR-85
Air filter
BR
NL-3 01/2016
Right front brake pipe assembly
Right front brake

hose assembly
ESC control module

(integrated EPB controller)
BR
NL-3 01/2016
Brake System - Right Front Brake Pipe Assembly BR-87
Removal

personal injury.
5. Remove the right front brake pipe assembly
1) Remove the tubing nut connecting the right front brake
BR
2) Remove the tubing nut connecting the right front brake

pipe assembly and the right front brake hose assembly.
3) Take down the right front brake pipe assembly from the
wheel side.
NL-3 01/2016
Installation
1. Install the right front brake pipe assembly

1) Install the tubing nut connecting the right front brake
2) Install the nut connecting the right front brake pipe

assembly and the right front brake hose assembly.
BR
NL-3 01/2016
Brake System - Left Rear No.1 Brake Pipe Assembly BR-89
Left Rear No.1 Brake Pipe Assembly

Component
Air filter
BR
NL-3 01/2016
BR-90 Brake System - Left Rear No.1 Brake Pipe Assembly
Left rear No.2brake pipe

assembly
ESC control module (integrated Left rear No.1 brake pipe

EPS controller) assembly
BR
NL-3 01/2016
Removal

personal injury.
filter”
4. Remove the left rear No.1 brake pipe assembly
1) Remove the tubing nut connecting the left rear No.1
BR

pipe assembly and the left rear No.2 pipe assembly.
3) Remove 1 dual-pipe clip connecting the left rear No.1
pipe assembly and the body.
NL-3 01/2016
Installation
1. Install the left rear No.1 brake pipe assembly

1) Install 1 dual-pipe clip connecting the left rear No.1 pipe
assembly and the body.
2) Install the tubing nut connecting the left rear No.1 pipe
assembly and the left rear No.2 pipe assembly.
BR
3) Install the tubing nut connecting the left rear No.1 pipe
assembly and the ESP control module.
NL-3 01/2016
Brake System - Right Rear No.1 Brake Pipe Assembly BR-93
Right Rear No.1 Brake Pipe Assembly

Component
Air filter
BR
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BR-94 Brake System - Right Rear No.1 Brake Pipe Assembly
Right rear No.2 brake pipe

assembly
Right rear No.1 brake
pipe assembly
BR
ESC control module (integrated EPS

controller)
NL-3 01/2016
Removal

personal injury.
4. Remove the right rear No.1 brake pipe assembly
1) Remove the tubing nut connecting the right rear No.1
brake pipe assembly and the ESP control module.
BR

brake pipe assembly and the right rear No.2 brake pipe
assembly.
NL-3 01/2016
3) Remove 1 dual-pipe clip connecting the right rear No.1

Installation
1. Install the right rear No.1 brake pipe assembly

1) Install 1 dual-pipe clip connecting the right rear No.1
BR
2) Install the tubing nut connecting the right rear No.1

assembly.
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brake pipe assembly and the ESP control module.
BR
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Left Rear No.1 Brake Pipe Assembly

Component
BR
Engine bottom guard

plate assembly
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Left rear No.2brake

pipe assembly
Left rear No.1 brake

pipe assembly
Left rear brake hose

assembly (EPB)
BR
NL-3 01/2016
Removal

personal injury.
“Left and right guard plates on bottom of engine”
4. Remove the left rear No.2 brake pipe assembly
brake pipe assembly and the left rear No.1 brake pipe
assembly.
BR

brake pipe assembly and the left rear brake hose
assembly.
NL-3 01/2016
3) Remove 2 single-pipe clips connecting the left rear No.2

brake pipe assembly and the body.
4) Remove 6 dual-pipe clips connecting the left rear No.2

BR
5) Remove 1 triple-pipe clip connecting the right rear No.2

NL-3 01/2016
6) Remove 3 quadruple-pipe clips connecting the left rear

No.2 brake pipe assembly and the body.
7) Take down the No.2 brake pipe assembly.
Installation
1. Install the left rear No.2 brake pipe assembly

1) Install 6 dual-pipe clips connecting the left rear No.2
BR
2) Install 1 triple-pipe clip connecting the left rear No.2

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3) Install 3 quadruple-pipe clips connecting the left rear

4) Install 2 single-pipe clips connecting the left rear No.2

BR
5) Install the tubing nut connecting the left rear No.2 brake
pipe assembly and the right rear brake hose assembly.
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6) Install the tubing nut connecting the left rear No.2 brake
pipe assembly and the left rear No.1 pipe assembly.
3. Fill the brake fluid
BR
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Right Rear No.2 Brake Pipe Assembly

Component
BR
Engine bottom guard

plate assembly
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Right rear brake hose

assembly (EPB)
Right rear No.2 brake

pipe assembly
BR Right rear No.1 brake

pipe assembly
NL-3 01/2016
Removal

personal injury.
“Left and right guard plates on bottom of engine”
4. Remove the right rear No.2 brake pipe assembly
assembly.
BR

brake pipe assembly and the right rear brake hose
assembly.
NL-3 01/2016
3) Remove 3 single-pipe clips connecting the right rear

4) Remove 6 dual-pipe clips connecting the right rear No.2

BR
5) Remove 1 triple-pipe clip connecting the right rear No.2

NL-3 01/2016
6) Remove 3 quadruple-pipe clips connecting the right rear

7) Take down the right rear No.2 brake pipe assembly.
Installation
1. Install the right rear No.2 brake pipe assembly

1) Install 3 single-pipe clips connecting the right rear No.2
BR
2) Install 6 dual-pipe clips connecting the right rear No.2

NL-3 01/2016
3) Install 1 triple-pipe clip connecting the right rear No.2

4) Install 3 quadruple-pipe clips connecting the right rear

BR

brake pipe assembly and the right rear brake hose
assembly.
NL-3 01/2016

assembly.
3. Fill the brake fluid & check the leakage of brake fluid
BR
NL-3 01/2016
BR-112 Brake System - Vacuum Booster Connecting Pipe (4G20)
Vacuum Booster Connecting Pipe (4G20)

Component
Air filter
BR
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Brake System - Vacuum Booster Connecting Pipe (4G20) BR-113
Component
Vacuum booster
BR
Vacuum booster assembly
NL-3 01/2016
Removal

filter”
3.Removal the vacuum booster connecting pipe
1) Remove the clamp between the connecting pipe and the
No.2 connecting hose of vacuum booster.
2) Remove the clamp between the connecting pipe and the

BR
No.1 connecting hose of vacuum booster.
3) Remove 2 fixing nuts connecting the pipe clip of vacuum

booster and the body.
4)Remove the vacuum booster connecting pipe
NL-3 01/2016
Brake System - Vacuum Booster Connecting Pipe (4G20) BR-115
5) Take down the pipe clip of vacuum booster.
Installation
1.Install the vacuum booster connecting pipe

1) Install the fixing clamp for connecting tube of vacuum
booster
BR
2) Install 2 fixing nuts connecting the pipe clip of vacuum

booster and the body.
NL-3 01/2016
3) Install the band clamp between the connecting pipe and

the No.1 connecting hose of vacuum booster.
Notice
If there is an identification mark shaped as "土" on the hose, it
must be ensured during assembly that the surface with the
identification mark faces up after assembly.
4) Install the band clamp between the connecting pipe and

the No.2 connecting hose of vacuum booster.
Notice
If there is an identification mark shaped as "土" on the hose, it
must be ensured during assembly that the surface with the
identification mark faces up after assembly.
BR 2. Install the air filter assembly
NL-3 01/2016
This Repair Manual provides the information about specification, diagnosis and repair of NL-3 model (2016 version).

All Rights Reserved
Foreword

All rights are reserved. Without written permission from Geely Automobile Co., Ltd., this manual may not be replicated in whole
or part.
Warning
− Carefully read through this manual. It is especially important to fully understand all "Warnings" and "Notes" in Section
"General" relating to fault diagnostic interface.
− Repair methods described in this manual are helpful for the repair work. When following the repair procedures in this
− When replacing parts, please use parts approved by Geely Automobile Co., Ltd. with the same part numbers. Do not use
inferior parts.
− In order to reduce the risk of personal injury in the course of repair, or reduce the likelihood that the vehicle becomes
damaged or unsafe owing to incorrect repair, please strictly comply with all "Warnings" and "Notes" relating to fault
diagnostic interface in this Manual. Just as important, please be noted that the "Warnings" and "Notes" relating to fault
− Before carrying out any repair on or near any component or circuit of airbag system, please refer to the Position Diagram
of Components of Airbag System in Section "Safety Protection Devices" relating to fault diagnostic interface in this
General Contents
Overview IN-1
JLD-4G18TDB Engine Control System ES-1
Clutch System CL-3
Brake System BR-3
Brake Control BC-4
Suspension System SP-4
Constant Velocity Drive Shaft DS-4
Power Takeoff System TP-4
TPMS System TP-4
Tire and Wheel TW-4
A/C System AC-4
Horn System HO-5
Door Lock DL-5
Sunroof System RF-6
Seat Belt SB-6
Door CD-6
Seats SE-6
Interior Trim IR-6
BC Brake Control - Contents BC - 1
BC Brake Control
Brake Control System............................................................................................................. BC-3

Precautions ........................................................................................................................................................... BC-3
Component position .............................................................................................................................................. BC-4
System diagram .................................................................................................................................................... BC-5
System description................................................................................................................................................ BC-6
How to carry out the analysis for elimination of fault ............................................................................................. BC-8
Test mode steps .................................................................................................................................................... BC-9
Table of fault symptoms ...................................................................................................................................... BC-11
Active test and data stream ................................................................................................................................ BC-13
Terminal of ESP electronic stability system ......................................................................................................... BC-15
Check/elimination of DTC components under the vehicle................................................................................... BC-22
Table of DTCs ..................................................................................................................................................... BC-26
ABS or EBD or ESP warning lamp is always lit................................................................................................... BC-31
BC
ABS or EBD or ESP warning lamp is never lit under all circumstances. ............................................................. BC-36
ESP OFF warning lamp is always lit or never lit.................................................................................................. BC-42
HDC warning lamp is always lit or never lit ......................................................................................................... BC-47
Diagnosis of power supply fault and inner fault of hydraulic electronic control unit assembly............................. BC-52
Fault diagnosis of wheel speed sensor ............................................................................................................... BC-56
Diagnosis of data communication fault ............................................................................................................... BC-60
Diagnosis of electronic parking brake system fault ............................................................................................. BC-66
Diagnosis of EPB switch fault ............................................................................................................................. BC-72
ABS sensor device ............................................................................................................... BC-77

Component ......................................................................................................................................................... BC-77
On-board Check.................................................................................................................................................. BC-78
Removal.............................................................................................................................................................. BC-78
Installation........................................................................................................................................................... BC-79
Front wheel speed sensor .................................................................................................... BC-81

Component ......................................................................................................................................................... BC-81
On-board Check.................................................................................................................................................. BC-83
Removal.............................................................................................................................................................. BC-83
Installation........................................................................................................................................................... BC-85
Rear wheel speed sensor (4WD) .......................................................................................... BC-87

Component ......................................................................................................................................................... BC-87
On-board Check.................................................................................................................................................. BC-89
Removal.............................................................................................................................................................. BC-89
Installation........................................................................................................................................................... BC-90
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BC - 2 BC Brake Control - Contents
Rear wheel speed sensor (2WD) .......................................................................................... BC-91

Component ......................................................................................................................................................... BC-91
On-board Check.................................................................................................................................................. BC-93
Removal.............................................................................................................................................................. BC-93
Installation........................................................................................................................................................... BC-94
BC
BC Brake Control - Brake Control System BC - 3
Brake Control System

Precautions
1. Notices for troubleshooting
a. In case of poor contact of terminal or installation fault of any part, removing and reinstalling the suspicious part may restore
the system to normal state completely or temporarily.
b. In order to decide the fault position, be sure to check all kinds of conditions when a fault occurs, for instance check DTC
output and freezing data and take a record before disconnecting any connector or removing and installing any part.
c. As the system could be affected by fault of other non-ESP systems, be sure to check DTC in other systems.
2. Notices for operation
(a) Please don’t remove or install ESP parts such as angle sensor unless otherwise specified as such parts can be hardly
adjusted to the extent of correct after removal and installation.
(b) To operate the ESP system, be sure to make preparation before work by the method specified in the repair manual and
confirm after completion of work.
(c) Unless specially specified in the check procedures, be sure to install controller, brake actuator and various sensors only
after the ignition switch is adjusted to OFF state.
(d) If controller, brake actuator or sensor has been removed and installed, it is necessary to check whether the system is at
BC
fault after installation of the parts. Use the fault diagnostic scanner to check DTC and use test mode to check and make sure
the system function and the signal received by ECU are normal.
3. DTC precautions
a. Some DTC warnings cannot be eliminated by mere replacement of the faulty part. If the warning information is displayed still
after repair, adjust the ignition switch to OFF state before start of DTC elimination procedure.
Notice
If the part is faulty still after elimination of DTC, then the DTC will be stored again.
4. Precautions for CAN communication system
a. CAN communication system is used for data communication among ESP controller, angle sensor, yaw rate sensor
(including acceleration sensor) and other controllers. If CAN communication line has any fault, then DTC of the communication
line will be output.
b. When DTC of any CAN communication line is output, then fault in the communication line shall be repaired and VSC system
shall be troubleshot after data communication is normal.
c. CAN communication line uses special cables for the sake of CAN communication. Cables used for different communication
lines are twisted pairs in the same length. Don’t use bypass harness preferably as it could damage the data under
transmission.
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BC - 4 BC Brake Control - Brake Control System
Component Position
ESP
Right rear wheel speed sensor assembly
Right front wheel speed sensor assembly
BC
Left and rear wheel speed sensor
assembly
Left front wheel speed sensor assembly

ABS sensor device
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System Diagram
ESP control system
Battery supply Left front wheel speed

sensor
The power switch is turned

“ON”
Right front wheel speed
sensor
EPB switch
Left rear wheel speed

sensor
Brake lamp switch
ESP OFF switch

Right rear wheel speed
sensor BC
HDC switch
Lift rear EPB motor
Gateway Right rear EPB motor
TCM (integrated SAS)
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System Description
ESP description
ESP system of the vehicle has following functions:
1. ABS+EBD
The function of anti-lock braking system (ABS) is able to identify the tendency of locking of one or several wheels and reduce
brake pressure of the one or several wheels so that the driver can avoid obstacles and reduce wheel speed or park in case of
emergency braking of the vehicle. The function of electronic brakeforce distribution (EBD) is able to identify the tendency that
the rear wheels are about to lock ahead of front wheels and adjust braking force of the rear wheels immediately to ensure the
rear wheels will not lock ahead of the front wheels and guarantee stability of the vehicle.
2. Traction control system (TCS)
The function of traction control system (TCS) reduces sliding of wheels in their rotation directions by means of engine control
and application of proper braking to the driving wheel in the process of driving.
3. Vehicle dynamic control (VDC)
The function of VDC identifies the difference between actual state of the vehicle and intention of the driver and forces the
vehicle to produce relevant yaw velocity by adjusting brake pressure of wheels or interfering engine management control (or
interfering transmission management control) so as to restrain instability of the vehicle as a result of under-steering and
over-steering and improve stability of the vehicle.
4. Hydraulic brake assist (HBA)
The function of hydraulic brake assist (HBA) is able to identify emergency braking and increase brake pressure actively to ABS
action level once the brake pressure becomes inadequate so as to shorten the braking distance.
BC 5. Hill-start assist control (HHC)
HHC function: When the driver releases brake pedal after applies brake and stops on a uphill ramp (for the vehicle with
manual transmission: depress the clutch also), the brake pressure will maintain internal pressure of the brake system in the
process of parking to prevent slip of the vehicle at the moment of start on a ramp.
6. Hill descent control (HDC)
The function of HDC could allow the vehicle to descend steep hill at the constant speed by limiting engine torque and applying
brake to the vehicle without interference of the driver.
7. Electronic rollover prevention (RMI)
The function of RMI is to prevent rollover of the vehicle under special operation state, which is required to satisfy requirements
in FMVSS 126.
System Operating Principle
1. Anti-lock Brake System (ABS)
In the anti-lock braking period, anti-lock brake system controls the oil fluid pressure of oil circuit on each wheel to prevent
wheel slip. Each wheel is equipped with a separate hydraulic oil circuit and specific solenoid valve. Anti-lock brake system can
reduce, maintain or increase brake fluid pressure of each wheel. However, the anti-lock brake system can not make the
pressure exceed the pressure provided by the brake master cylinder. In the course of anti-lock brake, a series of fast pulse
may be sensed on the brake pedal. When the ABS control module detects the speed sensor input and tries to prevent wheel
slip, each solenoid valve position rapidly changes. ABS pump starts working, resulting pulse. Pedal pulse only appears in the
course of anti-lock brake, and disappears after recovery of normal braking or parking. For the vehicle equipped with anti-lock
braking system, the vehicle can be parked by normal force applied on brake pedal. Anti-lock brake system can effectively
shorten the braking distance and maintain the vehicle stability.
In the course of anti-lock brake, brake system pressure is adjusted in three stages.
Pressure maintaining
When the wheel slips, the hydraulic electronic control unit closes oil inlet valve and keeps the oil drain valve closed so as to
isolate the system. It maintains the brake fluid pressure without increasing or decreasing.
Pressure decrease
When any wheel slips, the hydraulic electronic control unit reduces the pressure supplied to each wheel in the process of
deceleration operation. The inlet valve is closed, while the outlet valve is open. The excess fluid is stored in the accumulator
until the ABS pump returns the fuel pump to the master cylinder.
Pressure increase
When no wheel slips, the hydraulic electronic control unit gradually increases brake pressure of each wheel to reduce speed
of the wheels. Open the oil inlet valve and close the oil outlet valve. The pressure increased is provided by the brake master
cylinder.
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2. Electronic brake-force distribution (EBD)

Each wheel attached ground conditions may be different, and then the ground friction coefficient will be different. During
braking, the vehicle gravity center will change, so the vehicle is prone to slip, tilt, roll, etc. when braking. EBD's function is to
calculate four tires friction difference as a result of different adhesion coefficients at the braking moment, and then adjust the
hydraulic unit electromagnetic valve. The valve adjusts as the preset program to match the system power to the friction
(adhesion), ensure vehicle braking smooth and safety. Under the emergency braking situation, before the ABS takes action,
EBD has balanced each wheel grip, to prevent tail-flick and the lateral movement. EBD is actually an additional function of
ABS. Based on road and load changes, it automatically adjusts the braking force distribution, and improves the ABS efficiency.
3. Electronic stability program (ESP)
The electronic stability program (ESP) could reduce the risk of vehicle slip, which can work only when the engine is operating.
The function of ESP can be released under special conditions:
 When the vehicle runs with tire chains.
 When the vehicle runs in deep snow or on soft road.
 When the vehicle has to move front and back when stuck in any place (for instance stuck in muddy roads)
The ESP system shall be switched on when no above conditions exist.
ESP System working principle
Identify the difference between vehicle actual state and intention of the driver and adjust brake pressure of wheels or interfere BC
engine control (or interfere transmission management control) to prevent the vehicle gets out of control and improve stability of
the vehicle.
ESP system will decide driving intention of the driver according to information such as steering wheel angle, vehicle speed,
accelerator position and brake pressure and constantly compare with actual running state of the vehicle. When the vehicle
deviates from normal running path (for instance, when the vehicle happens to a sideslip), ESP system will exert braking force
to the relevant wheel to correct such deviation. If braking of a single wheel is not adequate to keep the vehicle stable, then
ESP will reduce output of the engine torque or brake other wheels to meet the requirement.
4. Steering wheel steering angle sensor
The steering wheel angle sensor is such a sensor that measures and calculates steering angle and steering angular speed of
the steering wheel and outputs signals through CAN bus.
The principle of measurement
Use giant magneto-resistance effect for measuring absolute value of non-contact and simulation angle. The absolute angle is
measured by 2 measuring gears with different number of teeth embedded small magnets. The giant magneto-resistance unit
that changes its resistance by change in the direction of magnetic field is able to detect angle change of the measuring gear.
The voltage value measured is sent to the microcomputer for angle calculation through SPI interface after analog-digital
conversion. Steering angle and speed signal are sent out through CAN bus.
NL-3 01/2016

Please use the following steps to check your faults. If following these steps carefully, you will find most of the automatic
transmission faults.
3. Check existing fault code (DTC) of the vehicle.
4. If fault symptom only appears occasionally and no fault code (DTC) appears, it indicates that it is an intermittent fault.
5. When the fault conditions can be verified but without a fault code (DTC) or the system cannot communicate with the
diagnostic scanner.
8. If the Diagnostic trouble code (DTC) is set again, refer to “Fault code list”.
9. If you do not reset the Diagnostic trouble code (DTC), it is the intermittent fault.
10. After repair, conduct the road test again, to confirm that the fault has been eliminated.
BC
NL-3 01/2016
Test mode steps

1. Check initial state of warning lamp and indicator lamp
(a) Release the parking brake.
Notice:
Before releasing the parking brake, turn the gear shift lever to
position P (for the vehicle with automatic transmission) for the
sake of safety.
Notice:
The brake warning lamp will light up when parking brake is
applied or when brake fluid level is low.
(b) Check whether ABS, EBD, ESP and HDC warning lamps
are lit for 3 seconds when the ignition switch is adjusted to
ON state.
Notice:
 ABS, brake warning lamp and other warning lamps will
light up if any DTC is stored in the brake control ECU.
 Eliminate circuit fault of following indicator lamps in case
that the indicator lamp is always lit or is never lid.
Fault position Refer to BC
Refer to “ABS or EBD or
ABS or EBD or ESP
ESP warning lamp is
warning lamp is always lit
always lit”
Refer to “ABS or EBD or
ABS or EBD or ESP
ESP warning lamp is never
warning lamp is never lit
lit under all circumstances”
Refer to “ESP OFF
ESP OFF warning lamp is
always lit or never lit
or never lit”
Refer to “HDC warning
HDC warning lamp is
lamp is always lit or never
lit”
2. The sensor signal is checked by the test mode (signal
check) (fault diagnostic scanner)
Notice:
When the ignition switch is adjusted from ON to ON (ACC) or
OFF state in the course of test mode (signal check), DTC
recorded in the signal check function will be deleted.
(a) The steps to enter the test mode.
(1) Turn off the ignition switch.
(2) Connect the fault tester to the diagnostic interface.
(3) Check whether the steering wheel is aligned, turn the gear
shift lever to position P (for automatic transmission) or pull up
the parking brake (for manual transmission).
(4) Adjust the ignition switch to ON state.
(5) Set the diagnostic scanner to the test mode (select signal
check).
Please refer to the manual for the diagnostic scanner
operators for details.
(6) Check whether ABS, EBD, ESP and HDC warning lamps
light up for several seconds and then flash in the test mode.
NL-3 01/2016
(b) Check sensor signal.

Drive straight forward.
Run at the speed equal to or higher than 45 km/h (28 mph)
and check whether ABS warning lamp goes out when the
brake pedal is depressed.
 Notice:
 Check of the sensor cannot be completed if any wheel is
turning or the steering wheel is turning during the check.
 ABS, EBD, ESP and HDC warning lamps will go out
after check of sensor signals is completed and the brake
pedal is depressed.
 ABS, EBD, ESP and HDC warning lamps will light up
immediately once any fault is detected in the course of
speed sensor signal check.
(c) Stop.
Notice:
 Check of the speed sensor signals may not be
completed if the check is started when the steering
BC
wheel is turning or any wheel is turning.
 If signal check is not completed, then ABS, EBD, ESP
and HDC warning lamps will flash and ABS system will
not work in the process of driving.
(d) Read the value of DTC according to hint on the tester
screen.
Notice:
 If only DTC is displayed, repair the fault area and
eliminate DTC.
 If DTC or test mode code (DTC of signal check function)
is displayed, then repair the fault area, eliminate DTC
and carry out check of the test mode.
Please refer to DTC list for details
Use the test mode to check sensor signals (signal check)
(check the conductor)
Notice:
When the ignition switch is adjusted from ON to ON (ACC) or
OFF state in the course of test mode (signal check), DTC
recorded in the signal check function will be deleted.
The test steps are similar to check of sensor signals.
Refer to “DTC list for the diagnosis fault code”.
NL-3 01/2016

Symptoms Suspected Parts: Reference/Measures
1. Check the DTC and confirm there
Access the module via diagnostic
are no historical and current fault
scanner.
codes.
2. Power circuit (terminals 1, 30, 36 of lamp is always lit” related to check of
ESP module harness connector the hydraulic electronic control unit
CA12) harness connector (voltage of terminal
1/30/36 of CA12).
3. Circuit of front speed sensor Refer to “Fault diagnosis of wheel
4. Circuit of rear speed sensor speed sensor".
ABS does not work
5. Check the brake hydraulic
electronic control unit with active test
function of the diagnostic scanner. If Refer to “Active test and data stream”.
abnormal, check whether or not the
hydraulic pipeline leaks.
6. If above suspected circuit has been
checked and deemed as normal, but
the fault still exists, the hydraulic Refer to “ABS sensor device” BC
electronic control unit assembly has to
be replaced.
1. Check the DTC and confirm there
Access the module via diagnostic
are no historical and current fault
scanner.
codes.
2. Circuit of front speed sensor Refer to “Fault diagnosis of wheel
3. Circuit of rear speed sensor speed sensor".
1. Confirm the brake lamp works
normally, or refer to “Brake lamp
doesn’t work”.
ABS fails to run effectively. 4. Brake lamp switch circuit 2. After depressing the brake pedal,
the voltage of terminal 30 of ABS
module harness connector CA12 shall
be power supply voltage.
5. Check the brake hydraulic
electronic control unit with active test
function of the diagnostic scanner. If Refer to “Active test and data stream”.
abnormal, check whether or not the
hydraulic pipeline leaks.
1. If above suspected circuit has been
checked and deemed as normal, but
ABS fails to run effectively. the fault still exists, the hydraulic Refer to “ABS sensor device”
electronic control unit assembly has to
be replaced.
ABS warning light fault (always keep 1. Combination instrument Refer to “ABS or EBD or ESP warning
on) 2. Hydraulic electronic control unit lamp is always lit”
3. ABS warning light fault (off) 1. Combination instrument lamp is never lit under all
circumstances”
Brake warning lamp fault(always Refer to “ABS or EBD or ESP warning
1. Circuit of brake warning light
keep on ) lamp is always lit”
1. ESP switch
ESP OFF warning lamp fault (always Refer to “ESP OFF the warning lamp is
2. Combination instrument
lit or never lit) always lit or never lit”
3. Hydraulic electronic control unit
NL-3 01/2016

1. ESP switch
HDC warning lamp fault (always lit or Refer to “HDC warning lamp is always
2. Combination instrument
never lit) lit or never lit”
3. Hydraulic electronic control unit
BC
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Active Test and Data Stream

Active test
Suggest:
It’s able to run the relay, actuator and other components under the circumstance of removal no parts during active test of the
diagnostic scanner. It’s able to save operating time if active test is conducted before troubleshooting.
Notice
The time of valve is opened in the action test shall not exceed 3s, otherwise ESP will be damaged. Repeated opening and
closing of the valve in a certain time may damage valve or pump.
1. Connect the fault sensor to the vehicle.
2. Operate the starter switch to turn the power supply mode to ON state.
3. Carry out the “Active test” according to the diagnostic scanner screen.
Diagnostic scanner
Test components Control range Test remarks
display
ABS solenoid works or fails to Solenoid works or fails to Operating noise of solenoid coil
Left front fuel inlet valve
work work can be heard
Left front oil outlet valve
BC
Right front fuel inlet ABS solenoid works or fails to Solenoid works or fails to Operating noise of solenoid coil
valve work work can be heard
Right front oil outlet ABS solenoid works or fails to Solenoid works or fails to Operating noise of solenoid coil
Left rear fuel inlet valve
Left rear oil outlet valve
Right rear fuel inlet ABS solenoid works or fails to Solenoid works or fails to Operating noise of solenoid coil
Right rear oil outlet ABS solenoid works or fails to Solenoid works or fails to Operating noise of solenoid coil
Motor actuates or fails to Working sound of the motor
Pump motor Motor actuates or fails to actuate
actuate could be heard.
Data stream
Description State
Vehicle speed 0km/h
Left front wheel speed 0km/h
Right front wheel speed 0km/h
Left rear wheel speed 0km/h
Right rear wheel speed 0km/h
Battery voltage 14.08V
Brake lamp switch Off
Valve relay ON
Pump motor Off
Left front solenoid valve (intake) Off
Left front solenoid valve (exhaust) Off
Right front solenoid valve (intake) Off
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Description State
Right front solenoid valve (exhaust) Off
Left rear solenoid valve (intake) Off
Left rear solenoid valve (exhaust) Off
Right rear solenoid valve (intake) Off
Right rear solenoid valve (exhaust) Off
Filling status BOSCH delivery state
Offline detection status BOSCH delivery state
BC
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Terminal of ESP Electronic Stability System

CA12 Electronic stability program control module harness connector
Terminal Description Terminal description State Specified condition

1 UB_MR Power supply of the right motor 10-39A
2 MRP Positive pole of the right motor 7-20A BC
3 MRM Negative pole of the right motor 7-20A
4 - - - -
5 CAN1_H High-mounted CAN bus 20-30mA
6 ESP_OFF ESP off 5-30mA
7 WSS_FL Left front wheel speed signal 6-34mA
8 - - - -
9 - - - -
10 - - - -
11 CAN2_H High-mounted CAN bus 20-30mA
12 MLM Negative pole of the left motor 7-20A
13 MLP Positive pole of the left motor 7-20A
14 GND MR Grounding of the right motor 10-39A
15 SW3 Switch 3 5-50mA
17 AVH_SW Autohold switch 5-30mA
18 - - - -
19 CAN1_L Low-mounted CAN bus 20-30mA
20 - - - -
Power supply of the right front wheel
21 WSP_FR 6-34mA
speed
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Power supply of the right rear wheel
22 WSP_RR 6-34mA
speed
23 WSS_RL Left rear wheel speed signal 6-34mA
24 WSP_FL Left front wheel speed power supply 6-34mA
25 CAN2_L Low-mounted CAN bus 20-30mA
26 WSS_FR Right front wheel speed signal 6-34mA
27 - - - -
28 - - - -
29 - - - -
30 UB_VR VR power supply 5-45A
33 - - - -
34 VSO Vehicle speed 10-20mA
35 WSO Wheel speed 5-30mA
36 WAU_IN1 Ignition 5-20mA
BC
37 WSS_RR Right rear wheel speed signal 6-34mA
38 - - - -
39 WSP_RL Power supply of left rear wheel speed 6-34mA
40 - - - -
41 - - - -
42 HID_SW HDC system switch 5-30mA
43 - - - -
44 - - - -
45 BLS Brake lamp switch 5-15mA
46 GND ECU ECU grounding 5-45A
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SO42 Electronic stability program control module harness connector
SO42 Left caliper motor harness connector

1 MLP Positive pole of the left motor 7-20A
2 MLM Negative pole of the left motor 7-20A
3 WSS_RL Left rear wheel speed signal 6-34mA BC
4 WSP_RL Power supply of left rear wheel speed 6-34mA
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IP83 Electronic stability program control module harness connector
IP83 EPB gateway harness connector

2 ILLUM Connect the backlight lamp
BC 4 SW4 Switch 4 5-50mA
5 EPB backlight lamp EPB backlight lamp
7 AVH_SW Autohold switch 5-30mA
8 AUTOHOLD backlight Autohold backlight lamp
9 EPB indicator lamp EPB indicator lamp
10 AUTOHOLD indicator lamp Autohold indicator lamp
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Diagnostic System
1. Diagnostic system
If the voltage is lower than 11V, please charge the battery
before diagnosis.
(b) The vehicle EMS uses ISO 15765-4 communication
protocol. Arrangement of terminals of the diagnostic
IP12 OBD diagnostic interface

interface conforms to ISO 15031-3 and is in the same
format as ISO15765-4.
BC
Terminal number Terminal description State Specified condition

1 -
2 -
3 -
4 Grounding of chassis Always Less than 1 Ω
5 Signal grounding Always Less than 1 Ω
Adjust the ignition switch to
6 Dia-CAN high-mounted bus 55~63Ω
OFF state
9 K-LIN Less than 1 Ω
OFF state
10 -
11 -
12 -
13 -
14 Dia-CAN low-mounted bus 55~63Ω
OFF state
16 Power supply （B+） Always 11~14
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Suggest:
Connect cable of the diagnostic scanner to the diagnostic
interface, adjust the ignition switch to ON state and try to
enable the diagnostic scanner. If the screen displays
communication fault information, then the vehicle or the tester
has fault.
If the tester communicates normally when connected to
another vehicle, then check the diagnostic interface on the
original vehicle.
If the diagnostic scanner cannot communicate even when it is
connected to another vehicle, then it may be the problem of
the diagnostic scanner itself. Refer to the user’s manual for
the scanner or contact the manufacturer.
Notice:
Before measuring the resistance, don’t operate the vehicle for
at least 1 minute, and don’t operate the ignition switch, any
other switch or door.
2. Diagnosis
Notice:
BC When releasing the parking brake, put a wedge to stabilize
the vehicle for the sake of safety.
(b) Adjust the ignition switch to ON state.
(c) When the brake control ECU detects any fault, then ABS,
EBD, ESP and HDC warning lamps and brake warning lamp
will light up to warn the driver.
3. Initial check of warning lamps
Notice:
When releasing the parking brake, put a wedge to stabilize
the vehicle for the sake of safety.
Notice:
The brake warning lamp will light up when parking brake is
applied or when the brake fluid level is low.
(b) When the ignition switch is adjusted to ON state, check
whether ABS, EBD, ESP and HDC warning lamps and brake
warning lamp light up and then go out after around 3
seconds.
(c) If the warning lamp is not lit or is always lit, check warning
light circuit and (or) brake warning lamp circuit.
Fault position Refer to page
ABS or EBD or ESP
ABS or EBD or ESP
warning lamp is never lit
ESP OFF warning lamp is
HDC warning lamp is
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4. Simulation of symptom
Gently beat to make it vibrate
Notice:
The most difficult circumstance in troubleshooting is that
there is no any symptom. In this case, you must thoroughly
analyze the described fault. Then simulate the same or
similar conditions and environment when user’s vehicle has
fault. Even for a very experienced technician, if carry out
troubleshooting without verifying the fault, it is likely to ignore
a number of important things, and even make misjudgments.
This will result in the fault can not be continued.
(a) Vibration method: used for the fault mainly caused by
Gently beat to make it
vibrate vibration.
Notice:
The simulation method can be used only at major check
stage (6 seconds approximately after the ignition switch is
adjusted to ON state). BC
(1) With a finger, gently shake the sensor that may be fault
and check for fault.
(2) Gently shake the sensor in the vertical and horizontal
Gently beat to make it vibrate
directions.
Notice:
The relay may be happened to open circuit if vibrated too
violently
(3) Gently shake the sensor wiring harness in the vertical and
horizontal directions Connector joint and vibration support are
the major parts to be thoroughly checked.
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Check/Elimination of DTC Components under the Vehicle

1. DTC check/elimination (check the conductor)
(a) DTC check
IP12 OBD diagnostic interface (1) Use the diagnostic scanner to connect the diagnostic
interface.
(3) Read the DTC information from brake system warning
lamp on the combination instrument.
Notice:
Check the terminal circuit and warning lamp circuit if no
code occurs.
(4) The code is interpreted in the table of fault code (refer

to the table of fault symptoms).
(5) Disconnect diagnostic scanner and interface and
power off the display screen. When 2 or more DTCs are
detected at the same time, then they will be displayed in
BC
ascending order.
(b) Elimination the DTC
(1) Use the diagnostic scanner to connect the diagnostic
interface.
IP12 OBD diagnostic interface
(3) Depress the brake pedal by more than 8 times within 5

seconds to eliminate the DTC stored in ECU.
(4) Check whether the warning lamp displays normal
system code.
(5) Remove the diagnostic scanner from the diagnostic
interface.
Notice:
Don’t eliminate the DTC by removing battery terminal or
ECU power fuse.
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2. DTC check/ elimination (during use of diagnostic scanner:)

(a) DTC check
(1) Connect the diagnostic scanner to the diagnostic
interface.
(3) Read the DTC value according to the hint on the screen of
the diagnostic scanner.
(b) Elimination the DTC
(1) Connect the diagnostic scanner to the diagnostic
interface.
(3) Operate the diagnostic scanner to eliminate the code.
3. End the check/elimination of DTC
(a) Adjust the ignition switch to ON state.
(b) Check whether warning lamps like ABS go out within 3
seconds.
BC
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Table of Failure Protection

1. Action of fault protection
In case of any fault of sensor signal or brake actuator system,
the brake control system ECU will prohibit power supply to
the brake actuator and end control of relevant system.
ABS control will be prohibited but EBD control will be
continued as far as possible. If EBD control is not available,
then the brake warning lamp will light up to remind the driver.
Notice:
If ABS system fails, then the brake system will operate
normally even without ABS control.
BC
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Data Sheet/Active Test

1. Data sheet
Notice:
On the basis of the date sheet displayed on fault diagnostic
scanner, under the circumstance that no part is removed, you
can read the value of switch, sensor, actuator and other
components. When eliminating a fault, please firstly read the
data sheet, which can shorten the working hours.
(a) Connect the fault diagnostic scanner to the fault
(c) Read “data sheet” according to what is displayed on the
display screen of the diagnostic scanner.
2. Active test
Notice:
It’s able to run the relay, actuator and other components
under the circumstance of removing no parts during active BC
test of the diagnostic scanner. When eliminating the fault,
firstly carry out the active test, so as to shorten the working
time.
It’s able to display data sheet during active test.
(a) Connect the fault tester to the diagnostic interface.
(c) Implement the "Active Test" according to the diagnostic
scanner screen.
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Table of DTCs
DTC Description
C100004 ECU hardware fault
C100104 CAN hardware fault
C100204 ABS/ESP control abnormal
C100304 Valve relay fault
C100409 Common valve fault (hardware fault)
C100498 Overheat of friction plate
C100504 Exhaust pump fault
C100664 Brake lamp switch fault
C100764 Signal fault of transverse acceleration sensor
C100864 Signal fault of longitudinal acceleration sensor
C100A64 Signal fault of yaw angle sensor
C100B08 Signal fault of reverse gear
C100D01 Fault of left front wheel speed sensor (the specific fault reason is not detected)
C100D11 The left front wheel sensor is short to ground
BC C100D12 The left front wheel speed sensor is short to power supply
C100D13 Left front wheel speed sensor open circuit
C100D64 Signal fault of left front wheel speed sensor (excess of scope, loss, noise and discontinuity)
C100E01 Fault of right front wheel speed sensor (the specific fault reason is not detected)
C100E11 The right front wheel speed sensor is short to ground
C100E12 The right front wheel speed sensor is short to power supply
C100E13 Right front wheel speed sensor open circuit
C100E64 Signal fault of right front wheel speed sensor (excess of scope, loss, noise and discontinuity)
C100F01 Fault of left rear wheel speed sensor (the specific fault reason is not detected)
C100F11 The left rear wheel speed sensor is short to ground
C100F12 The left rear wheel speed sensor is short to power supply
C100F13 Left rear wheel speed sensor open circuit
C100F64 Signal fault of left rear wheel speed sensor (excess of scope, loss, noise and discontinuity)
C101001 Fault of right rear wheel speed sensor (the specific fault reason is not detected)
C101011 The right rear wheel speed sensor is short to ground
C101012 The right rear wheel speed sensor is short to power supply
C101013 Right rear wheel speed sensor open circuit
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DTC Description
C101064 Fault of right rear wheel speed sensor (excess of scope, loss, noise and discontinuity)
C101104 Common fault of wheel speed sensor (replacement of sensor, fault of several sensors)
C101204 Fault of left front liquid inlet valve
C101304 Fault of left front liquid outlet valve
C101404 Fault of right front liquid inlet valve
C101504 Fault of right front liquid outlet valve
C101604 Fault of left rear liquid inlet valve
C101704 Fault of left rear liquid outlet valve
C101804 Fault of right rear liquid inlet valve
C101904 Fault of right rear liquid outlet valve
C101A04 Fault of circuit control valve 1
C101B04 Fault of circuit control valve 2
C101C04 Fault of high-pressure control valve 1
C101D04 Fault of high-pressure control valve 2
C101E01 Fault of pressure sensor circuit
BC
C101E64 Signal fault of pressure sensor
C101F29 Fault of angle sensor
C101F54 Fault of calibration of angle sensor
C102004 The PATA switch is wrong
C102100 Right brake fault of automatic park brake
C102200 Left brake fault of automatic park brake
C102312 Fault of autohold button circuit
C102401 There is an electrical fault in autohold left brake
C10241E Fault of left brake line H axle of autohold brake
C102501 Electrical fault of right brake of automatic park brake
C10251E Fault ofright brake line H axle of autohold brake
C102719 Overcurrent of left motor of automatic park brake
C102B62 The autohold brake is abnormal
C102C71 Catching of automatic park brake button
U007300 The CAN bus-off is wrong
U010082 The Message EMS_EngineRPM(ID=0x094) counter is wrong
U010083 The Message EMS_EngineRPM(ID=0x094) checksum is wrong
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DTC Description
U010087 The communication with engine control system is lost
U010187 The communication with transmission control system is lost
U012382 The airbag counter is wrong
U012383 The airbag checksum is wrong
U012687 The communication with steering wheel angle sensor is lost
U012682 The message SAS_Status counter is wrong
U012683 The message SAS_Status checksum is wrong
U014087 The communication with body controller is lost
U015187 The communication with airbag controller is lost
U010287 The communication with 4WD system is lost
U010387 The communication with HVAC is lost
U010487 The communication with ICU is lost
U010587 The communication with PEPS is lost
U023587 The communication with radar is lost
U023582 The radar counter is wrong
U023583 The radar checksum is wrong
BC
U031800 The ECU software is wrong
U040186 Engine control system signal invalid
U040286 Transmission control system signal invalid
U042286 The signal of body control system is invalid
U042886 Steering angle sensor signal invalid
U040386 The signal of 4WD control system is invalid
U040486 The signal of HVAC system is invalid
U040586 The signal of ICU system is invalid
U040686 The signal of PEPS system is invalid
U043386 The signal of radar system is invalid
U045286 The signal of airbag system is invalid
U100016 The ECU supply voltage is low
U100017 The ECU supply voltage is high
U130055 The variant content is wrong
P004003 The yaw angle sensor is wrong
P004007 Fault of brake pipeline
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DTC Description
P004008 The instrument display signal is interrupted
P00400b PDM cannot be written in
P00400d The steering angle sensor is wrong
P00400e The motor is wrong
P004010 The left front wheel speed sensor is wrong
P004011 The right front wheel speed sensor is wrong
P004012 The left rear wheel speed sensor is wrong
P004013 The right rear wheel speed sensor is wrong
P004014 The direction of the wheel speed sensor is wrong
P004015 The ESP valve is wrong
P00401a The vacuum sensor is wrong
C000900 The hydraulic module works in excess of limit
C006102 The transverse acceleration value is invalid
C006202 The longitudinal acceleration value is invalid
C006302 The yaw angle speed is invalid
BC
C0085 The initialization is not completed
C100300 The clutch switch is non-trusted
U000500 NET overvoltage
U000700 NET undervoltage
U100104 The NET communication is wrong
U160308 The signal of clutch is invalid
C15870B The current of the left electronic caliper is higher than the highest threshold value
C15870C The current of the left electronic caliper is lower than the lowest threshold value
C15880B The current of the right electronic caliper is higher than the highest threshold value
C15880C The current of the right electronic caliper is lower than the lowest threshold value
C056D36 The state of the caliper is unknown (due to abnormal power off)
C056E38 The ECU hardware/software is wrong
C028B5A The vehicle slips
C056000 The caliper is excessively released
C056E4B The Initialization of the caliper is not completed
C056143 State of the caliper is unknown (due to eeprom fault)
C056D38 Fault of memory write-in of the electronic caliper
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DTC Description
C056D39 Fault of ESP host communication
C080003 Operating voltage of the caliper is too low
BC
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ABS or EBD or ESP Warning Lamp is Always Lit

Circuit schematic:
Combination instrument Gateway
BC
Diagnostic steps:
Step 1 Use the diagnostic scanner to visit the hydraulic electronic control unit
Go to Diagnostic trouble code(DTC) list and

Yes
repair according to fault codes.
No

(a) Use a multimeter to measure the battery voltage.
No Overhaul fault of the charging system
Yes
Step 3 Check the hydraulic electronic control unit harness connector.
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No Correctly connect the connector.
Yes
Step 4 Check whether the fuse ESP is blown out.

(a) Check whether the fuses EF03, EF04 are blown out.

Yes Replace the fuse.
BC
No
Step 5 Check the hydraulic electronic control unit harness connector (terminal voltage).
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to OFF state.

(b) Disconnect the control module harness connector.
to ON state.
(d) Measure the voltage between the terminal 1/30/36 of the
hydraulic electronic control unit harness connector CA12 and
the grounding on the vehicle body.
Yes
Check the hydraulic electronic control unit harness connector (conductivity of the grounding
Step 6
terminal).
(a) Measure the resistance between the terminal 14/46 of BC
the hydraulic electronic control unit harness connector
CA12 and the grounding on the vehicle body.
value.
Repair or replace the harness or harness

No
connector.
Yes
Step 7 Check the CAN network signal line (line connected with ESP).
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(a) Measure the resistance between the terminal 5/19 of

the ESP control unit CA12 and the terminal 2/12 of the
CA12 Electronic stability program control module harness connector gateway CA08.
value.

No
connector.
CA08 Gateway
BC
Yes
Step 8 Replace the hydraulic electronic control unit assembly.

(a) Replace the hydraulic electronic control unit. Refer to
“EABS sensor device”.
(b) Connect the battery positive.
(c) Operate the starter switch to turn power supply mode to
OFF state and confirm whether ABS warning lamp goes out
after illumination.
No
Step 9 Check the CAN network signal line (line connected with instrument).
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(a) Measure the resistance between the terminal 3/13 of the

gateway CA08 and the terminal 31/32 of the instrument IP17.
CA08 Gateway harness connector Confirm whether the resistance meets the standard value.

No
connector.
BC
Yes
Step 10 Check the combination instrument.

(a) Connect the diagnostic scanner.
(b) Select “active test” → “ABS warning lamp” in function test.
(c) Check whether ABS warning light works normally.
No
Step 11 Replace the combination instrument control unit.

(a) Disconnect the negative battery cable. Refer to “Removal
of the battery cable”.
(b) Replace the combination instrument control unit. Refer to
“Instrument panel”.
(c) Confirm the repair is completed.
Next Step
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ABS or EBD or ESP Warning Lamp is Never Lit under All Circumstances.
Circuit schematic:
BC
Diagnostic steps:

Yes
No

(b) Confirm whether the voltage meets the standard value.
Yes
Step 3 Check the combination instrument connectors.
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mode to OFF state.
(b) Disconnect the negative cable from the battery.
(c) Check whether the connector is correctly connected on
the combination instrument assembly.
Yes

(a) Check whether the fuses EF03, EF04 are blown out.
Engine compartment fuse, relay box Yes Replace the fuse.
BC
No
Step 5 Check the wiring harness (combination instrument assembly — power supply, grounding).
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to OFF state.
(c) Disconnect the harness connector IP17 from the
IP17 Combination instrument harness connector combination instrument assembly.
(d) Connect the battery negative cable to battery.
to ON state.
(e) Measure the voltage between the combination instrument
harness connector IP17 terminals 1, 2 and car body
grounding.
(g) Operate the starter switch to turn the power supply mode
to OFF state.
(h) Measure the resistance between terminals 3, 4 of
combination instrument harness connector IP17 and body
grounding.
(i) Confirm whether the measured value meets the standard
value.

BC
Yes
Confirm whether the resistance meets the standard value.
CA08 Gateway

No
connector.
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Yes

No
Step 8 Replace the combination instrument.

(a) Replace the combination instrument assembly. Refer to
(b) Check whether ABS warning light works normally.
No BC
to OFF state.
CA12 Electronic stability program control module
(b). Disconnect the control module harness connector.
harness connector
to ON state.
Yes
Step 10
terminal).
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CA12 Electronic stability program control module harness connector the grounding on the vehicle body.
(b) Confirm whether the resistance meets the standard value.
No Repair or replace the harness or harness

connector.
Yes

BC ESP control unit CA12 and the terminal 2/12 of the gateway
CA08.

No
connector.
CA08 Gateway
Yes
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“ABS sensor device”.
Next Step
BC
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ESP OFF Warning Lamp is Always Lit or Never Lit

Circuit schematic:
ESC OFF
switch
Combination
instrument Gateway
BC
Diagnostic steps:

Yes
No

Yes

(a) Check whether the harness connector is connected
correctly.
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Yes
Step 4 Check the ESP switch.

(a) Disconnect the control module harness connector CA12.
(b) Press the ESP switch and measure the resistance
CA12 Electronic stability program control module harness connector between the terminal 6 of CA12 and the grounding on the
vehicle body with a multimeter.
(c) Turn off the ESP switch and use a multimeter to
measure the resistance between the terminal 6 of CA12
and the grounding on the vehicle body.
Standard resistance value: 10kΩ or higher
value.
No Replace the ESP switch.

BC
Yes
(a) Check whether the fuses EF03, EF04 and IF17are blown
Engine compartment fuse, relay box out.
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No
mode to OFF state.
CA12 Electronic stability program control

BC (c) Operate the starter switch to turn the power supply
module harness connector
mode to ON state.
hydraulic electronic control unit harness connector CA12
Yes
Step 7
terminal).
(a) Measure the resistance between the terminal 14/46 of
value.

No
connector.
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Yes
ESP control unit CA12 and the terminal 2/12 of the gateway
CA08.

No
connector.
BC
CA08 Gateway harness connector
Yes
Step 9 Replace the hydraulic electronic control unit..

(b) Connect the battery positive electrode.
after illumination.
No

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No
CA08 Gateway (b) Confirm whether the resistance meets the standard value.

No
connector.
BC
Yes

Next Step
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HDC Warning Lamp is Always Lit or Never Lit

Circuit schematic:
Central Switch
Combination
Gateway
instrument
BC
Diagnostic steps:

Yes
No

Yes

correctly.
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Yes
Step 4 Check the HDC switch.

(a) Disconnect the control module harness connector CA12.
(b) Engage the HDC switch and use a multimeter to
CA12 Electronic stability program control module harness connector measure the resistance between the terminal 6 of CA12
(c) Turn off the HDC switch and use a multimeter to
measure the resistance between the terminal 6 of CA12
Standard resistance: 10kΩ or higher
value.
No Replace the HDC switch.

BC
Yes

(a) Check whether the fuses EF03, EF04 and IF17 are
Engine compartment fuse, relay box blown out.
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No
mode to OFF state. BC
mode to ON state.
Yes
Step 7
terminal).

No
connector.
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Yes
ESP control unit CA12 and the terminal 2/12 of the gateway
CA12 Electronic stability program control module harness connector CA08.

No
co nector.
BC
CA08 Gateway
Yes

(b) Connect the battery positive electrode.
after illumination.
No

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No
CA08 Gateway Confirm whether the resistance meets the standard value.

No
connector.
BC
Yes

(a) Disconnect the negative battery cable. Refer to “Removal
Next Step
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Diagnosis of Power Supply Fault and Inner Fault of Hydraulic Electronic Control Unit Assembly
DTC Description
U100016 The ECU supply voltage is low
U100017 The ECU supply voltage is high
P00400e The motor is wrong
U130055 The variant content is wrong
P004003 The yaw angle sensor is wrong
P004015 The ESP valve is wrong
C100004 ECU hardware fault
C100104 CAN hardware fault
C100204 ABS/ESP control abnormal
C100304 Valve relay fault
C100409 Common valve fault (hardware fault)
C100498 Overheat of friction plate
C100504 Exhaust pump fault
C101204 Fault of left front liquid inlet valve
BC C101304 Fault of left front liquid outlet valve

C101404 Fault of right front liquid inlet valve
C101504 Fault of right front liquid outlet valve
C101604 Fault of left rear liquid inlet valve
C101704 Fault of left rear liquid outlet valve
C101804 Fault of right rear liquid inlet valve
C101904 Fault of right rear liquid outlet valve
C101A04 Fault of circuit control valve 1
C101B04 Fault of circuit control valve 2
C101C04 Fault of high-pressure control valve 1
C101D04 Fault of high-pressure control valve 2
C056E38 The ECU hardware/software is wrong
C056143 State of the caliper is unknown (due to eeprom fault)
C000900 The hydraulic module works in excess of limit
C0085 The initialization is not completed
C056D39 Fault of ESC host communication
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BC
Diagnostic steps:

Yes
No

Yes

correctly.
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Yes

(a) Check whether the fuses EF03, EF04 and IF17 are blown
Engine compartment fuse, relay box out.
BC
No
mode to OFF state.

mode to ON state.
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Yes
Step 6
terminal).

No
connector.
Yes
BC

Next Step
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Fault Diagnosis of Wheel Speed Sensor

Table of fault diagnosis Description
C100D01 Fault of left front wheel speed sensor (the specific fault reason is not detected)
C100D11 The left front wheel sensor is short to ground
C100D12 The left front wheel speed sensor is short to power supply
C100D13 Left front wheel speed sensor open circuit
C100D64 Signal fault of left front wheel speed sensor (excess of scope, loss, noise and discontinuity)
C100E01 Fault of right front wheel speed sensor (the specific fault reason is not detected)
C100E11 The right front wheel speed sensor is short to ground
C100E12 The right front wheel speed sensor is short to power supply
C100E13 Right front wheel speed sensor open circuit
C100E64 Signal fault of right front wheel speed sensor (excess of scope, loss, noise and discontinuity)
C100F01 Fault of left rear wheel speed sensor (the specific fault reason is not detected)
C100F11 The left rear wheel speed sensor is short to ground
C100F12 The left rear wheel speed sensor is short to power supply
C100F13 Left rear wheel speed sensor open circuit
BC C100F64 Signal fault of left rear wheel speed sensor (excess of scope, loss, noise and discontinuity)
C101001 Fault of right rear wheel speed sensor (the specific fault reason is not detected)
C101011 The right rear wheel speed sensor is short to ground
C101012 The right rear wheel speed sensor is short to power supply
C101013 Right rear wheel speed sensor open circuit
C101064 Fault of right rear wheel speed sensor (excess of scope, loss, noise and discontinuity)
C101104 Common fault of wheel speed sensor (replacement of sensor, fault of several sensors)
P004010 The left front wheel speed sensor is wrong
P004011 The right front wheel speed sensor is wrong
P004012 The left rear wheel speed sensor is wrong
P004013 The right rear wheel speed sensor is wrong
P004014 The direction of the wheel speed sensor is wrong
Notice
This maintenance manual only introduces the fault diagnosis of left front wheel speed sensor, and the diagnosis way of the
rest wheel speed sensors are similar. Please refer to “Fault diagnosis of wheel speed sensor”.
NL-3 01/2016
Circuit schematic:
Left rear wheel speed sensor
BC
Right front wheel speed sensor Right rear wheel speed Left front wheel speed sensor
sensor
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Diagnostic steps:
Step 1 Check the left front wheel speed sensor.
(a) Read the data stream of ABS system with diagnostic
scanner.
(b) One technician drives the vehicle and the other reads ABS
wheel speed value.
(c) Observe whether wheel speed value of Left front wheel is
consistent with that of the rest three wheels.
No Go to step 3.
Yes
Step 2 Check the left front wheel speed sensor.

(a) Eliminate the DTC with the diagnostic scanner.
(b) Test run the vehicle and read DTC again. Observe
whether DTC occurs.

BC No
Yes
Step 3 Check whether the left front wheel speed sensor harness connector is installed correctly.
(a) Check whether the left front wheel speed sensor harness
connector is installed correctly.
No Connect the harness connector properly.
Yes
Step 4 Check installation of the left front wheel speed sensor.

(a) Check whether the left front wheel speed sensor is
installed correctly.
Install the correctly the left front wheel

No
speed sensor.
Yes
Check the harness between the left front wheel speed sensor and the hydraulic electronic control
Step 5
unit.
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(b) Disconnect the ESP harness connector CA12 and
disconnect the left front wheel speed sensor harness
connector CA17.
(c) Measure the resistance between the terminal 1 of left front
wheel speed sensor harness connector CA17 and the
terminal 7 of ESP harness connector CA12.
(d) Measure the resistance between the terminal 2 of left front
wheel speed sensor harness connector CA17 and the
terminal 24 of ESP harness connector CA12.
(e) Confirm whether the measured value meets the standard
value.
Overhaul the line fault, and replace the

No
CA17 Left front wheel speed sensor harness harness if necessary.
BC
Yes
Step 6 Replace the left front wheel speed sensor.

(a) Replace the left front wheel speed sensor. Refer to “Front
wheel speed sensor”.
(b) Replace the left front wheel speed sensor and check
whether the fault is eliminated.
Install correctly the left front wheel speed

Yes
sensor.
No
Step 7 Replace the ESP control module.

(a) Replace the ESP control module.
Next Step
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Diagnosis of data communication fault

DTC Description
C100104 CAN hardware is wrong
C100664 Brake lamp switch fault
C100764 Signal fault of transverse acceleration sensor
C100864 Signal fault of longitudinal acceleration sensor
C100A64 Signal fault of yaw rate sensor
C100B08 Signal fault of reverse gear
C101E01 There is fault in circuit of the pressure sensor
C101E64 Signal fault of pressure sensor
C101F29 Fault of angle sensor
C101F54 Fault of calibration of angle sensor
P00401a The vacuum sensor is wrong
U007300 The CAN bus-off is wrong
U010087 The communication with engine control system is lost
U010187 The communication with transmission control system is lost
BC U012687 The communication with steering wheel angle sensor is lost

U014087 The communication with body controller is lost
U015187 The communication with airbag controller is lost
U023587 The communication with radar is lost
U031800 The ECU software is wrong
U040186 Engine control system signal invalid
U040286 Transmission control system signal invalid
U042286 The signal of body control system is invalid
U042886 Steering angle sensor signal invalid
U043386 The signal of radar system is invalid
U045286 The signal of airbag system is invalid
U051386 Invalid signal is received from ACU
U010082 The Message EMS_EngineRPM(ID=0x094) counter is wrong
U010083 The Message EMS_EngineRPM(ID=0x094) checksum is wrong
U012382 The airbag counter is wrong
U012383 The airbag checksum is wrong
U012682 The message SAS_Status counter is wrong
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DTC Description
U012683 The message SAS_Status checksum is wrong
U010287 The communication with 4WD system is lost
U010387 The communication with HVAC is lost
U010487 The communication with ICU is lost
U010587 The communication with PEPS is lost
U023582 The radar counter is wrong
U023583 The radar checksum is wrong
U040386 The signal of 4WD control system is invalid
U040486 The signal of HVAC system is invalid
U040586 The signal of ICU system is invalid
U040686 The signal of PEPS system is invalid
P00400d The steering angle sensor is wrong
P004008 The instrument display signal is interrupted
P004007 Fault of brake pipeline
P00400b PDM cannot be written in
BC
C006102 The transverse acceleration value is invalid
C006202 The longitudinal acceleration value is invalid
C006302 The yaw angle speed is invalid
C100300 The clutch switch is non-trusted
u000500 NET overvoltage
u000700 NET undervoltage
U100104 The NET communication is wrong
U160308 The signal of clutch is invalid
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Notice
When there is U code of data communication, first use fault diagnostic scanner to try to communicate with other control
modules and if failed, refer to “Data communication fault diagnosis”.
Circuit schematic:
BC
Diagnostic steps:
Step 1 Use the diagnostic scanner to visit the hydraulic electronic control unit.
to OFF state.
(b) Connect the fault diagnostic scanner to DTC fault
to ON state.
(d) Use the fault diagnostic scanner to try to communicate
with the hydraulic electronic control unit on D-CAN data line.
(e) Confirm whether the fault diagnostic scanner can
communicate with the hydraulic electronic control unit.
Yes Go to step 3.
Yes
Step 2 Check the battery.

(a) Measure the voltage of battery.
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Yes
(a) Check whether the fuses EF03, EF04 and IF17are

BC
No
Step 4 Check ESP data bus circuit.
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to OFF state.
(b) Disconnect the negative battery cable. Refer to “Removal
(c) Disconnect the hydraulic electronic control unit harness
connector CA12.
(e) Measure the resistance between the terminal 19 the
Standard resistance value: 10kΩ or higher
(f) Measure the resistance between the terminal 5 of
the terminal 2 of the gateway harness connector CA08.
(g) Measure the resistance between the terminal 19 of
the terminal 12 of the gateway harness connector CA08.
BC (h) Measure the resistance between terminals 2 and 12 of
gateway harness connector CA08.
Standard resistance value: 50~70Ω
(i) Confirm whether the resistance meets the standard value.
(j) Connect the battery negative cable.
(k) Measure the voltage between the terminal 5 of the
the grounding point.
(l) Measure the voltage between the terminal 19 of the
the grounding point.
Standard voltage value：0V
Yes
mode to OFF state.
to ON state.
Check the fuse, repair or replace the

No
harness.
Yes
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Step 6
terminal).
No Check the fuse, repair or replace the

harness.
Yes
Step 7 Replace the hydraulic electronic control unit. BC

(b) Confirm the repair is completed.
Next Step
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Diagnosis of electronic parking brake system fault

DTC Description
C102100 Right brake fault of automatic park brake
C102200 Left brake fault of automatic park brake
C102312 Fault of autohold button circuit
C102401 There is an electrical fault in autohold left brake
C10241E Fault of left brake line H axle of autohold brake
C102501 Electrical fault of right brake of automatic park brake
C10251E Fault of right brake line H axle of autohold brake
C102601 Common electrical fault of APB actuator driver
C102719 Overcurrent of left motor of automatic park brake
C102B62 The autohold brake is abnormal
C102C71 Catching of automatic park brake button
C15870B The current of the left electronic caliper is higher than the highest threshold value
C15870C The current of the left electronic caliper is lower than the lowest threshold value
C15880B The current of the right electronic caliper is higher than the highest threshold value
BC C15880C The current of the right electronic caliper is lower than the lowest threshold value
C056D36 The state of the caliper is unknown (due to abnormal power off)
C028B5A The vehicle slips
C056000 The caliper is excessively released
C056D38 Fault of memory write-in of the electronic caliper
C080003 Operating voltage of the caliper is too low
Notice
When there is U code of data communication, first use fault diagnostic scanner to try to communicate with other control
modules and if failed, refer to “Data communication fault diagnosis”.
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Circuit schematic:
EPB switch
EPB
backlight
AUTOHOLD
lamp
EPB indicator
backlight
lamp
indicator
Gateway
combination
To combination
IP17-9
instrument
instrument
To
BC
Left caliper Right caliper
Left rear wheel sensor Right rear wheel sensor
Diagnostic steps:
Go to Diagnostic trouble code (DTC) list and

Yes
No

No
Overhaul fault of the charging system
Yes

correctly.
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Yes
Step 4 Check whether the ESP fuse is blown out.

BC
No
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mode to OFF state.
mode to ON state.
(d) Measure the voltage between the terminal 1/30/36 of
(e) Confirm whether the voltage meets the standard
value.
Yes
Step 6
terminal).
(a) Measure the resistance between the terminal 14/46 of the BC

No
connector.
Yes

“ABS sensor device”
Repair is completed and the system

Yes
becomes normal.
No
Step 8 Check the EPB caliper harness connector.

correctly.
Yes
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Step 9 Check the EPB caliper harness connector (terminal voltage).

to OFF state.
SO74 Left caliper motor harness connector (b) Disconnect the caliper harness connector.
to ON state.
(d) Measure the voltage between the terminal 1/2 of the EPB
caliper harness connector SO74 and the grounding on the
vehicle body.
No Check the fuse, repair or replace the

harness.
Yes
Step 10 Check the EPB caliper control circuit.

BC (a) Disconnect the negative battery cable.
SO74 Left caliper motor harness connector mode to OFF state.
(c) Disconnect the ESP control unit harness connector
CA12.
(d) Disconnect the left caliper harness connector SO74.
(e) Measure the resistance between the terminal 1/2 of EPB
caliper harness connector SO74 and the terminal 12/13 of
CA12.
value

connector.
Yes
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Yes
Step 11 Replace the EPB control module assembly.

(b) Check whether EPB parking brake indicator lamp works
normally.
(c) Confirm the repair completed.
Next Step
BC
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Diagnosis of EPB Switch Fault

DTC Description
C102004 The PATA switch is wrong
Circuit schematic:
EPB switch
EPB
backlight
indicator
AUTOHOLD
lamp
AUTOHOL
D backlight
lamp
EPB
indicator
Gateway
To combination
IP17-9
To combination
IP17-10
instrument
instrument
BC
Diagnostic steps:
Go to Diagnostic trouble code (DTC) list and

Yes
No

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Yes

correctly.
Yes

BC
No
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mode to OFF state.
mode to ON state.
(d) Measure the voltage between the terminal 1/30/36 of
(e) Confirm whether the voltage meets the standard
value.
Yes
Step 6
terminal).
BC hydraulic electronic control unit harness connector CA12 and
CA12 electronic stability program control module harness connector

No
connector.
Yes

Yes Repair is completed and the system

becomes normal.
No
Step 8 Check the EPB switch harness connector.

(a). Check whether the harness connector is connected
correctly.
No
Connect the harness connector properly.
Yes
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Step 9 Check the EPB switch control module harness connector (conductivity of ESP terminal).
to OFF state.
IP83 EPB switch harness connector (c) Operate the starter switch to turn the power supply mode
to ON state.
(d) Measure the resistance between the terminal 1/3/4/6 /7 of
EPB switch control module harness connector IP83 and the
terminal 31/15/32/16/17 of CA12.
BC
Yes
Step 10 Check the EPB switch control module harness connector (conductivity of grounding terminal).
(a) Measure the resistance between the terminal 1/3/4/6 /7
of EPB switch control module harness connector IP83 and
the grounding point on the vehicle body.
IP83 EP switch harness connector Standard resistance value: Less than 1 Ω
value.

connector.
Yes
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Step 11 Replace the EPB switch control module assembly.

(b) Check whether the EPB switch works normally.
(c) Confirm the repair completed.
Next Step
BC
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BC Brake Control - ABS Sensor Device BC - 77
ABS Sensor Device

Component
controller)
ABS shock pad
ESC module fixing bracket
BC
Air filter
N·m(lb-ft): specified torque
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BC - 78 BC Brake Control - ABS Sensor Device
On-board Check
1. Select the fault diagnosis scanner
1) Adjust the ignition switch to ON state.
3). Start the engine and let it idle.
5) Enter the menu item for more detailed information.
Please refer to operation manual of the fault diagnostic
scanner.
Removal
filter”
5. Remove the ESP control module
BC 1) Press connector pin, pull up to lock the fastener and

disconnect the ESP harness connector.
2). Mark the positions for reconnection with labels or

records.
Tips:
① To the vacuum booster brake master cylinder.
② To the vacuum booster brake master cylinder.
③ To the left rear brake assembly.
④ To the right front brake assembly.
⑤ To the left front brake assembly.
⑥ To the right rear brake assembly.
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BC Brake Control - ABS Sensor Device BC - 79
3) Remove 6 collar nuts for the brake oil pipe from the ESP
control module and wipe off the spilt brake fluid
immediately.
4) Remove 2 fixing nuts between ESP control module and

module fixing bracket and remove the ESP control module.
BC
Installation
1. Install the ESP control module
1) Install 2 fixing nuts of the ESP control module bracket.
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BC - 80 BC Brake Control - ABS Sensor Device
2) Install 6 collars nuts for the brake oil pipe of the ESP
control module according to the label or the record.
Torque: 16N·m (Metric)12b-ft (English)
3) Press down the fastener and connect ESP control unit

harness connector.
4. Bleed the air in the brake system.
BC 5. Check whether the brake fluid leaks.
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BC Brake Control - Front Wheel Speed Sensor BC - 81
Front Wheel Speed Sensor

Component
BC
Vehicle wheel nut
Wheel assembly
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BC - 82 BC Brake Control - Front Wheel Speed Sensor
Front strut assembly
Front wheel speed sensor assembly (intelligent type)
BC
Bracket assembly of left front wheel speed sensor 2

Engine compartment harness assembly
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On-board Check
1. Run the vehicle right ahead
Accelerate the vehicle to 45 km/h (28 mph) or higher speed
and keep for several seconds and check whether the ABS
warning lamp goes out.
Notice
The sensor check may not be completed if any wheel slips.
ABS warning lamp will flash after the sensor check is
completed and the brake pedal is depressed.
Notice
ABS warning lamp will light up immediately if any fault is
detected in the course of speed sensor check.
2. Stop the vehicle.
Notice
The check of wheel speed sensor may not be completed if its
check is started when the steering wheel is turning or any
wheel is slipping.
The sensor check code will be stored again when the vehicle
speed exceeds 80 km/h (50 mph) after the ABS warning lamp
goes out. Decelerate or stop the vehicle before its speed BC
arrives at 80 km/h (50 mph).
ABS warning lamp will flash and ABS will not operate if the
sensor check is not completed. ABS does not run.
Notice
After the sensor check is completed, ABS warning lamp will
go out while the vehicle is running and will flash in the test
mode while the vehicle is static.
Removal
Notice
Left front and right front wheel speed sensors have similar
installation and removal methods.
4. Remove lining plate of left front fender. Refer to “Lining
plate of front fender”
5. Remove the front wheel speed sensor.
1). Disconnect the wiring harness connector of rear wheel
speed sensor.
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2) Remove fixing bolts of the front wheel speed sensor and

pull out the front wheel speed sensor.
3) Remove fixing bolts for brackets of the front wheel

speed sensor 1 and 2.
BC
4) Disconnect 5 clamps of the sensor harness.

5) Remove the front wheel speed sensor assembly.
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Installation
1. Install the front wheel speed sensor.
1) Install the front wheel speed sensor and using the bolt
with a flat washer to tighten.
2) Install fixing bolts for brackets of the front wheel

speed sensor 1 and 2.
Torque: 23 N·m (Metric) 17lb-ft(English)
BC
3) Fix 5 fixing clamps between the front wheel speed

sensor and the vehicle body.
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4) Connect the harness connector of front wheel speed

sensor.
2. Install the front fender liner.
3. Install front wheels.
BC
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BC Brake Control - Rear Wheel Speed Sensor (4WD) BC - 87
Rear Wheel Speed Sensor (4WD)

Component
BC
Vehicle wheel nut
Wheel assembly
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BC - 88 BC Brake Control - Rear Wheel Speed Sensor (4WD)
Left longitudinal beam body assembly of the rear floor
The bracket assembly of left rear wheel sensor 1
BC
Left rear wheel speed sensor assembly (4WD)
Rear brake assembly
Bottom plate harness assembly (4WD)
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On-board Check
Notice
completed and the brake pedal is depressed. ABS warning
lamp will light up immediately if any fault is detected in the
course of speed sensor check.
2. Stop the vehicle
Notice
The check of acceleration sensor and master cylinder
pressure sensor shall be completed before check of the
speed sensor.
The check of the speed sensor may not be completed if its
wheel is slipping.
ABS warning lamp will flash and ABS will not operate if the BC
Notice
Removal
Notice
Left rear and right rear wheel speed sensors have similar
4. Remove the rear wheel speed sensor.
1) Disconnect the harness connector of rear wheel speed
sensor.
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2) Remove the fixing bolts for rear wheel speed sensor.

3) Remove the rear wheel speed sensor.
Installation
1. Install the rear wheel speed sensor
1) Install fixing bolts of the rear wheel speed sensor and
install the rear wheel speed sensor.
BC

2. Install the rear wheel.
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Rear Wheel Speed Sensor (2WD)

Component
BC
Vehicle wheel nut
Wheel assembly
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BC
Left rear wheel speed sensor assembly (intelligent type)
The bracket assembly of left rear wheel
speed sensor 3
Rear brake assembly
Rear wheel sensor assembly (2WD)

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On-board Check
Notice
completed and the brake pedal is depressed. ABS warning
lamp will light up immediately if any fault is detected in the
course of speed sensor check.
2. Stop the vehicle
Notice
The check of acceleration sensor and master cylinder
pressure sensor shall be completed before check of the
speed sensor.
The check of the speed sensor may not be completed if its
wheel is slipping.
Sensor check the code will be stored again when the vehicle BC
speed exceeds 80 km/h(50 mph) after the ABS warning lamp
goes out. Decelerate or stop the vehicle before its speed
arrives at 80 km/h (50 mph).
ABS warning lamp will flash and ABS will not operate if the
Notice
Removal
Notice
Left rear and right rear wheel speed sensors have similar
4. Remove the rear wheel speed sensor.
1) Disconnect the harness connector of rear wheel speed
sensor.
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2) Remove the fixing bolts for rear wheel speed sensor.

3) Remove the rear wheel speed sensor.
Installation
1) Install fixing bolts of the rear wheel speed sensor and
install the rear wheel speed sensor.
BC

2. Install the rear wheel.
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Suspension System - Contents SP - 1
SP suspension system
Suspension System ....................................................................................................................SP - 5

Component Position (2WD) ....................................................................................................................................... SP - 5
Component position (4WD)........................................................................................................................................ SP - 6
Front Wheel Alignment ...............................................................................................................SP - 8

Adjustment ................................................................................................................................................................. SP - 8
Rear wheel alignment ............................................................................................................... SP - 11

Adjustment ............................................................................................................................................................... SP - 11
Front Subframe .........................................................................................................................SP - 12

Component .............................................................................................................................................................. SP - 12
Removal................................................................................................................................................................... SP - 17
Installation................................................................................................................................................................ SP - 18
Lower Swing Arm Assembly .................................................................................................... SP - 20

Component .............................................................................................................................................................. SP - 20
Removal................................................................................................................................................................... SP - 22
Installation................................................................................................................................................................ SP - 23 SP
Front strut assembly ................................................................................................................ SP - 25
Component .............................................................................................................................................................. SP - 25
Removal................................................................................................................................................................... SP - 27
Installation................................................................................................................................................................ SP - 29
Front vibration damper assembly ............................................................................................ SP - 31

Component .............................................................................................................................................................. SP - 31
Removal................................................................................................................................................................... SP - 34
Check....................................................................................................................................................................... SP - 35
Installation................................................................................................................................................................ SP - 36
Disposal ................................................................................................................................................................... SP - 36
Lower swing arm ball joint ....................................................................................................... SP - 38

Component .............................................................................................................................................................. SP - 38
Removal................................................................................................................................................................... SP - 40
Installation................................................................................................................................................................ SP - 41
Front Stabilizer Bar assembly .................................................................................................. SP - 43

Component .............................................................................................................................................................. SP - 43
Removal................................................................................................................................................................... SP - 44
Installation................................................................................................................................................................ SP - 45
SP - 2 Suspension System - Contents
Connecting rod of the front stabilizer bar ............................................................................... SP - 46

Component .............................................................................................................................................................. SP - 46
Removal................................................................................................................................................................... SP - 48
Installation................................................................................................................................................................ SP - 49
Steering Knuckle.......................................................................................................................SP - 50
Component .............................................................................................................................................................. SP - 50
Removal................................................................................................................................................................... SP - 54
Installation................................................................................................................................................................ SP - 58
Front wheel hub ........................................................................................................................SP - 62

Component .............................................................................................................................................................. SP - 62
On-board Check....................................................................................................................................................... SP - 66
Removal................................................................................................................................................................... SP - 66
Installation................................................................................................................................................................ SP - 70
Resonance block ......................................................................................................................SP - 75

Component .............................................................................................................................................................. SP - 75
Removal................................................................................................................................................................... SP - 77
Installation................................................................................................................................................................ SP - 77
SP
Front suspension crossbeam assembly ................................................................................. SP - 78
Component .............................................................................................................................................................. SP - 78
Removal................................................................................................................................................................... SP - 81
Installation................................................................................................................................................................ SP - 82
Longitudinal beam assembly of the front suspension ........................................................... SP - 83

Component .............................................................................................................................................................. SP - 83
Removal................................................................................................................................................................... SP - 87
Installation................................................................................................................................................................ SP - 87
Front suspension reinforcing plate ......................................................................................... SP - 89

Component .............................................................................................................................................................. SP - 89
Removal................................................................................................................................................................... SP - 90
Installation................................................................................................................................................................ SP - 91
Rear auxiliary frame (4WD)....................................................................................................... SP - 92

Component .............................................................................................................................................................. SP - 92
Removal................................................................................................................................................................. SP - 102
Installation.............................................................................................................................................................. SP - 103
Rear auxiliary frame (2WD)..................................................................................................... SP - 105

Component ............................................................................................................................................................ SP - 105
Removal................................................................................................................................................................. SP - 112
Installation.............................................................................................................................................................. SP - 112
Suspension System - Contents SP - 3
Rear vibration damper assembly ........................................................................................... SP - 114

Component ............................................................................................................................................................ SP - 114
Removal................................................................................................................................................................. SP - 115
Installation.............................................................................................................................................................. SP - 116
Rear stabilizer bar assembly (2WD)....................................................................................... SP - 117

Component ............................................................................................................................................................ SP - 117
Removal................................................................................................................................................................. SP - 119
Installation.............................................................................................................................................................. SP - 119
Rear stabilizer bar assembly (4WD)....................................................................................... SP - 121

Component ............................................................................................................................................................ SP - 121
Removal................................................................................................................................................................. SP - 124
Installation.............................................................................................................................................................. SP - 125
Rear Stabilizer Bar Connection Assembly ............................................................................ SP - 127

Component ............................................................................................................................................................ SP - 127
Removal................................................................................................................................................................. SP - 128
Installation.............................................................................................................................................................. SP - 128
Rear longitudinal arm and rear longitudinal arm mounting bracket assembly .................. SP - 130
SP
Component ............................................................................................................................................................ SP - 130
Removal................................................................................................................................................................. SP - 132
Installation.............................................................................................................................................................. SP - 133
Rear suspension swing arm 1 assembly............................................................................... SP - 135

Component ............................................................................................................................................................ SP - 135
Removal................................................................................................................................................................. SP - 137
Installation.............................................................................................................................................................. SP - 138
Rear suspension swing arm 2 and rear suspension spiral spring assembly ..................... SP - 139
Component ............................................................................................................................................................ SP - 139
Removal................................................................................................................................................................. SP - 141
Installation.............................................................................................................................................................. SP - 142
Rear suspension upper swing arm assembly ....................................................................... SP - 145

Component ............................................................................................................................................................ SP - 145
Removal................................................................................................................................................................. SP - 147
Installation.............................................................................................................................................................. SP - 148
Rear axle head seat (4WD) ..................................................................................................... SP - 150

Component ............................................................................................................................................................ SP - 150
Removal................................................................................................................................................................. SP - 156
Installation.............................................................................................................................................................. SP - 159
SP - 4 Suspension System - Contents
Rear axle head seat (2WD) ..................................................................................................... SP - 163

Component ............................................................................................................................................................ SP - 163
Removal................................................................................................................................................................. SP - 167
Installation.............................................................................................................................................................. SP - 169
Rear wheel hub assembly (2WD) ........................................................................................... SP - 172

Component ............................................................................................................................................................ SP - 172
Removal................................................................................................................................................................. SP - 175
On-board Check..................................................................................................................................................... SP - 175
Installation.............................................................................................................................................................. SP - 176
Rear wheel hub assembly (4WD) ........................................................................................... SP - 178

Component ............................................................................................................................................................ SP - 178
Removal................................................................................................................................................................. SP - 181
On-board Check..................................................................................................................................................... SP - 182
Installation.............................................................................................................................................................. SP - 183
SP
Suspension System - Suspension System SP - 5
Suspension System
Component Position (2WD)
SP
Rear suspension
Front suspension
NL-3 01/2016
SP - 6 Suspension System - Suspension System
Component Position (4WD)
Rear suspension (4WD)
SP
Front suspension
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Suspension System - Suspension System SP - 7
Table of fault symptoms

The vehicle is overloaded -
The front spring has low rigidity Replace the front spring
The rear spring has low rigidity Replace the rear spring
The vehicle sags Replace the front vibration damper. Please
The front vibration damper is worn
refer to "Front vibration damper assembly"
Replace the rear vibration damper. Please
The rear vibration damper is worn
refer to “Rear vibration damper assembly”
Exchange tires. Please refer to “Wheel and
The tire is worn
tire”
Replace the front stabilizer bar. Please refer
The front stabilizer bar is bent or ruptured
to “Front stabilizer bar assembly”
The rear stabilizer bar is bent or ruptured Replace the rear stabilizer bar. Please refer
(2WD) to “Rear stabilizer bar assembly (2WD)”
When the vehicle is tilting.
The rear stabilizer bar is bent or ruptured Replace the rear stabilizer bar. Please refer
(4WD) to “Rear stabilizer bar assembly (4WD)”
Replace front/rear vibration damper. Please
The front vibration damper (worn) the rear
refer to “Front vibration damper assembly
vibration damper (worn)
and the rear vibration damper assembly”
Left and right springs have different rigidity. Replace left/right spring
The tire is worn
tire”
The wheels lose balance Make dynamic balance of the wheels
Replace the vibration damper. Please refer
SP
Shock absorber wear; to “Front vibration damper assembly and the
rear vibration damper assembly”
Front wheel shimmy Re-align. Please refer to “Alignment of front
Front wheel alignment is incorrect;
wheels and alignment of rear wheels”.
Replace the lower swing arm ballhead.
The lower ball joint is worn Please refer to “Lower swing arm ballhead
assembly”
Hub bearing is worn Replace the bearing
The steering gear is damaged. Replace the steering gear
The tire is worn
tire”
The wheels lose balance Make dynamic balance of the wheels
Replace the vibration damper. Please refer
Shock absorber wear; to “Front vibration damper assembly and the
Rear wheel shimmy
rear vibration damper assembly”
Re-align. Please refer to “Alignment of front
Front wheel alignment is incorrect;
wheels and alignment of rear wheels”.
Hub bearing (2WD) is worn Replace the bearing
Hub bearing (4WD) is worn Replace the bearing
The tire is worn
tire”
Re-align. Please refer to “Alignment of front
Alignment of front wheels is wrong
wheels”.
Re-align. Please refer to "Alignment of rear
Abnormal tire wear Alignment of rear wheels is wrong
wheels".
Replace the front vibration damper. Please
The front vibration damper is worn
refer to "Front vibration damper assembly"
Replace the rear vibration damper. Please
The rear vibration damper is worn
refer to “Rear vibration damper assembly”
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SP - 8 Suspension System - Front Wheel Alignment
Front Wheel Alignment

Adjustment
1. Check the wheels
2. Measure height of the vehicle
Notice
Before check the alignment of wheels, adjust height of the
vehicle to the specified value. Be sure to measure on the
horizontal surface. When measurement under the vehicle
bottom is required, confirm the parking brake is applied and
the vehicle is fixed with stop wedges.
1) Make the vehicle bounce for several times at every
corner to stabilize its suspensions.
2) Measure height of the vehicle
Measuring point:
A: Ground clearance from the center of front wheels
B: Ground clearance from the center of fixing bolt at the
rear point of left/right lower swing arm assembly of the
front suspension
C: Ground clearance from the center of rear wheels
SP D: Ground clearance from the center of fixing bolt at the

front point of left/right rear longitudinal arm assembly
Height of the vehicle (2WD): A-B
Height of the vehicle (4WD): A-B
Height of the vehicle (2WD): C-D
Height of the vehicle (4WD): C-D
3. Check the wheel angles
1) Mark center of the tread on the last point of the turning
radius meter.
2) Turn the steering wheel left and right to the fully locked
position and measure the steering angle.
The maximum interior steering angle of front wheels 37.7°
Front The maximum exterior steering angle of front
wheels :31.6°
A: Inside
B: Outside
4. Check camber
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Suspension System - Front Wheel Alignment SP - 9
1) Install the alignment tester of front wheels tester and put

the front wheel at the center of the wheel alignment tester.
2) Check the camber angle, caster angle and inclination
angle.
Alignment tester Camber angle of front wheel: -0°20′±30′
Instrument
5. Adjustment of camber
Notice
Check the toe-in after adjustment of the camber angle.
1) Remove the front wheel.
2) Remove 2 connecting nuts between the front column
assembly and the steering knuckle.
Notice
Keep the bolts inserted.
3) Clean up installation surfaces of the front column SP
4) Temporarily install 2 nuts
5) Push or pull the front axle wheel hub to the bottom in the
desired adjustment direction as necessary.
6) Tighten up nuts.
7) Install front wheels.
6. Check camber
Use the following formula to calculate the required
adjustment amount if the measured value is out of the
specified scope.
Camber angle adjustment amount = the intermediate value of
the specified scope – the measured value.
Notice
Adjust the camber angle to the intermediate value of the
specified scope to the extent possible.
Notice
Replace nuts during replacement of bolts.
7. Check the toe-in
Toe-in of front wheels 0°±15'
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SP - 10 Suspension System - Front Wheel Alignment
8. Adjust the toe-in

1) Loose fixing nuts at both ends of the tie rod.
2) Adjust setting of toe-in of front wheels by rotating the tie
rod clockwise or counterclockwise.
3). Tighten the left and right fixing nuts at the two sides of
tie rod.
SP
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Suspension System - Rear Wheel Alignment SP - 11
Rear wheel Alignment

Adjustment
1. Check the wheels
2. Measure the height of vehicle. Refer to “Alignment of front
wheels”
3. Check the toe-in of rear wheels
1) Make the vehicle bounce for several times at every
corner to stabilize its suspensions.
2) Release the parking brake and set the gear shift lever to
the neutral position.
3) Push the vehicle right forward by around 5 m (16.4 ft.)
right ahead.
4) Mark the center of treads on the front wheels at the most
rear positions and measure the distance between marks.
5) Taking the front tire valves as reference points, push the
vehicle slowly right ahead to make its front wheels roll by
180°.
Notice
Don’t roll wheels by more than 180°.
6) Measure the distance between center marks on the front SP
treads of wheels.
Toe-in =B-A
The toe-in of rear wheels: 0°±15′
4. Adjust the toe-in of rear wheels
1) Keep the vehicle horizontal and free, measure values of
the rear wheels and adjust according to the standard
value.
2) Lock the lock nuts at both ends of the connecting sleeve
by the end of adjustment.
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SP - 12 Suspension System - Front Subframe
Front Subframe
Component
SP
Vehicle wheel nut
Wheel assembly
Tire valve assembly
Wheel trim cover
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Suspension System - Front Subframe SP - 13
SP
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Slotted nut
Front subframe
Left steering
knuckle
Split pin
SP
The lower swing arm ballhead of front suspension
The lower swing arm of front suspension
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Right front vibration damper assembly
Front Subframe
Front stabilizer bar link assembly
SP
Left front vibration damper assembly
Front Stabilizer Bar assembly
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Engine rear bracket
Mechanical steering gear with tie rod assembly
Right reinforcement plate of front suspension
SP
Front auxiliary frame assembly front suspension
Front suspension right longitudinal beam assembly
Front suspension left longitudinal beam assembly
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Removal
3. Remove the lower swing arm assembly. Refer to “Lower
swing arm assembly”
4. Remove the left longitudinal beam assembly and right
longitudinal beam assembly of the front suspension. Refer to
“Longitudinal beam assembly of front suspension”
5. Remove the front stabilizer bar assembly. Refer to “Front
stabilizer bar assembly”
6. Remove the front subframe assembly
1) Remove 2 connecting bolts and 2 nuts between the front
subframe and rear vibration isolating pad of the engine.
SP
2) Remove 2 connecting bolts between the front subframe

and the mechanical steering gear & tie rod assembly.
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3) Put a hydraulic jack under the subframe to jack up the

front subframe.
4) Remove 2 nuts connecting the front point of the front
subframe and the vehicle body.
5) Remove 2 connecting bolts between the rear point of

the front subframe and the vehicle body.
6) Remove the left/right reinforcing plate of the front
suspension.
7) Take out the front subframe.
SP
Installation
1. Install the front auxiliary frame.
1) Use a hydraulic jack to jack up the front subframe.
2) Install 2 connecting nuts between the front point of the
front subframe and the vehicle body.
Torque: 142N·m (Metric)104.8b-ft (English)
Notice
First apply pre-tightening torque and then tighten with the
specified torque after the front subframe is completely
installed.
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3) Install 2 connecting nuts between the rear point of the

front subframe and the vehicle body.
Torque: 180N·m (Metric ) 132.8lb-ft (English )
Notice
installed.
4) Install the left/right reinforcing plate of the front
suspension.
5) Install 2 connecting bolts between the front subframe

Bolt
Notice
installed.
SP
6) Install 2 connecting bolts and 2 nuts between the front

subframe and the rear vibration isolating pad of the engine.
Notice
installed.
2. Install the front stabilizer bar
3. Install the left/right longitudinal beam of the front
suspension.
4. Install the lower swing arm assembly.
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SP - 20 Suspension System - Lower Swing Arm Assembly
Lower Swing Arm Assembly

Component
SP
Vehicle wheel nut
Wheel assembly
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Suspension System - Lower Swing Arm Assembly SP - 21
Slotted nut
Front Subframe
Left steering
knuckle
Split pin
SP
The lower swing arm ballhead of
front suspension
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Removal
Notice
The right lower swing arm is the same as the left lower swing
arm in terms of removal and installation procedures.
The removal and installation procedures below are applicable
to the left lower swing arm.
Notice
Before starting the following removal procedures, turn the
steering wheel until it is locked.
2. Remove the lower swing arm assembly
1) Remove 2 connecting nuts and 1 bolt between the lower
swing arm assembly and the lower swing arm ballhead.
SP
2) Remove the connecting bolt between the lower swing

arm and the rear section of the front subframe.
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Suspension System - Lower Swing Arm Assembly SP - 23
3) Remove the connecting through bolt between the lower

swing arm and the front subframe.
4) Remove the lower swing arm assembly
Installation
Notice
Use the correct fastener in the correct location. Replacement
fasteners must be the correct part number for that application.
Fasteners requiring replacement or fasteners requiring the
use of thread locking compound or sealant are identified in
the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces
unless specified.
SP
These coatings affect fastener torque and clamp force and
may damage the fastener.
Use the correct tightening sequence and tightening torque
when installing fasteners in order to avoid damage to parts
and systems.
1. Install the lower swing arm assembly.
1) Install and tighten up the connecting through bolts
between the lower swing arm and the front section of the
front subframe.
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2) Install the connecting bolts between the lower swing arm

and the rear section of the front subframe.
Notice
Tighten the bolts by the specified torque after removing the
wheels.
3) Install 1 fixing bolt and 2 fixing nuts connecting the lower

swing arm and the lower swing arm ballhead.
SP
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Suspension System - Front Strut Assembly SP - 25
Front Strut Assembly

Component
SP
Vehicle wheel nut
Wheel assembly
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SP - 26 Suspension System - Front Strut Assembly
Left Front Column Assembly
SP
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Removal
Notice
The right front column assembly is the same as the left front
column assembly in terms of removal and installation
procedures.
to the left front column assembly.
2. Remove the front column assembly
1) Remove bolts on the wheel speed sensor bracket
connecting it to the front column assembly.
SP
2) Remove the clamp of the wheel speed sensor on the
front column assembly.
3) Disconnect pipeline of the wheel speed sensor.
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4) Remove 2 connecting bolts between the front column

5) Remove connecting nuts between the front column

assembly and the stabilizer bar connecting rod.
SP
6) Use the slotted screwdriver to remove dust cap on the

upper bracket of the front vibration damper.
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7) Remove 3 fixing nuts between the upper part of the front

vibration damper and the vehicle body.
8) Take out the front column assembly from the side of
wheel cover.
Installation
1. Install the front strut assembly
1) Put the front column assembly to the installation
position.
2) Fix 3 fixing nuts at the upper part.
Notice
First pre-tighten up 3 fixing screws of the column assembly
and bottom the wheel after installation with the brake. Then
SP
tighten up bolts with the specified torque and install dust cap
of the upper bracket.
3) Install the front shock absorber upper bearing dust

cover.
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4) Install 2 bolts and 2 nuts connecting the steering

knuckle and the front column assembly.
5) Install the connecting harness clamp between the wheel

speed sensor and the front column assembly.
SP
6) Install bolts on the wheel speed sensor bracket

connecting it to the front column assembly and connect
pipeline of the wheel speed sensor.
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Suspension System - Front Vibration Damper Assembly SP - 31
Front Vibration Damper Assembly

Component
SP
Vehicle wheel nut
Wheel assembly
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SP - 32 Suspension System - Front Vibration Damper Assembly
Left Front Column Assembly
SP
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Hexagon flange nuts
Dust cap of the front vibration

damper upper bracket
Helical spring of front
suspension Full metal hexagon flange locking nut
Front shock absorber upper bearer

assembly
Upper vibration isolator of front coil

spring
Front column bearing
Front coil spring lower vibration

isolator
Front shock absorber dust cap
SP
Front vibration damper

Front shock absorber buffer block
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Removal
Notice
The right front vibration damper assembly is the same as the
left front vibration damper assembly in terms of removal and
installation procedures.
to the left front vibration damper assembly.
2. Remove the front column assembly. Refer to “Front column
assembly”
3. Remove the front vibration damper assembly
1) Install 1 screw caps and 2 bolts on shock absorber
bracket, and then fix the front shock absorber assembly on
table vice.
SP
2) Use the spring compression tool to compress coil

spring;
Notice
You cannot use a pneumatic wrench; otherwise this will
damage the compression tool.
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3) Remove the dust cover of upper bearing of front shock

absorber, and use tool to fix spring bearing and remove
locknut.
4) Remove the upper bearing assembly of front shock

absorber, upper support of front coil spring, upper vibration
isolator of front suspension coil spring, coil spring of front
suspension, dust cover of front shock absorber, buffer
block of front shock absorber, lower vibration isolator of coil
spring.
SP
Check
1. Compress and extend the vibration damper rod for 4 or
more times.
Standard: no abnormal resistance or sound exists and
the operating resistance is normal.
Notice
In case of any abnormality, replace the front vibration damper
and re-perform the check operation.
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Installation
1. Install the front vibration damper assembly
1). Use the spring compression tool to compress coil
spring;
2). Install the front coil spring lower vibration isolator, front
shock absorber buffer block, front shock absorber dust
cover, front suspension coil spring, front suspension coil
spring upper vibration isolator, front coil spring upper
support, and front shock absorber upper bearing assembly
on shock absorber bracket.
Notice
SP
The lower end of the coil spring is installed on the notch of the
damper spring seat.
3) Install the locknuts.

Disposal
1. Disposal of the front vibration damper
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1) Put the front vibration damper assembly horizontally,

make the vibration damper rod fully extend as shown in the
figure, and use a drilling machine to drill in the middle of
point A and point B on the cylinder to exhaust gas inside
the cylinder.
Notice
 The gas is colorless, tasteless and toxic-free.
 Be careful during drilling as the metal chips may splash.
Therefore, be sure to use proper safety equipment.
SP
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SP - 38 Suspension System - Lower Swing Arm Ball Joint
Lower Swing Arm Ball Joint

Component
SP
Vehicle wheel nut
Wheel assembly
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Suspension System - Lower Swing Arm Ball Joint SP - 39
Slotted nut
Front Subframe
Left steering
knuckle
Split pin
SP
Front suspension lower swing arm ballhead
Front suspension lower swing arm
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Removal
Notice
The right lower swing arm ballhead assembly is the same as
the left lower swing arm ballhead assembly in terms of
removal and installation procedures
to the left lower swing arm ballhead assembly
2. Remove the lower swing arm ballhead assembly
1) Remove cotter pin 1 and hexagonal slotted nut 2
connecting the lower swing arm ballhead and the steering
knuckle.
SP
2) Remove 2 fixing nuts and 1 fixing bolt connecting the
lower swing arm ballhead and the lower swing arm.
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Suspension System - Lower Swing Arm Ball Joint SP - 41
3) Use the special tool to disconnect the connection

between the lower swing arm ballhead and the steering
knuckle.
Notice
Only use the general tools to separate the lower ball joint and
steering knuckle, and you should not remove the lower ball
joint from the steering knuckle with hand hammer or crowbar.
If you do not use the recommended tools, it will lead to
damages to lower ball joint and seals.
4) Remove the lower swing arm ballhead assembly.
Installation
1. Install the lower swing arm ballhead assembly
1) Install and tighten up the 1 fixing bolt between the lower
swing arm ballhead assembly and the lower swing arm
assembly.
SP
2) Install and tighten up 2 fixing nuts between the lower

assembly.
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3) Install and tighten up fixing nuts of the tie rod ballhead

and insert the cotter pin.
4). Snap the lower ball joint into the steering knuckle,
screw up the hexagon slotted nut 1 and engage cotter pin
2.
SP
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Suspension System - Front Stabilizer Bar Assembly SP - 43

Component
Front Subframe
SP
Front stabilizer bar bushing
Left front vibration

damper assembly
Front stabilizer bar

bushing
Front Stabilizer Bar

assembly
Right fixing bracket of the front

stabilizer bar
Left fixing bracket of the front stabilizer bar
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Removal
2. Lift the vehicle
3. Remove the stabilizer bar assembly.
1) Remove 2 nuts and 1 bolt between the lower swing arm
and the lower swing arm ballhead.
2) Disconnect the connection between the lower swing arm
and the lower swing arm ballhead.
3) Remove the connecting nut between the front stabilizer

bar and connecting rod of the front stabilizer bar.
SP
4) Remove 4 connecting bolts between the left fixing

bracket of the front stabilizer bar with lining assembly and
the front subframe.
5) Remove 4 connecting bolts between the right fixing
bracket of the front stabilizer bar with lining assembly and
the front subframe.
6) Remove the front stabilizer bar assembly.
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Suspension System - Front Stabilizer Bar Assembly SP - 45
Installation
1. Install the front stabilizer bar assembly.
1) Put the front stabilizer bar to the installation position and
install lining of the front stabilizer bar.
2) Install 4 connecting bolts between the left fixing bracket
of the front stabilizer bar and the front subframe.
Torque: 100N·m (Metric ) 74lb-ft (English )
3) Install 4 connecting bolts between the right fixing
bracket of the front stabilizer bar and the front subframe.
Notice
The installation position of the stabilizer bar lining is based on
the mark line indicated on the stabilizer bar
4) Instal 1 connecting nut between the stabilizer bar and
connecting rod of the stabilizer bar.
2. Install the left lower lower swing arm assembly of the front
suspension
3. Install the right lower lower swing arm assembly of the front
suspension
SP
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SP - 46 Suspension System - Connecting Rod Of The Front Stabilizer Bar
Connecting Rod of the Front Stabilizer Bar

Component
SP
Vehicle wheel nut
Wheel assembly
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Suspension System - Connecting Rod of The Front Stabilizer Bar SP - 47
Front Subframe
Left front vibration damper

SP
assembly
Right fixing bracket of the front stabilizer bar
Front stabilizer bar link

assembly
Left fixing bracket of the front stabilizer bar
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SP - 48 Suspension System - Connecting Rod Of The Front Stabilizer Bar
Removal
Notice
The connecting rod of the right front stabilizer bar is the same
as the connecting rod of the left front stabilizer bar in terms of
removal and installation procedures.
to the connecting rod of the left front stabilizer bar
2. Remove the connecting rod of the front stabilizer bar
1) Remove the connecting nut of front stabilizer connecting
rod and front stabilizer bar.
Notice
When removing, the ball pin need to be fixed by hexagon
head
SP
2) Remove the connecting nut of front stabilizer connecting
rod and front strut assembly.
Notice
When removing, the ball pin is fixed by hexagon head
3) Remove the connecting rod of the front stabilizer bar.
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Suspension System - Connecting Rod of The Front Stabilizer Bar SP - 49
Installation
1. Install the connecting rod of stabilizer bar
1) Install the connecting nut between the stabilizer bar and
connecting rod of the stabilizer bar.
2) Install the connecting nut between connecting rod of the

stabilizer bar and the front column assembly.
SP
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SP - 50 Suspension System - Steering Knuckle
Steering Knuckle
Component
SP
Vehicle wheel nut
Wheel assembly
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Suspension System - Steering Knuckle SP - 51
Slotted nut
Front Subframe
Left steering knuckle
Split pin
SP
The lower swing arm ballhead of front suspension
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SP

Engine compartment harness
assembly
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Left front constant velocity

drive shaft
Steering Knuckle
SP
Left lower swing arm assembly

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Removal
Notice
The right steering knuckle is the same as the left steering
knuckle in terms of removal and installation procedures.
to the left steering knuckle
2. Remove the lower swing arm ballhead assembly. Refer to
“Lower swing arm ballhead assembly”
3. Remove the steering knuckle
1) Remove bolts for fixing bracket of the front brake hose
fixing it on the steering knuckle.
SP
2) Remove the fixing bolt fixing the front wheel speed

sensor on the steering knuckle and disconnect the
connection between the front wheel speed sensor and the
steering knuckle.
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3) Remove two fixing bolts between the front brake caliper

assembly and the steering knuckle and disconnect the
brake disc & brake caliper assembly from the steering
knuckle.
Notice
It is not necessary to disconnect the brake oil pipe.
4) Remove the cotter pin next to ballhead of the

mechanical steering gear & tie rod.
SP
5) Remove the slotted nut next to the ballhead of the

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6) Use the special tool to separate the steering knuckle

7) Remove 2 connecting bolts between the steering

SP
8) Remove the semi-axle nut between the front wheel hub

and the drive shaft.
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9) Manually push the drive shaft outside to separate from

the steering knuckle.
10) Remove the fixing snap spring of front wheel hub
SP
11) Remove the front wheel hub from steering knuckle by

special tool GL401-001.
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12) Remove 4 connecting bolts between the front dust

cover and the steering knuckle.
13) Remove the front dust cover.
14) Remove the steering knuckle.
Installation
1. Install the steering knuckle.
1) Pad the wooden block with wheel hub, and install the
front wheel hub into front steering knuckle.
Notice
Protection bearing inner race cannot mismatch.
SP
2) Install the fixing snap spring of front wheel hub.
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3) Install cotter pins and slotted nuts between the

mechanical steering gear & tie rod assembly and the
steering knuckle.
4) Install 2 bolts between the steering knuckle and the front

column assembly.
Torque: 240N·m (Metric) 176.9 lb-ft(English)
SP
5) Install 4 connecting bolts between the front dust cover

and the steering knuckle.
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6) Push exterior end of the drive shaft into splined hole of

the steering knuckle and confirm it is pushed to due
position.
7) Install and tighten up the semi-axle nut between the

front wheel hub and the drive shaft and lock it to prevent
looseness.
Notice
When installation, the fixing nut need to be replaced a new
one.
SP
8) Install the fixing bolt of the front wheel speed sensor

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9) Install two fixing bolts between the front brake caliper

Torque: 110N·m (Metric ) or 77lb-ft (English )
10) Install the connecting bolt of the front brake hose fixing
it on the steering knuckle upper bracket.
SP
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SP - 62 Suspension System - Front Wheel Hub
Front Wheel Hub

Component
SP
Vehicle wheel nut
Wheel assembly
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Suspension System - Front Wheel Hub SP - 63
Slotted nut
Front Subframe
Left steering
knuckle
Split pin
SP
Lower swing arm ballhead of

front suspension
Lower swing arm of front suspension
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SP
Bracket assembly of left front wheel

Engine compartment harness speed sensor 2
assembly
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Left front vibration damper
Steering Knuckle
SP
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On-board Check
2. Remove the front brake caliper assembly. Refer to “Front
brake caliper assembly”
3. Remove the front brake disc. Refer to “Front brake caliper
assembly”
4. Check the looseness of the front wheel hub bearing
1) Use a dial indicator to check whether center of the front
wheel hub is loose.
Notice
Make sure the dial indicator is vertically placed on the
measuring surface.
5. Check the radial runout of the front wheel hub

SP
1) Use a dial indicator to check the radial runout on the
surface of axle wheel hub outside the wheel hub bolt
The maximum radial runout: 0.03 mm (0.0010 in.)
Notice
measuring surface.
Notice
Replace the front axle wheel hub if the radial runout exceeds
the maximum limit
6. Install the front brake disc.
7. Install the front brake caliper assembly
Removal
Notice
The right front wheel hub is the same as the left front wheel
hub in terms of removal and installation procedures
to the left front wheel hub
“Lower swing arm ballhead assembly”
3. Remove the front wheel hub
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1) Remove the connecting bolt fixing the front brake hose

on the steering knuckle upper bracket.
2) Remove the cotter pin next to the ballhead of the

SP
3) Remove the slotted nut next to the ballhead of the

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4) Use the special tool to separate the steering knuckle

5) Remove the fixing bolt fixing the front wheel speed

sensor on the steering knuckle and disconnect the
connection between the front wheel speed sensor and the
steering knuckle.
SP
6) Remove two fixing bolts between the front brake caliper

assembly and the steering knuckle and disconnect the
brake disc & brake caliper assembly from the steering
knuckle.
Notice
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7) Remove 2 connecting bolts between the steering

8) Remove the semi-axle nut between the front wheel hub

and the drive shaft.
SP
9) Manually push the drive shaft outside to separate from

the steering knuckle.
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10) Remove the fixing snap spring of front wheel hub
11) Remove the front wheel hub from steering knuckle by

special tool GL401-001.
12) Remove the front wheel hub.
SP
Installation
1. Install the front wheel hub
1) Pad the wooden block with wheel hub, and install the
front wheel hub into front steering knuckle.
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2) Install the fixing snap spring of front wheel hub.
3) Install cotter pins and slotted nuts between the

mechanical steering gear & tie rod assembly and the
steering knuckle.
SP
4) Install 2 bolts between the steering knuckle and the front

column assembly.
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position.
6) Install and tighten up the semi-axle connecting nut

between the front wheel hub and the drive shaft.
Notice
When installation, the fixing nut need to be replaced a new
one.
SP
7) Install the fixing bolt of the front wheel speed sensor

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8) Install two fixing bolts between the front brake caliper

9) Install connecting bolts fixing the front brake hose on the

steering knuckle upper bracket.
3. Install wheels.
SP
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SP
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Suspension System - Resonance Block SP - 75
Resonance Block
Component
SP
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SP - 76 Suspension System - Resonance Block
SP
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Suspension System - Resonance Block SP - 77
Removal
1. Lift the vehicle
3. Remove resonance block of the front subframe
1) Remove 2 fixing nuts on the resonance block of the front
subframe
2) Remove the resonance block.
Installation
1. Install two fixing nuts on the resonance block of the front
subframe. SP
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SP - 78 Suspension System - Front Suspension Crossbeam Assembly
Front Suspension Crossbeam Assembly

Component
SP
Vehicle wheel nut
Wheel assembly
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Suspension System - Front Suspension Crossbeam Assembly SP - 79
SP
Left front fender liner assembly

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SP
Front suspension crossbeam assembly
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Suspension System - Front Suspension Crossbeam Assembly SP - 81
Removal
2. Remove the engine left/right guard plate Please refer to
3. Remove the lining plate of the front fender. Refer to “Lining
plate of front fender”
4. Remove the front suspension crossbeam assembly
suspension crossbeam and the front vibration isolating pad
assembly of the engine.
SP
2) Remove the connecting bolt between the front
suspension crossbeam and the front suspension left
longitudinal arm and the front suspension right longitudinal
arm assembly.

suspension crossbeam and the vehicle body.
4) Remove the front crossbeam assembly.
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Installation
1. Install the front suspension crossbeam assembly
1) Install 4 connecting bolts between the front suspension
crossbeam and the vehicle body.
2) Install the connecting bolt between the front suspension

crossbeam and the front suspension left longitudinal arm
and the front suspension right longitudinal arm assembly.
SP
3) Install the connecting bolt between the front suspension

crossbeam and the engine vibration isolating pad.
2. Install the front fender liner.
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Suspension System - Longitudinal Beam Assembly Of The Front Suspension SP - 83
Longitudinal Beam Assembly Of The Front Suspension

Component
SP
Vehicle wheel nut
Wheel assembly
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SP - 84 Suspension System - Longitudinal Beam Assembly of The Front Suspension
Engine right guard plate assembly Engine left guard plate assembly
SP
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Suspension System - Longitudinal Beam Assembly of The Front Suspension SP - 85
Front suspension left SP

Front suspension crossbeam assembly
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Front suspension left longitudinal

SP beam assembly

assembly
NL-3 01/2016
Suspension System - Longitudinal Beam Assembly of The Front Suspension SP - 87
Removal
Notice
The right longitudinal beam assembly of the front suspension
is the same as the left longitudinal beam assembly of the front
suspension in terms of removal and installation procedures.
to the left longitudinal beam assembly of the front
suspension.
3. Remove the engine left/right guard plate Please refer to
4. Remove the longitudinal beam assembly of the front
suspension.
suspension longitudinal beam and the front suspension
crossbeam.
SP

suspension longitudinal beam and the front subframe.
3) Remove the left longitudinal beam assembly.
Notice
The right longitudinal beam assembly of the front suspension
is the same as the left longitudinal beam assembly of the front
suspension in terms of removal and installation.
Installation
1. Install the left longitudinal beam assembly of the front
suspension.
NL-3 01/2016
1) Put the left longitudinal beam of the front suspension to

the installation position.
2) Remove 2 connecting bolts between the left longitudinal
beam of the front suspension and the front subframe.
3) Install 2 connecting bolts between the left longitudinal

beam of the front suspension and the front suspension
crossbeam.
SP
NL-3 01/2016
Suspension System - Front Suspension Reinforcing Plate SP - 89
Front suspension reinforcing plate

Component
SP
Front suspension left reinforcing plate
NL-3 01/2016
SP - 90 Suspension System - Front Suspension Reinforcing Plate
Removal
Notice
The right reinforcing plate of the front suspension is the same
as the left reinforcing plate of the front suspension in terms of
to the left reinforcing plate of the front suspension.
1. Lift the vehicle
2. Remove the front suspension reinforcement girder
1) Install the 1 connecting bolt between the front
suspension reinforcing plate and the front subframe.
SP
suspension reinforcing plate and the vehicle body.
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Suspension System - Front Suspension Reinforcing Plate SP - 91
Installation
1) Install 2 connecting bolts between the front suspension
reinforcing plate and the vehicle body.
2) Install the 1 connecting bolt between the front

suspension reinforcing plate and the front subframe.
SP
NL-3 01/2016
SP - 92 Suspension System - Rear Auxiliary Frame (4WD)
Rear Auxiliary Frame (4WD)

Component
Vehicle wheel nut
SP
Wheel assembly
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Suspension System - Rear Auxiliary Frame (4wd) SP - 93
Rear rubber seat
Rear muffler assembly
SP
Sealing gasket of exhaust pipe
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Rear Subframe
Rear stabilizer bar assembly
SP
Rear Stabilizer Bar Connection
Assembly

Assembly
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Rear constant velocity drive shaft assembly
Rear main reducer and differential assembly
SP

Drive shaft assembly
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Rear suspension device (4WD)
SP
Rear main reducer and

differential assembly
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Install the vibration isolating cushion on rear spiral spring
Rear suspension limiter
Rear suspension spiral spring (2WD)
Rear Stabilizer Bar Connection Assembly
Lower bracket of rear spiral spring
Left swing arm 2 assembly of the rear suspension
Rear brake assembly
SP
Rear Subframe
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Rear Subframe
Rear brake assembly
Swing arm 1 subassembly of the rear

suspension
SP
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Rear suspension left upper swing arm assembly
Rear Subframe
SP
Rear brake assembly
The bracket assembly of left rear wheel speed sensor 1
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Rear Shock Absorber Assembly
Rear vibration damper lining
Rear Shock Absorber Dust Cap
SP
Mounting assembly of the rear vibration damper

Mounting bracket assembly of the left rear vibration damper
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SP
Rear subframe assembly (4WD)
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Removal
2. Remove the rear muffler. Refer to “Muffler”
3. Remove the rear constant velocity drive shaft assembly.
Refer to “Rear constant velocity drive shaft assembly（4WD)”
4. Remove the rear main reducer and differential assembly.
Refer to “Rear main reducer and differential assembly”
5. Remove the rear stabilizer bar assembly. Refer to “Rear
stabilizer bar assembly (2WD)”
6. Remove the torque manager assembly. Refer to “Torque
manager assembly”
7. Remove the rear suspension swing arm 2 assembly. Refer
to “Rear suspension swing arm 2 and rear suspension spiral
spring assembly”
to “Rear suspension swing arm 1 assembly”
9. Remove the rear suspension upper swing arm assembly.
Refer to “Rear suspension upper swing arm assembly”
10. Remove the rear vibration damper assembly. Refer to
“Rear vibration damper assembly”
SP
11. Disconnect pipelines on the rear subframe.
1) Loose locknut of the left rear brake rigid tube assembly
2 to make it separate from the brake hose assembly.
2) Remove the L-shaped spring clip and disconnect the
rear brake hose.
3) Disconnect harness of the wheel speed sensor.
4) Disconnect harness of the torque manager harness
connector.
12. Remove the rear subframe

5) Remove 2 connecting bolts and 2 nuts between the rear
6) Remove the rear subframe.
NL-3 01/2016
Installation
1. Install the rear subframe
1) Install 2 connecting bolts between front point of the rear
Torque: 160N·m (Metric ) 118.4 lb-ft (English )
2) Install 2 connecting bolts between rear point of the rear

Torque: 142N·m (Metric ) 105 lb-ft (English )
SP
NL-3 01/2016
2. Connect pipelines on the rear subframe

1) Install the L-shaped spring clip to connect it with the
brake hose assembly.
2) Tighten up locknut of the left rear brake rigid tube
assembly 2.
3) Connect harness of the wheel speed sensor.
4) Install harness of the torque manager harness
connector
3. Install the rear stabilizer bar assembly.
4. Install the rear vibration damper assembly
5. Install the upper swing arm assembly of the rear
suspension
6. Install the rear suspension swing arm 1 assembly
8. Install the torque manager assembly
9. Install the rear main reducer and differential assembly
10. Install the rear constant velocity drive shaft assembly
11. Install the rear muffler assembly
SP
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Suspension System - Rear Auxiliary Frame (2WD) SP - 105
Rear Auxiliary Frame (2WD)

Component
Vehicle wheel nut
SP
Wheel assembly
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Rear rubber seat
Rear muffler assembly
SP
Sealing gasket of exhaust pipe
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Rear Coil Spring Upper vibration isolator
Rear stabilizer bar connection assembly
Lower bracket of rear spiral spring
Rear brake assembly
SP
Rear Subframe
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Rear Subframe
Rear brake assembly

suspension
SP
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Rear suspension left upper

swing arm assembly
Rear Subframe
SP
Rear brake assembly
Bracket assembly of left rear wheel speed sensor 1
Bracket assembly of left rear wheel speed

sensor 3
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Rear vibration assembly
Rear shock absorber dust cover
SP
Mounting assembly of the rear vibration damper
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SP
Rear subframe assembly (2WD)
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Removal
spring assembly”
to “Rear suspension swing arm 1 assembly”
5. Remove the rear suspension upper swing arm assembly.
Refer to “Rear suspension upper swing arm assembly”
6. Remove the rear vibration damper assembly. Refer to
“Rear vibration damper assembly”
7. Remove the rear stabilizer bar assembly. Refer to “Rear
stabilizer bar assembly (2WD)”
8. Remove the rear subframe
1) Loose locknut of the left rear brake rigid tube assembly
2 to make it separate from the brake hose assembly.
2) Remove the L-shaped spring clip and disconnect the
rear brake hose.
3) Disconnect harness of the wheel speed sensor.
SP
4) Disconnect harness of the torque manager harness
connector.
5) Remove 4 connecting bots between the rear subframe

6) Remove the rear subframe.
Installation
1. Install the rear subframe
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1) Install 2 connecting bolts between the front point of the

rear subframe and the vehicle body.
2) Install 2 connecting bolts between rear point of the rear

Torque: 142N·m (Metric ) 105 lb-ft (English )
SP
3) Install the L-shaped spring clip.

4) Tighten up locknut of the left rear brake rigid tube
assembly 2.
5) Connect harness of the wheel speed sensor.
6) Install harness of the torque manager harness
connector
suspension
7. Install the rear muffler assembly
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SP - 114 Suspension System - Rear Vibration Damper Assembly
Rear Vibration Damper Assembly

Component
SP
Rear Shock Absorber Assembly
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Suspension System - Rear Vibration Damper Assembly SP - 115
Removal
Notice
The right rear vibration damper assembly is the same as the
left rear vibration damper assembly in terms of removal and
to the left rear vibration damper assembly
1. Lift the vehicle
2. Remove the rear vibration damper assembly
1) Remove 1 connecting bolt between the rear vibration
damper and the rear subframe.
SP
2) Remove 1 bolt between the rear vibration damper and
the mounting bracket of the rear vibrating damper.
3) Remove the rear vibration damper assembly.
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SP - 116 Suspension System - Rear Vibration Damper Assembly
Installation
1) Install 1 connecting bolt between the rear vibration
damper and the rear subframe.
2) Install 1 connecting bolt between the mounting bracket

of the rear vibration damper and the rear vibration damper.
SP
NL-3 01/2016
Suspension System - Rear Stabilizer Bar Assembly (2WD) SP - 117
Rear Stabilizer Bar Assembly (2WD)

Component
Vehicle wheel nut
SP
Wheel assembly
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SP - 118 Suspension System - Rear Stabilizer Bar Assembly (2WD)
Rear Subframe
SP
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Removal
1. Lift the vehicle
2. Remove the rear stabilizer bar assembly.
1) Remove the connecting nut between the rear stabilizer
bar and the connecting rod of rear stabilizer bar.
Notice
When removing, the ball pin is fixed by hexagon head
2) Remove 4 connecting nuts between the fixing clamp of

the rear stabilizer bar and the rear subframe.
3) Remove the rear stabilizer bar assembly.
SP
Installation
1) Install 4 nuts between the rear stabilizer bar and the rear
subframe.
Notice
Before installation of the stabilizer bar, assemble stabilizer
bar, lining and and fixing clamp on the specific installing tool
bench.
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2) Install the connecting nut between the rear stabilizer bar

and the connecting rod of stabilizer bar.
SP
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Rear Stabilizer Bar Assembly (4WD)

Component
Vehicle wheel nut
SP
Wheel assembly
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Lower base of the rear spiral spring
Rear brake assembly
SP
Rear Subframe
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SP
Rear main reducer and differential

assembly
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Rear Subframe
SP
Assembly
Removal
1. Lift the vehicle
spring assembly”
Notice
Remove 3 fixing bolts between the rear main reducer and
differential assembly and the subframe to leave the space for
removal and installation.
5. Remove the rear stabilizer bar assembly
bar and the connecting rod of left stabilizer bar.
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bar and the connecting rod of right stabilizer bar.
3) Remove 4 connecting nuts between the fixing clamp of

the rear stabilizer bar and the rear subframe.
4) Remove the rear stabilizer bar assembly.
SP
Installation
Notice
Before installation, assemble stabilizer bar, lining and and
fixing clamp on the specific installing tool bench.
1) Install 4 nuts between the rear stabilizer bar and the rear
subframe.
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and the connecting rod of right stabilizer bar.

and the connecting rod of left stabilizer bar.
3. Install 3 fixing bolts between the rear main reducer and the
subframe.
Notice
Be careful when installing the three bolts between the rear
SP main reducer and the subframe to prevent damage to their
threads.
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Suspension System - Rear Stabilizer Bar Connection Assembly SP - 127

Component
Rear Subframe
SP
Rear stabilizer bar connection

assembly
Rear stabilizer bar connection

assembly
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SP - 128 Suspension System - Rear Stabilizer Bar Connection Assembly
Removal
Notice
The connecting rod of right rear stabilizer bar is the same as
the connecting rod of left rear stabilizer bar in terms of
to the connecting rod of left rear stabilizer bar.
1. Lift the vehicle
2. Remove connecting rod assembly of the rear stabilizer bar
bar and the connecting rod of stabilizer bar and disconnect
the connection between the rear stabilizer bar and the
connecting rod of stabilizer bar.
SP
2) Remove the connecting nut between the stabilizer bar
connecting rod and the swing arm 2 assembly.
Notice
Use the hexagonal head tool to fix the axle head pin during
removal.
3) Remove the connecting rod assembly of stabilizer bar.
Installation
1. Install the connecting rod assembly of the rear stabilizer
bar
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Suspension System - Rear Stabilizer Bar Connection Assembly SP - 129
1) Install the connecting nut between the connecting rod of

rear stabilizer bar and the rear suspension swing arm 2
assembly.

and the connecting rod of stabilizer bar.
SP
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SP - 130 Suspension System - Rear Longitudinal Arm And Rear Longitudinal Arm Mounting Bracket Assembly
Rear Longitudinal Arm and Rear Longitudinal Arm Mounting Bracket Assembly
Component
Vehicle wheel nut
SP
Wheel assembly
NL-3 01/2016
Suspension System - Rear Longitudinal Arm And Rear Longitudinal Arm Mounting Bracket Assembly SP - 131
Left longitudinal beam large

assembly of the rear floor
Rear brake assembly
Mounting bracket of the left rear

longitudinal arm
SP
Left rear longitudinal arm assembly
NL-3 01/2016
Removal
Notice
The right rear longitudinal arm and the rear longitudinal arm
mounting bracket are the same as the left rear longitudinal
arm and the rear longitudinal arm mounting bracket in terms
of removal and installation procedures.
to the left rear longitudinal arm and the rear longitudinal arm
mounting bracket.
2. Remove the rear longitudinal arm and the rear longitudinal
arm mounting bracket assembly.
1) Remove 2 connecting bolts and nuts between the rear
longitudinal arm assembly and rear axle head seat.
SP
2) Remove 1 connecting nut between the rear longitudinal

arm assembly and the rear longitudinal arm mounting
bracket.
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Suspension System - Rear Longitudinal Arm And Rear Longitudinal Arm Mounting Bracket Assembly SP - 133
3) Remove 3 bolts between the rear longitudinal arm

mounting bracket and the vehicle body.
4) Remove rear longitudinal arm and the rear longitudinal

arm mounting bracket assembly and separate the rear
longitudinal arm assembly and the rear longitudinal arm
mounting bracket assembly.
SP
Installation
1. Install the rear longitudinal arm and the rear longitudinal
arm mounting bracket assembly.
1) Install 1 bolt between the rear longitudinal arm assembly
and rear longitudinal arm mounting bracket assembly.
Notice
Tighten up at the design height and control the direction of
the hollow lining towards the vehicle front and back.
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2) Install 3 bolts between the rear longitudinal arm

mounting bracket and the vehicle body.
3) Tighten up the 1 nut between the rear longitudinal arm

assembly and the rear longitudinal arm mounting bracket.
SP
4) Tighten up 2 nuts between the rear longitudinal arm

assembly and the rear axle head seat.
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Suspension system - Rear suspension swing arm 1 assembly SP - 135
Rear Suspension Swing Arm 1 Assembly

Component
Vehicle wheel nut
SP
Wheel assembly
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SP - 136 Suspension System - Rear Suspension Swing Arm 1 Assembly
Rear Subframe
Rear brake assembly
Swing arm 1 subassembly of

the rear suspension
SP
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Suspension System - Rear Suspension Swing Arm 1 Assembly SP - 137
Removal
Notice
The right rear suspension swing arm 1 is the same as the left
rear suspension swing arm 1 in terms of removal and
to the left rear suspension swing arm 1.
2. Remove the rear suspension swing arm 1 assembly
1) Remove the connecting bolt between the rear
suspension swing arm 1 assembly and the rear subframe.
SP
suspension swing arm 1 assembly and the rear axle head
seat.
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SP - 138 Suspension System - Rear Suspension Swing Arm 1 Assembly
Installation
1) Install the connecting nut between the rear suspension
swing arm 1 assembly and the rear axle head seat
2) Install the connecting bolt between the rear suspension

swing arm 1 assembly and the rear subframe.
3) Adjust the toe-in of the rear wheels to the target value
and tighten up according to the torque requirement.
SP
NL-3 01/2016
Suspension System - Rear Suspension Swing Arm 2 And Rear Suspension Spiral Spring Assembly SP - 139
Rear Suspension Swing Arm 2 and Rear Suspension Spiral Spring Assembly
Component
Vehicle wheel nut
SP
Wheel assembly
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SP - 140 Suspension System - Rear Suspension Swing Arm 2 And Rear Suspension Spiral Spring Assembly
Rear brake
assembly
SP
Rear Subframe
NL-3 01/2016
Removal
Notice
The right rear suspension swing arm 2 and the rear
suspension spiral spring are the same as the left rear
suspension swing arm 2 and the rear suspension spiral
spring in terms of removal and installation.
to the left rear suspension swing arm 2 and the rear
suspension spiral spring.
2. Remove the rear suspension swing arm 2 and rear
suspension spiral spring assembly
Notice
Remove the rear suspension swing arm 2 assembly
previously jacked up by the hydraulic jack.
suspension swing arm 2 assembly and the rear axle head
seat.
SP
2) Remove the connecting nut between the rear

suspension swing arm 2 and the connecting rod of rear
stabilizer bar.
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4) Slowly lower the hydraulic jack and gradually release

compression force of the rear suspension spiral spring.
5) Remove the rear suspension spiral spring, then the
upper vibration isolating pad of the rear suspension spiral
spring and finally the lower base of the rear spiral spring.
6) Remove the rear suspension swing arm 2.
SP
Swing arm 2
Installation
1. Install the rear suspension swing arm 2 and the rear
suspension spiral spring assembly
1) Install the upper vibration isolating pad of the rear
suspension spiral spring and the suspension spiral spring.
Notice
Keep the end of spring with a color mark upward and match
with vibration isolating pad of the spring.
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2) Install 1 connecting bolt and nut between the rear

Notice
Don’t tighten up the connection between the rear suspension
swing arm 2 assembly and the rear subframe with the
specified torque.
3) Align the locating pin shaft of the rear suspension spiral

spring lower base with the locating hole of the rear
suspension swing arm 2 and assemble them.
Notice
The locating pin of the spring lower base shall face the small
hole in the front and back direction of the vehicle, otherwise
unpredictable consequence could occur.
SP
4) Install the rear suspension spiral spring and use the

hydraulic jack to jack up the rear suspension swing arm 2.
Swing arm 2
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5) Install the connecting bolt and nut between the rear

suspension swing arm 2 assembly and rear axle head
seat: 115N·m (Metric) 84.8lb-ft (English)
6) Adjust camber angle of rear wheels to the standard

value.
7) Tighten up the connecting nut between the rear
SP
8) Tighten up the connecting nut between the rear

suspension swing arm 2 and the connecting rod of rear
stabilizer bar.
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Suspension System - Rear Suspension Upper Swing Arm Assembly SP - 145
Rear Suspension Upper Swing Arm Assembly

Component
Vehicle wheel nut
SP
Wheel assembly
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SP - 146 Suspension System - Rear Suspension Upper Swing Arm Assembly
Bottom plate harness

assembly (4WD)
Rear suspension left upper swing

arm assembly
Rear Subframe
SP Rear brake assembly
NL-3 01/2016
Removal
Notice
The right rear suspension upper swing arm is the same as the
left rear suspension upper swing arm in terms of removal and
to the left rear suspension upper swing arm.
2. Remove the rear suspension upper swing arm assembly
1) Remove the connecting nut between the rear
suspension upper swing arm assembly and two harness
fixing brackets of the wheel speed sensor and disconnect
harness of the wheel speed sensor.
SP
2) Remove 1 bolt between the rear suspension upper
swing arm assembly and the rear subframe.
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SP - 148 Suspension System - Rear Suspension Upper Swing Arm Assembly
3) Remove the connecting bolt and nut between the rear

suspension upper swing arm and the rear axle head seat.
Installation
suspension
suspension upper swing arm assembly and the rear
subframe
Notice
Don’t tighten with specified torque temporarily
SP

suspension upper swing arm assembly and rear axle head
seat.
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suspension upper swing arm assembly and the rear
subframe
Notice
Tighten up at the design height.
4) Install 2 connecting nuts for the pipeline bracket of

wheel speed sensor on the rear suspension upper swing
arm assembly.
SP
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SP - 150 Suspension system - Rear axle head seat (4WD)
Rear Axle Head Seat (4WD)

Component
Vehicle wheel nut
SP
Wheel assembly
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Suspension System - Rear Axle Head Seat (4WD) SP - 151
Rear auxiliary frame
Rear brake assembly

suspension
SP
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SP - 152 Suspension System - Rear Axle Head Seat (4WD)
Left rear wheel speed sensor assembly (4WD)
SP
Bracket assembly of left rear wheel speed sensor

1
Rear brake assembly
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Rear brake hose assembly

Rear axle head seat
Left rear EPB integrated caliper assembly
Rear brake baseplate SP
Rear brake disc
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Left longitudinal beam large assembly of the rear floor
Rear brake assembly
SP Mounting bracket of the left rear longitudinal arm
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Rear vibration damper

assembly
Rear constant-velocity drive shaft
Mounting bracket assembly of the left rear

vibration damper
SP
Rear axle head

assembly
Rear brake assembly
Swing arm 1 subassembly of the rear suspension
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Removal
Notice
The dismantling/installing procedures of right and left rear
axle head assembly are the same
The following listed procedures are applicable to the left rear
axle head assembly
3. Remove wheels. Refer to "Wheel and tire"
to "Rear suspension swing arm 1 assembly"
5. Remove rear wheel speed sensor assembly. Please refer
to t "Rear wheel speed sensor (2WD)"
6. Remove the rear axle head assembly
1) Remove the nut at the connection between rear
constant-velocity drive shaft and rear wheel hub
SP
2) Remove 2 bolts at the connection between rear brake

caliper assembly and rear axle head seat
3) Disconnect the brake disc with brake caliper assembly
from rear wheel hub assembly
Notice
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4) Remove 2 connecting bolts between the rear axle head

seat and the rear vibration damper mounting bracket
5) Remove connecting bolt between the rear axle head

seat and the rear suspension longitudinal arm
SP
6) Remove connecting bolt between the rear axle seat and

the rear suspension 2nd longitudinal arm
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the rear suspension upper swing arm assembly
8) Disconnect the connection between rear axle head seat

and rear constant-velocity drive shaft
SP
9) Remove 4 connecting bolts between the rear axle head

seat and the rear wheel hub
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10) Remove 1 connecting bolt between the rear axle head

seat and the rear brake baseplate, remove rear brake
baseplate
11) Remove the rear axle head seat
Installation
1. Install the rear axle head seat
1) Install and fasten the bolt at the connection between
rear brake baseplate and rear axle head seat
Torque: 10 N·m (Metric) 7 lb-ft(English)
SP
2) Install 4 bolts at the connection between rear axle head

seat and rear wheel hub
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3) Install the rear constant-velocity drive shaft into the

installation hole of rear axle head seat, make sure it is in
place
4) Install the rear axle head seat, and fasten 2 fixing bolts
between rear longitudinal arm and rear axle head seat
SP
5) Install and tighten up the nut at the connection between

2nd swing arm and subframe
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6) Install and fasten through bolt between rear suspension

upper swing arm and rear axle head seat
7) Install and fasten the nut at the connection between rear

vibration damper seat and rear axle head seat
SP
8) Install 2 bolts at the connection between rear brake

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9) Install the nut at the connection between rear

3. Install the rear wheel speed sensor assembly
SP
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Rear Axle Head Seat (2WD)

Component
Vehicle wheel nut
SP
Wheel assembly
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Rear Subframe
Rear brake assembly

SP suspension
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Rear Subframe
SP
Rear brake assembly
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Mounting bracket assembly of the left

rear vibration damper
SP
Rear axle head

assembly
Rear brake assembly
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Removal
Notice
axle head assembly are the same
axle head assembly
5. Remove rear wheel speed sensor assembly. Please refer
to t "Rear wheel speed sensor (2WD)"
6. Remove rear axle head seat assembly
Notice
SP
3) Remove 2 bolts at the connection between rear axle

head seat and rear vibration damper mounting bracket
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4) Remove the bolt at the connection between rear axle

head seat and rear suspension longitudinal arm

the rear suspension 2nd longitudinal arm
SP

the rear suspension upper swing arm assembly
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7) Remove 4 bolts at the connection between rear axle

head seat and rear wheel hub
8) Remove 1 bolt at the connection between rear axle

head seat and rear brake baseplate, remove rear brake
baseplate
9) Remove the rear axle head seat
SP
Installation
1. Install the rear axle head seat
1) Install the rear axle head seat
2) Install and fasten the bolt at the connection between
rear brake baseplate and rear axle head seat
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3) Install 4 bolts at the connection between rear axle head

seat and rear wheel hub
4) And fasten 2 fixing bolts between rear longitudinal arm

and rear axle head seat
SP
5) Install and fasten the nut at the connection between 2nd

swing arm and rear axle head seat
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6) Install and fasten through bolt between rear suspension

upper swing arm and rear axle head seat
7) Install and fasten the nut at the connection between rear

vibration damper seat and rear axle head seat
SP

3. Install the rear wheel speed sensor assembly
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SP - 172 Suspension System - Rear Wheel Hub Assembly (2WD)
Rear Wheel Hub Assembly (2WD)

Component
Vehicle wheel nut
SP
Wheel assembly
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Suspension System - Rear Wheel Hub Assembly (2wd) SP - 173
Rear suspension left upper swing arm

assembly
Rear brake assembly

SP
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Rear suspension assembly (2WD)
SP
Rear axle head assembly
Rear wheel hub assembly (2WD)
Rear brake caliper with brake disc assembly
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Removal
Notice
wheel hub are the same
wheel hub
3. Remove the rear wheel. Refer to "Wheel and tire"
4. Remove the rear wheel speed sensor. Please refer to
"Rear wheel speed sensor" (2WD)
5. Remove the rear wheel hub assembly
Notice
SP
3) Remove 4 fixing bolts at the connection between rear

wheel hub and rear axle head seat, remove rear wheel hub
assembly
On-board Check
1. Lift the vehicle
3. Check laxity of rear wheel hub bearing
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Notice
3) Use dial indicator to check whether the front axle wheel

hub center around is loose
Notice
measuring surface.
SP
4. Check rear wheel hub’s radial runout

1) Use dial indicator to check wheel hub surface outside of
wheel hub bolt’s radial runout
Notice
measuring surface.
Notice
Replace the front axle wheel hub if the radial runout exceeds
the maximum limit
Installation
1. Install rear wheel hub assembly
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1) Install 4 fixing bolts at the connection between rear

wheel hub and rear axle head seat
Torque: 104N·m (Metric) 76.6b-ft (English)

SP
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Rear Wheel Hub Assembly (4WD)

Component
Vehicle wheel nut
SP
Wheel assembly
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Suspension System - Rear Wheel Hub Assembly (4WD) SP - 179
Rear brake assembly

SP
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SP
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Removal
Notice
wheel hub are the same
wheel hub
4. Remove the rear wheel hub assembly
1) Remove the locking nut outside the connection between
drive shaft and rear wheel hub
SP

Notice
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6) Remove the rear wheel hub assembly
On-board Check
1. Lift the vehicle
3.Check laxity of rear wheel hub bearing
SP

Notice
NL-3 01/2016
5) Use the dial indicator to check whether is loose or not

near the rear axle wheel hub center
Notice
measuring surface.
4. Check rear wheel hub’s radial runout

1) Use a dial indicator to check the radial runout on the
surface of axle wheel hub outside the wheel hub bolt
Notice
measuring surface.
Notice
Replace the front axle wheel hub if the radial runout exceeds SP
the maximum limit
5. Install the rear brake disc
6. Install the rear brake caliper assembly
Installation
1. Install rear wheel hub assembly
1) Install 4 fixing bolts at the connection between rear
NL-3 01/2016

3) Install the locking nut outside the connection between

SP
NL-3 01/2016
Constant-Velocity Drive Shaft - Contents DS-1
DS Constant-Velocity Drive Shaft
Constant-Velocity Drive Shaft System ............................................................................................................................DS- 3
Table Of Fault Symptoms............................................................................................................................................DS- 3

Component Position (6MT-2WD) ................................................................................................................................DS- 4
Component Position (6AT-4WD) .................................................................................................................................DS- 5
Component Position (6AT-2WD) .................................................................................................................................DS- 6
Front Constant-Velocity Drive Shaft ................................................................................................................................DS- 7
Component .................................................................................................................................................................DS- 7
Removal....................................................................................................................................................................DS- 13
Disassembling ..........................................................................................................................................................DS- 19
Check........................................................................................................................................................................DS- 20
Assembling ...............................................................................................................................................................DS- 21
Installation .................................................................................................................................................................DS- 22
Front Constant-Velocity Drive Shaft Oil Seal ................................................................................................................DS- 27
Component ...............................................................................................................................................................DS- 27
Removal....................................................................................................................................................................DS- 32
Drive Shaft Assembly (4WD) ..........................................................................................................................................DS- 33
Component ...............................................................................................................................................................DS- 33
DS
Removal....................................................................................................................................................................DS- 34
Installation .................................................................................................................................................................DS- 35
Rear Main Reducer And Differential Oil ........................................................................................................................DS- 37
Adjustment ................................................................................................................................................................DS- 37
Right Constant Velocity Drive Shaft Assembly (4WD) .................................................................................................DS- 38
Component ...............................................................................................................................................................DS- 38
Removal....................................................................................................................................................................DS- 44
Disassembling ..........................................................................................................................................................DS- 46
Check........................................................................................................................................................................DS- 47
Assembling ...............................................................................................................................................................DS- 48
Installation .................................................................................................................................................................DS- 48
Rear Main Reducer And Differential Assembly ............................................................................................................DS- 51
Component ...............................................................................................................................................................DS- 51
Removal....................................................................................................................................................................DS- 57
Installation .................................................................................................................................................................DS- 58
NL-3 01/2016
DS-2 Constant-Velocity Drive Shaft - Contents
Rear Constant-Velocity Drive Shaft Oil Seal .................................................................................................................DS- 59
Component ...............................................................................................................................................................DS- 59
Removal....................................................................................................................................................................DS- 64
Installation .................................................................................................................................................................DS- 64
Torque Manager Assembly .............................................................................................................................................DS- 65
Component ...............................................................................................................................................................DS- 65
Removal....................................................................................................................................................................DS- 66
Installation .................................................................................................................................................................DS- 67
Intelligent Torque Manager Control Unit .......................................................................................................................DS- 68
Component ...............................................................................................................................................................DS- 68
Removal....................................................................................................................................................................DS- 70
Installation .................................................................................................................................................................DS- 71
DS
NL-3 01/2016
Constant-Velocity Drive Shaft - Constant-Velocity Drive Shaft System DS-3
Constant-Velocity Drive Shaft System

Symptoms Suspected Parts: Measures/References
Abrasion on front constant-velocity
Front wheel shimmy
drive shaft
Abrasion on rear constant-velocity drive
Rear wheel shimmy
shaft (4WD)
DS
NL-3 01/2016
DS-4 Constant-Velocity Drive Shaft - Constant-Velocity Drive Shaft System
Component Position (6MT-2WD)
DS
Manual gearbox
Left front constant velocity drive shaft assembly
NL-3 01/2016
Constant-Velocity Drive Shaft - Constant-Velocity Drive Shaft System DS-5
Component Position (6AT-4WD)
Right rear constant-velocity drive

Intelligent torque manager control unit shaft assembly
Right front constant velocity drive shaft
Left rear constant-velocity drive shaft

assembly
DS
Power takeoff (PTO)
NL-3 01/2016
DS-6 Constant-Velocity Drive Shaft - Constant-Velocity Drive Shaft System
Component Position (6AT-2WD)
DS
NL-3 01/2016
Constant-Velocity Drive Shaft - Front Constant-Velocity Drive Shaft DS-7
Front Constant-Velocity Drive Shaft

Component
DS
Vehicle wheel nut
Wheel assembly
NL-3 01/2016
DS-8 Constant-Velocity Drive Shaft - Front Constant-Velocity Drive Shaft
DS
NL-3 01/2016
Slotted nut
Left steering knuckle
Split pin
DS
The lower swing arm

ballhead of front suspension
NL-3 01/2016
Left front constant

velocity drive shaft
Steering Knuckle

DS
NL-3 01/2016
Right constant velocity drive shaft assembly (4G18TD_6MT)

Right constant velocity drive shaft assembly (4G20_6MT)


Right front constant velocity drive shaft assembly (4G246AT)
DS
Left front constant velocity drive shaft

assembly (AT)
NL-3 01/2016
Left front constant-velocity drive shaft (2WD)
Right front constant-velocity drive shaft (2WD)
DS
NL-3 01/2016
Removal
3. Remove the left front constant-velocity drive shaft (2WD)
1) Remove the cotter pin at the connection between
mechanical steering gear with tie rod ballhead and left
knuckle.
2) Remove the slotted nut at the connection between

mechanical steering gear with tie rod ballhead and left
knuckle.
DS

between tie rod and steering knuckle
NL-3 01/2016
4) Remove 2 fixing nuts and 1 fixing bolt at the connection

between lower swing arm ballhead and lower swing arm
5) Use the crowbar to disconnect the connection between
lower swing arm ballhead assembly and lower swing arm
assembly
6) Use hand to push left drive shaft outwards to let it

disconnect from left steering knuckle
DS
7) Use the special tool Gl401-002 to remove left drive shaft
NL-3 01/2016
4. Remove the right front constant-velocity drive shaft

assembly (2WD)
1) Remove 3 bolts at the connection between bearing
bracket and engine
2) Remove the cotter pin at the connection between

mechanical steering gear with tie rod ballhead and right
steering knuckle
DS

steering knuckle
NL-3 01/2016

between tie rod ballhead and right steering knuckle

assembly
DS
7) Use hand to push left drive shaft outwards to disconnect

it from right steering knuckle
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8) Take out the right drive shaft with special tool

Gl401-002.
5. Remove the right front constant-velocity drive shaft

assembly (4WD)
1) Remove the bearing fixing bolt, and remove circlip
DS
2) Remove 3 fixing bolts on bearing fixing bracket
NL-3 01/2016

steering knuckle

between tie rod ballhead and right steering knuckle
DS

assembly
NL-3 01/2016
7) Use hand to push left drive shaft outwards to disconnect

it from right steering knuckle
8) Use the special tool Gl401-002 to remove right drive

shaft
DS
Disassembling
1. Disassemble the left front constant-velocity drive shaft
assembly
1) Remove the large clamp at the connection between
mobile dust cover and skid tripod universal joint
2) Small clamp connecting mobile dust cover and middle
shaft
3) Remove the skid tripod universal joint and mobile dust
cover
NL-3 01/2016

fixed constant-velocity universal joint and fixed dust cover
5) Remove the small clamp at the connection between
fixed dust cover and middle shaft
6) Remove the fixed constant-velocity universal joint and
fixed dust cover, skid tripod universal joint
Notice
Make fitting marks at fixed constant-velocity universal joint
and middle shaft
Notice
Cannot use drift to make marks
2. Disassemble the right front constant-velocity drive shaft
1) Use the same method as disassembling left front
constant-velocity drive shaft to remove right front
constant-velocity drive shaft upper clamp, fixed
constant-velocity universal joint, fixed dust cover, middle
shaft, clamp 1, mobile dust cover
2) Remove 2 dust caps and dust cap rings from long
handle slide bush
3) Use the plier to tighten up bearing collar 1, remove
bearing bracket
4) Remove the bearing end collar 2, remove bearing
Notice
DS
Make bearing bracket as spare parts alone, removable; do
not replace bearing alone
Check
1. Check the left front constant-velocity drive shaft assembly,
right front constant-velocity drive shaft assembly
1) Check the dust cover for damages
2) Check and make sure the gap on skid tripod universal
joint radial is not too big
3) Check and make it is smooth when skid tripod universal
joint is sliding upwards
4) Check and make sure the gap in fixed constant-velocity
universal joint is not too big
NL-3 01/2016
Assembling
1. Assemble the left front constant-velocity drive shaft
assembly
1) Assemble the clamp at the connection between fixed
constant-velocity universal joint and fixed dust cover
following the fitting marks
2) Assemble the middle shaft, fixed dust cover and small
clamp following the fitting marks
3) Assemble the skid tripod universal joint, mobile large
clamp, small clamp
4) Use the special tool to assemble ABS gear ring following

the fitting marks
DS
2. Assemble the right front constant-velocity drive shaft

1) Use the same method as assembling left front
constant-velocity drive shaft to assemble right front
constant-velocity
2) Assemble the bearing, bearing collar 2, bearing collar 1,
bearing bracket, dust cover lining, 2 dust caps
NL-3 01/2016
Installation
1. Install the left front constant-velocity drive shaft
1) Remove the left front constant-velocity drive shaft input
shaft oil seal cover
2) Install the inside drive shaft to gearbox hole input shaft
mounting hole, make sure it is in place, then pull reversely,
obvious tension can be felt from circlip

position.
DS
4) Connect the cotter pin and slotted nut at the connection

between mechanical steering gear with tie rod and steering
knuckle
Torque: 33±3N·m (Metric) 24.3±2.2lb-ft (English)
NL-3 01/2016
5) Install and fasten 1 fixing bolt at the connection between

lower swing ballhead assembly and lower swing arm
assembly

assembly.
DS
7) Install and fasten the outer locking nut at the connection

between drive shaft and front wheel hub
NL-3 01/2016
2. Install the right front constant-velocity drive shaft (4WD)

1) Install the inner drive shaft.
2) Install the drive shaft bearing bracket, and fasten 3 fixing

bolts
DS
3) Insert the drive shaft assembly, install circlip

Notice
The torque of fixing screw is fine as long as it is in position, no
need to push the screw to the end, otherwise the front rubber
will be damaged, even break the bearing
NL-3 01/2016
4) Fasten the bearing fixing bolt

Torque: 15N·m (Metric)11.lb-ft (English)

position.
DS
6) Connect the cotter pin and slotted nut at the connection

between mechanical steering gear with tie rod and steering
knuckle
NL-3 01/2016
7) Install and fasten 1 fixing bolt at the connection between

assembly

assembly.
9) Install and fasten the outer locking nut at the connection

DS
between drive shaft and front wheel hub
NL-3 01/2016
Constant-Velocity Drive Shaft - Front Constant-Velocity Drive Shaft Oil Seal DS-27
Front Constant-Velocity Drive Shaft Oil Seal

Component
DS
Vehicle wheel nut
Wheel assembly
NL-3 01/2016
DS-28 Constant-Velocity Drive Shaft - Front Constant-Velocity Drive Shaft Oil Seal
DS
NL-3 01/2016
Slotted nut
Left steering
knuckle
Split pin
DS
Lower swing arm ballhead of

front suspension
Lower swing arm of front suspension
NL-3 01/2016

drive shaft
Steering Knuckle

DS
NL-3 01/2016
Right constant velocity drive shaft assembly (4G18TD_6MT)

Right constant velocity drive shaft assembly (4G20_6MT)
DS

NL-3 01/2016
Removal
"Lower swing arm ballhead assembly"
4. Remove the front constant velocity drive shaft. Please refer
to "Front constant velocity drive shaft"
5. Remove the gearbox output shaft oil seal
1) Use the crowbar to lift seal part outer lip
2) Remove the output shaft oil seal
Notice
When using the crowbar to open seal parts, please be
especially careful not to damage gearbox housing and seal
parts
Installation
DS 1. Install the input shaft oil seal

1) Apply the gearbox oil on drive shaft oil seal component
lip
2) Use the special tool GL201-009, GL201-010 to install
drive shaft oil seal components
Notice
Replace the new oil seal components
2. Install the left constant-velocity drive shaft
NL-3 01/2016
Constant-Velocity Drive Shaft - Drive Shaft Assembly (4WD) DS-33
Drive Shaft Assembly (4WD)

Component
DS
Middle shaft
Power takeoff (PTO)
NL-3 01/2016
Removal
1. Lift the vehicle
2. Remove the drive shaft assembly
Notice
This service project need cooperation of two people to
complete.
1) Depress the brake pedal and hold.
2) Make fitting marks on the flange at the connection
between two sides of the drive shaft.

drive shaft and torque manager assembly flange
DS
4) Remove 4 fixing bolts at the connection between font

drive shaft and power takeoff flange
NL-3 01/2016
Constant-Velocity Drive Shaft - Drive Shaft Assembly (4WD) DS-35
5) Remove 2 bolts at the connection between drive shaft

central bracket and vehicle baseplate
6) Remove the drive shaft assembly of central bearing
Installation
1. Install the drive shaft assembly
1) Depress the brake pedal and hold
2) Align the fitting marks on drive shaft and flange, fasten 4
bolts at the connection between front drive shaft and power
takeoff
DS
3) Fasten 2 bolts at the connection between drive shaft

central bracket and vehicle baseplate
NL-3 01/2016
4) Align the fitting marks on drive shaft and flange, fasten 4

bolts at the connection between rear drive shaft and torque
manager flange
DS
NL-3 01/2016
Constant-Velocity Drive Shaft - Rear Main Reducer And Differential Oil DS-37
Rear main reducer and differential oil

Adjustment
1. Check and adjust rear main reducer and differential oil
level
1) Park the vehicle on a flat road.
2) Remove the rear main reducer and differential oil plug
and gasket
3) Check if the oil level is lower than 5mm (0.20 in.) from
the minimum position of rear main reducer and differential
oil inlet plug opening inner surface or not
Notice
Too much or less of rear main reducer and differential oil
might cause fault.
After replacing rear main reducer and differential oil, drive the
vehicle and check oil level
4) Check the gear oil for leakage when the oil level is too
low.
5) Install the rear main reducer and differential oil inlet plug
and new gasket.
DS
NL-3 01/2016
DS-38 Constant-Velocity Drive Shaft - Right Constant Velocity Drive Shaft Assembly (4WD)
Right Constant Velocity Drive Shaft Assembly (4WD)

Component
Vehicle wheel nut
DS Wheel assembly
NL-3 01/2016
Constant-Velocity Drive Shaft - Right Constant Velocity Drive Shaft Assembly (4WD) DS-39
DS
NL-3 01/2016
Install the vibration isolating cushion on rear

spiral spring

Assembly
Left swing arm 2 assembly of the

rear suspension
Rear brake
assembly
DS
NL-3 01/2016
Rear Vibration Damper

Assembly
Mounting bracket assembly of the

left rear vibration damper
Left rear longitudinal

arm assembly
DS
Rear axle head

assembly
Rear brake assembly
NL-3 01/2016
Rear constant velocity drive

shaft assembly
DS
NL-3 01/2016
DS
NL-3 01/2016
Removal
Notice
The dismantling/installing procedures of right and left side are
the same
The following listed procedures are applicable to the left side
4. Remove the rear suspension 1st swing arm. Please refer
to "Rear suspension 1st swing arm assembly"
5. Remove the rear constant-velocity drive shaft
1) Remove the self-locking nut at the connection between
rear constant-velocity drive shaft and rear wheel hub
DS
Notice
NL-3 01/2016
4) Remove 1 bolt at the connection between rear vibration

damper assembly and rear vibration damper mounting
bracket, disconnect the connection between rear vibration
bracket
5) Remove 2 bolts at the connection between rear

longitudinal arm assembly and rear axle head seat,
disconnect the connection between rear longitudinal arm
assembly and rear axle head seat
DS
6) Use the hydraulic jack to lift rear suspension 2nd swing
arm
2 号摆臂
NL-3 01/2016
7) Remove 1 bolt at the connection between rear

suspension 2nd swing arm and rear axle head seat
8) Remove the connection between rear suspension 2nd
swing arm and rear axle head seat
9) Disconnect the connection between rear axle head seat

and rear constant-velocity drive shaft
DS
10) Disconnect the connection between rear

constant-velocity drive shaft and main reducer and
differential
11) Remove the rear constant-velocity drive shaft
Disassembling
1. Disassemble the left rear constant-velocity drive shaft
assembly
NL-3 01/2016

mobile dust cover and skid tripod universal joint
2) Remove the small clamp at the connection between skid
tripod universal joint and middle shaft
3) Remove the skid dust cover
Notice
Make fitting marks on skid tripod universal joint and middle
shaft
Notice

fixed constant-velocity universal joint and fixed dust cover.
5) Remove the small clamp at the connection between
fixed dust cover and middle shaft.
6) Remove the fixed constant-velocity universal joint and
fixed dust cover.
Notice
Make fitting marks at fixed constant-velocity universal joint
and middle shaft.
Notice DS
Check
1. Check the left rear constant-velocity drive shaft assembly,
right rear constant-velocity drive shaft assembly
1) Check the dust cover for damages
2) Check and make sure the gap on skid tripod universal
joint radial is not too big
3) Check and make it is smooth when skid tripod universal
joint is sliding upwards
4) Check and make sure the gap on fixed constant-velocity
universal joint is not too big
NL-3 01/2016
Assembling
1. Assemble the rear constant-velocity drive shaft assembly
1) Assemble the large clamp at the connection between
fixed constant-velocity universal joint and fixed dust cover
2) Assemble the small clamp at the connection between
fixed dust cover and middle shaft
3) Assemble the middle shaft and mobile dust cover
4) Assemble the skid tripod universal joint, mobile large
clamp, skid small clamp and skid dust cover.
Notice
The dismantling/installing procedures of right rear
constant-velocity drive shaft is familiar with the left.
Installation
1. Install the rear constant velocity drive shaft assembly
1) Install the connection between rear constant-velocity
drive shaft and rear main reducer and differential.
DS
2) Install the rear constant-velocity drive shaft into the

installation hole of rear axle head seat, make sure it is in
place
NL-3 01/2016
3) Install 1 bolt at the connection between rear suspension

2nd swing arm and rear axle head seat
4) Install two bolts at the connection between rear

longitudinal arm assembly and rear axle hear seat
DS
5) Fasten 1 bolt at the connection between rear vibration

bracket
NL-3 01/2016

Torque: 104N·m (Metric) 76..6lb-ft (English)
7) Install the nut at the connection between rear

2. Install the rear suspension 1st swing arm
DS
NL-3 01/2016
Constant-Velocity Drive Shaft - Rear Main Reducer And Differential Assembly DS-51
Rear Main Reducer and Differential Assembly

Component
Vehicle wheel nut
DS
Wheel assembly
NL-3 01/2016
DS-52 Constant-Velocity Drive Shaft - Rear Main Reducer And Differential Assembly
Mounting bracket assembly of the left

rear vibration damper
DS
Rear axle head

assembly
Rear brake assembly
NL-3 01/2016
Install the vibration isolating cushion on rear spiral spring
Rear brake assembly
DS
NL-3 01/2016
Rear brake caliper with brake

disc assembly
DS
NL-3 01/2016
Rear constant velocity drive shaft
Rear constant velocity

DS

NL-3 01/2016

shaft assembly

DS shaft assembly
Rear main reducer and

NL-3 01/2016
Removal
Notice
Use the hydraulic jack to support rear main reducer and
4. Remove the rear muffler. Refer to "Muffler"
6. Remove the rear constant-velocity drive shaft. Please refer
to "Rear constant-velocity drive shaft assembly" (4WD)
7. Remove the torque manager assembly. Refer to "Torque
manager assembly"
8. Remove the rear main reducer and differential assembly
1) Remove the rear main reducer and differential assembly
oil drain bolt
2) Drain the rear main reducer and differential oil
3) Install the rear main reducer and differential assembly
oil drain bolt
DS
4) Remove 3 bolts at the connection between rear main

reducer and differential assembly and subframe
NL-3 01/2016
Installation
1. Install the rear main reducer and differential assembly
1) Use the hydraulic jack to support rear main reducer and
2) Install 3 bolts and nuts at the connection between rear

main reducer and differential assembly and subframe
DS

oil filling bolt
4) Use the special filling tool to fill rear main reducer and
differential assembly oil
Rear main reducer and differential oil: SAE
GL-4/5 ,75W/90
Filling amount: 650±30ml
5) Install the rear main reducer and differential assembly
oil filling bolt
Torque: 67.5 N·m (Metric) 49.8 lb-ft(English)
2. Install the rear constant-velocity drive shaft
NL-3 01/2016
Constant-Velocity Drive Shaft - Rear Constant-Velocity Drive Shaft Oil Seal DS-59
Rear Constant-Velocity Drive Shaft Oil Seal

Component
Vehicle wheel nut
DS
Wheel assembly
NL-3 01/2016
DS-60 Constant-Velocity Drive Shaft - Rear Constant-Velocity Drive Shaft Oil Seal
DS
NL-3 01/2016
Vbration isolating cushion on rear spiral spring
Rear brake assembly
DS
NL-3 01/2016
Rear Vibration Damper

Assembly
Mounting bracket assembly of the

left rear vibration damper
Left rear longitudinal arm

assembly
DS
Rear axle head

assembly
Rear brake assembly
NL-3 01/2016

shaft assembly DS
NL-3 01/2016
Removal
5. Remove the rear constant-velocity drive shaft. Please refer
to "constant-velocity drive shaft assembly’ (4WD)
6. Remove the rear differential output shaft input shaft oil seal
1) Use the appropriate tool to pry out rear differential
output shaft oil seal
Notice
Do not damage the mounting surface of differential halfshaft
gear shaft oil seal
Installation
DS 1. Install the rear differential output shaft oil seal
1) Apply the gear oil onto drive shaft oil seal component lip
2) Use the special tool GL201-009, GL201-010 to install
rear constant-velocity drive shaft oil seal components.
2. Install the rear constant-velocity drive shaft
NL-3 01/2016
Constant-Velocity Drive Shaft - Torque Manager Assembly DS-65
Torque Manager Assembly

Component
DS
Rear constant velocity
NL-3 01/2016
Removal
1. Lift the vehicle
2. Remove the torque manager assembly
1) Disconnect harness connector from torque manager
2) Remove 4 bolts at the connection between torque

manager and drive shaft assembly flange
DS
3) Remove 4 bolts at the connection between torque

manager and rear main reducer and differential assembly
4) Remove the torque manager assembly
NL-3 01/2016
Constant-Velocity Drive Shaft - Torque Manager Assembly DS-67
Installation
1) Install 4 bolts at the connection between torque
manager and rear main reducer and differential assembly
2) Install 4 bolts at the connection between torque

manager and drive shaft assembly flange
DS
3) Connect the harness connector from torque manager

assembly
NL-3 01/2016
DS-68 Constant-Velocity Drive Shaft - Intelligent Torque Manager Control Unit
Intelligent Torque Manager Control Unit

Component
Seat head pillow
Front seat assembly _ manual

Front seat right rear mounting bracket
trim cover
DS
Front seat left rear mounting bracket

trim cover
Front seat front mounting bracket trim cover
NL-3 01/2016
Constant-Velocity Drive Shaft - Intelligent Torque Manager Control Unit DS-69
Intelligent torque manager control unit
DS
NL-3 01/2016
Removal
3. Remove the right front seat assembly. Please refer to
"front seat"
4. Remove the intelligent torque manager control unit
1) Lift up the blanket.
2) Disconnect the harness connector of intelligent torque
manager control unit
3) Remove 2 nuts at the connection between intelligent

torque manager and vehicle body
4) Remove the intelligent torque manager control unit
DS
NL-3 01/2016
Constant-Velocity Drive Shaft - Intelligent Torque Manager Control Unit DS-71
Installation
1. Install the torque manager control unit
1) Connect two bolts at the connection between intelligent
torque manager control unit and vehicle body
2) Connect the harness connector from intelligent torque

manager control unit
3) Cover the carpet
2. Install the right front seat assembly
DS
NL-3 01/2016
DS
NL-3 01/2016
Power Takeoff System - Contents TP-1
TP Power Takeoff System
Power Takeoff System ..................................................................................................................................................... TP - 2
Component Position................................................................................................................................................... TP - 2
Power Takeoff (PTO) ........................................................................................................................................................ TP - 3
Component ................................................................................................................................................................ TP - 3
Removal..................................................................................................................................................................... TP - 9
Installation................................................................................................................................................................ TP - 10
TP
NL-3 01/2016
TP - 2 Power Takeoff System - Power Takeoff System
Power Takeoff System

Component Position
Right front constant velocity drive

shaft assembly
TP
Power takeoff (PTO) Transmission
NL-3 01/2016
Power Takeoff System - Power Takeoff (PTO) TP-3
Power Takeoff (PTO)

Component
Vehicle wheel nut

TP
Wheel assembly
NL-3 01/2016
TP - 4 Power Takeoff System - Power Takeoff (PTO)
Right front constant velocity drive shaft assembly（4G18TD_6AT）

Right front constant velocity drive shaft assembly（4G24_6AT）
Left front constant velocity drive shaft assembly (AT)
TP

NL-3 01/2016
Engine rear bracket
Right reinforcement plate of front suspension

front suspension
TP

longitudinal beam
assembly
NL-3 01/2016
TP
Middle shaft
Power takeoff (PTO)
NL-3 01/2016
Front oxygen sensor
Rear oxygen sensor
TP
Three-way catalytic converter assembly
NL-3 01/2016
Power takeoff (PTO)
Power takeoff bracket Middle shaft

Engine assembly (4G24_6AT)

TP
NL-3 01/2016
Removal
2. Remove the engine bottom guard plate. Refer to "Left and
3. Remove the right front constant velocity drive shaft. Refer
to "Front constant velocity drive shaft"
4. Remove the drive shaft assembly. Refer to "Drive shaft
assembly (4WD)"
5. Remove the three-way catalytic converter assembly (do
not need to remove 4G24). Refer to "Three-way catalytic
converter assembly"
6. Remove the power takeoff
1) Remove 4 fixing bolts at the connection between power
takeoff flange and drive shaft flange
TP

takeoff bracket and engine
NL-3 01/2016

takeoff bracket and power takeoff
4) Remove the power takeoff bracket

takeoff and gearbox
6) Remove the power takeoff
TP Installation
1. Install the power takeoff and power takeoff bracket
1) Install 4 fixing bolts at the connection between power
takeoff and gearbox assembly
NL-3 01/2016

takeoff bracket and power takeoff

takeoff bracket and engine
Torque: 23±3N·m (Metric) 17±2.2lb-ft (English)
TP

takeoff and drive shaft flange
3. Install the drive shaft assembly
4. Install the right front constant-velocity drive shaft
5. Install the left front constant-velocity drive shaft
6. Supplement fuel, check oil level
NL-3 01/2016
TP
NL-3 01/2016
TPMS System –Contents TP-1
TP TPMS System
TPMS System ..................................................................................................................................................................... TP- 2
Component Position.................................................................................................................................................... TP- 2
TPMS System Diagram .............................................................................................................................................. TP- 3
System Instructions..................................................................................................................................................... TP- 4
How to Carry out the Analysis for Elimination of Fault ................................................................................................ TP- 7
Check the Working Conditions .................................................................................................................................... TP- 9
Table of Fault Symptoms .......................................................................................................................................... TP- 10
TPMS Terminal ......................................................................................................................................................... TP- 11
Table of DTCs ........................................................................................................................................................... TP- 13
Tire Pressure Monitoring System (TPMS) Indicator Lamp Is Always on ................................................................... TP- 14
Tire Pressure Monitoring System (TPMS) Indicator Lamp Does Not Light up When Tire Pressure Is in Severe Shortage .
.................................................................................................................................................................................. TP- 18
DTC: B200216, B200316, B200416, B200516, B100631, B100731, B100831, B100931 ........................................ TP- 22
DTC: U130055, U100016, U100017 ......................................................................................................................... TP- 23
DTC: U007300, B100106, U015587, U012187, U007388 ........................................................................................ TP- 25
TPMS Controller Unit ........................................................................................................................................................ TP- 28
Component ............................................................................................................................................................... TP- 28
Removal.................................................................................................................................................................... TP- 30
Installation................................................................................................................................................................. TP- 31
TPMS Sensor .................................................................................................................................................................... TP- 33
Component ............................................................................................................................................................... TP- 33
Removal.................................................................................................................................................................... TP- 34
Installation................................................................................................................................................................. TP- 35
TP
NL-3 01/2016
TP-2 TPMS System -TPMS System
TPMS System
Component Position
TPMS sensor
TPMS control unit
TPMS sensor
TPMS sensor
TP
TPMS sensor
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TPMS System -TPMS System TP-3
TPMS System Diagram

Control system
Tire pressure monitoring sensor (whole vehicle)
Radio frequency signal
Gateway
Combination
instrument
TP
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System Instructions
Function general
Tire Pressure Monitoring System (TPMS), by using tire pressure sensor unit and tire pressure monitoring unit of radio
frequency communication, achieved real-time automatic monitoring of tire pressure and temperature while the vehicle is
moving, and alarm when the tire pressure is abnormal, in order to ensure driving safety
1. Low tire pressure alarm
When the vehicle is moving and the tire pressure monitoring sensor detect the current tire pressure is lower than the
pressure limit, tire pressure monitoring sensor will send low pressure alarm message
Single tire: low pressure alarm when lower than 75% of standard tire pressure; multiple tires: low pressure alarm when
lower than 75% of cold tire pressure or lower than 150Kpa
2. High tire pressure alarm
When the vehicle is moving and the tire pressure monitoring sensor detect the current tire pressure is higher than 320Kpa,
tire pressure monitoring sensor will send high pressure alarm message
3. High tire temperature alarm
When the vehicle is moving and the tire pressure monitoring sensor detect the current tire temperature is higher than 85 ℃,
tire pressure monitoring sensor will send high temperature alarm message within 10s
4. Rapid air leakage alarm
When the vehicle is moving and the tire pressure monitoring sensor detect the tire is leaking with rate higher than
30kPa/min, tire pressure monitoring sensor will send rapid air leakage alarm message within 1min
5. Low voltage alarm
When the vehicle is moving and the tire pressure monitoring sensor detect the current voltage is lower than 2.14V, tire
pressure monitoring sensor will send low voltage alarm message within 10min, when low voltage alarm is occurring, the
controller will not process other alarm signals
6. System failure alarm
After TPMS system is working, when situations such as sensor damaged or missing, hardware failure, etc. are
encountered, tire pressure monitoring sensor will send system malfunction alarm within 10min
Operating mode introduction
Mode transition diagram
Hibernation
TP Exit hibernation
State
Sampling vehicle,
Enter hibernation
Tx rate
(X-single case)
<6G rotary force
Alarm still Still mode

mode
None None Run mode

None
Run mode
≥6G rotary force
Alarm run Run mode

mode
Re-measure
Re-measure
Input factor instructions

Accelerometer reading ≥ 6G
LF activate Accelerometer reading < 6G

Constant pressure
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Mode transition table

Pressure
Operating RF transmitting Transmitting Transmitting
sampling Encourage Message
condition mode interval (s) frame rate
interval
Enter
P ＜ 30 kPa Normal Single event, 3
hibernation
Hibernation 30 when
P ≥ 30 kPa Exit hibernation Normal 3
necessary
≥ 6G Accel None n/a 0
△P≥ Pressure
Learn 3
0.8.25kPa trigger Single event,
Still mode 30 Learn –LF when
LF activate Learn 16
trigger necessary
≥ 6G Accel Run mode Normal 3
△P≥ Every 8s (first
Re-measure Normal 3
30+ run mode 0.8.25kPa 10 times);
Run mode
delay value ≥ 6G Accel Run mode Normal every 2
0
＜ 6G Accel None n/a samples
△P≥ Pressure
Learn 3
0.8.25kPa trigger Single event,
Alarm still
1 Learn –LF when
mode LF activate Learn 16
trigger necessary
≥ 6G Accel None 0
Single event,
△P≥
Alarm run Re-measure Normal when 3
1 0.8.25kPa TP
mode necessary
＜ 6G Accel None n/a n/a 0
Mode contents description
1. Hibernation mode
Test period:
Pressure test period: 30s; temperature test period: 30s; do not test acceleration; voltage test period: 3600s; do not transmit
data
Entry conditions:
When the vehicle is stopping, when the tire pressure lower than 0.3bar is detected, transmit data every 1min, each time 3
frames, enter hibernation mode after 5min
Exit conditions:
When tire pressure greater or equal to 0.3bar is detected, exit hibernation mode, enter still mode
2. Still mode (still mode state)
Test period:
Pressure test period: 30s; temperature test period: 30s; acceleration test period: 30s; voltage test period: 3600s: do not
transmit data under still mode
Mode transition:
a. Transmitter does not transmit data under still mode
b. When the difference between current pressure and last transmitted pressure value larger or equal to 8.25kPa is detected,
run a pressure test immediately, after further confirmation, transmit 3 frames of header byte as Learn and "Pressure
Triggered Mode" data, enter still alarm mode, and reboot 8s test
c. When tire acceleration larger than 6G is detected, after transmitting 3 frames of "run mode" data, enter run mode
3. Run mode (run mode state)
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Test period:
Pressure test period: (30+ run mode delay value)s; temperature test period: 30s; acceleration test period: 30s;
Voltage test period: 3600s; data transmit interval: 2*(30+run mode delay value)s.
Mode transition:
a. Under run mode, transmitter send data of 3 frames once every 60s
b. When tire acceleration smaller than 6G is detected, enter still mode
c. When the difference between current pressure and last transmitted pressure value larger or equal to 8.25kPa is detected,
run a pressure test immediately, after further confirmation, transmit 3 frames of "Re-Measure Data Mode" data, enter alarm
run mode, and reboot 8s test
4. Alarm still mode (alarm, still mode, state)
Test period:
Pressure test period: 1s; temperature test period: 30s; acceleration test period: 30s; voltage test period: 3600s
Mode transition:
a. After further confirmation that the pressure is larger or equal to 8.25kPa, start 8s test
b. When the detected pressure difference within 8s is lower than 8.25kPa, exit alarm still mode, enter still mode
c. When tire acceleration larger than 6G is detected, enter alarm run mode
5. Alarm run mode (run mode, still mode, state)
Test period:
Pressure test period: 1s; temperature test period: 30s; acceleration test period: 30s; voltage test period: 3600s
Mode transition:
a. When the detected pressure difference is larger or equal to 8.25kPa, start 8s test
b. When the detected pressure difference within 8s is lower than 8.25kPa, exit alarm run mode, enter run mode
c. When tire acceleration smaller than 6G is detected, enter alarm still mode
6. Low frequency wakeup function
TP Use coding handle to wakeup transmitter, can be used to inquire transmitter ID number, pressure, temperature Note:
ΔP=8.25kPa, explanation: under normal condition, when the pressure difference between two tests (30s interval) is larger than
± 8.25 kPa, enter 1s pressure sampling period, when the difference is ± 8.25 kPa within 8s, the sensor will keep alert mode (air
leakage alarm) When the pressure difference is smaller than ± 8.25kPa at 8s interval, it recovers to normal (alarm free)
condition, Stationary or Rolling.
7. Winter mode
TPMS can enter mode through diagnosis tool setting, after entering winter mode, controller will send CAN message regularly,
CAN message includes TPMS mode status=1 (winter mode), TPMS system should be in hibernation mode, instruments show
TPMS system shutdown information
8. Sensor ID learning function
TPMS’s transmitter ID learning is divided into production line, after-sale learning method, use tool to learn wirelessly
Use tool to learn wirelessly (write through tool diagnosis interface)
1) Tool activate left front wheel transmitter, transmitter transmit ID learning data information, tool record ID
2) Follow the sequence of left front wheel, right front wheel, right rear wheel, left rear wheel, activate transmitter one by
one, tool will learn and record all tire ID
3) Connect toll and vehicle diagnosis interface, write ID information into TPMS receiving module
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Step 1 Send vehicle into repair shop
Next Step
Step 2 Customer mentioned fault analysis
(a) System instructions, start system diagnosis after

being familiar with system function and operation
content, this can help to determine the correct fault
diagnosis procedures when there is a fault, more
importantly, this can help make sure if the situation
being described by customer is normal operation or
not
Next Step
Step 3 Use diagnostic scanner to read DTC
(b) Check if there is DTC
Repair the fault according to the DTC

Yes
list.
No
Step 4 Symptoms simulation
Next Step
Step 5 Check CAN communication system

TP
Notice, make sure to check CAN communication system
is working properly before troubleshooting
Next Step
Step 6 The table of fault symptoms
(a) Refer to “The table of fault symptoms”.
Next Step
Step 7 Circuit check.
Next Step
Step 8 Fault identification
Next Step
Step 9 Repair or replace
Next Step
Step 10 Confirmation test
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Next Step
Step 11 Finish.
TP
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Check the Working Conditions

Visual inspection:
1. Check after-sale installed device that might affect TPMS system operation
2. Check system parts which are easy to contact or can be seen, to see if there is obvious damage or have situation that
might cause fault
3. Check each tire pressure for damage, air leakage, etc.
Activation of sensor
Tire pressure sensor activation tool: GEELY-CE-2Q (as diagram shown below)
SD card slot
Screen
DB9 interface
Backlight key
Power key
Up key
ENTER key (confirm key)
Down key
TP
ESP key (exit key/return key)
Tire pressure sensor activation tool instructions:

1. Press power key to boot, version flag is shown after booting, then show GEELY logo, enter main menu after 3 seconds; at
main menu interface, press up key or down key to choose corresponding menu, then press ENTER key to enter the
corresponding menu interface
2. Under main menu, press ENTER key to enter 1. Read Sensor submenu
3. Under Read Sensor submenu, press ENTER key to select 2. Geely Sensor menu
4. Menu 1 LFD Force MP is used to switch Shipping Mode to Park mode;
5. Menu 2 LFD Force TX is used to read ID, pressure, temperature, battery status; after being triggered, the interface will
show the ID of the current transmitter being woken up, current tire pressure P and temperature T, battery state.
6. When being triggered, the handle is close to the valve, the distance between trigger tool and valve should be controlled
within 6cm, which is the best working distance for trigger tool
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Symptoms Suspected Parts: Measures/
Harness Refer to "Tire pressure monitoring
TPMS control unit system (TPMS) indicator lamp is always
Tire pressure monitoring system
Combination instrument on"
(TPMS) indicator lamp is always on
Gateway
Read DTCs. Refer to "Table of DTCs"
TPMS have DTC
Tire pressure monitoring system Gateway
(TPMS) indicator lamp does not light Harness
up when tire pressure is higher than TPMS control unit
the limit Combination instrument Refer to "Tire pressure monitoring
Tire pressure monitoring system Harness system (TPMS)" indicator lamp does
(TPMS) indicator lamp does not light TPMS control unit not light up"
up when tire pressure is in severe Gateway
shortage Combination instrument
Harness
Tire pressure monitoring system Refer to "Tire pressure monitoring
TPMS control unit
(TPMS) indicator lamp lights up when system (TPMS)"indicator lamp is
Gateway
tire pressure is at normal value always on
TP
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TPMS Terminal
SO27 TPMS harness connector
SO27 Tire pressure monitoring system harness connector
Terminal Terminal abbreviation Terminal description State Specified condition

CAN communication
1 CANH - -
interface bus is high
CAN communication
2 CANL - -
interface bus is low
3 - Undefined - -
4 - Undefined - -
5 - Undefined - -
Tire pressure
Grounding wire pulse
6 GND monitoring controller -
≤ ±1V TP
grounding
7 - Undefined - -
8 - Undefined - -
9 - Undefined - -
10 - Undefined - -
11 - Undefined - -
12 - Undefined - -
13 - Undefined - -
14 - Undefined - -
15 - Undefined - -
16 - Undefined - -
Tire pressure
17 KL30 monitoring controller - -
power supply
18 - Undefined - -
19 - Undefined - -
20 - Undefined - -
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Terminal Terminal abbreviation Terminal description State Specified condition

21 - Undefined - -
Startup switch and
22 KL15 Startup switch "ON" -
input information
23 - Undefined - -
24 - Undefined - -
TP
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Table of DTCs
DTC Description
B100106 Electric rewritable programmable read-only memory fault
B200216 Left front sensor low voltage fault
B200316 Right front sensor low voltage fault
B200416 Right rear sensor low voltage fault
B200516 Left rear sensor low voltage fault
B100631 Left front sensor high frequency signal loss fault
B100731 Right front sensor high frequency signal loss fault
B100831 Right rear sensor high frequency signal loss fault
B100931 Left rear sensor high frequency signal loss fault
U015587 ICU communication lost fault
U012187 ABS communication lost fault
U014787 HVAC communication lost fault
U007300 CAN main wire shutdown fault
U100016 Receiver low voltage fault
U100017 Receiver high voltage fault
U130055 Receiver function configuration fault
TP
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Tire Pressure Monitoring System (TPMS) Indicator Lamp Is Always on

Circuit schematic:
Combination
instrument
Gateway
TP Diagnostic steps:
Step 1 Use diagnostic scanner to access TPMS control unit
Go to “Table of DTCs”, and repair

Yes
according to DTC.
No

Yes
Step 3 Check fuse IF09, IF23.
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(b) Check whether fuse IF23 is blown out.
Rated capacity of fuse：15A
(c) Check whether the fuse IF09 is blown out.
Yes Overhaul the fuse circuit, and replace

the rated capacity fuse.
No
Step 4 Check TPMS control unit power supply

mode to OFF state.
(b) Disconnect TPMS control unit harness connector
SO27.
(c) Use multimeter to measure the voltage between TPMS
control unit harness connector SO27 terminal 17 and
vehicle body grounding
value. TP
No Check, repair or replace the harness.
Yes
Step 5 Check TPMS control unit grounding.
(a) Use multimeter to measure the resistance between

SO27 terminal 6 and vehicle body grounding
value.
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Yes
Step 6 Check TPMS control unit IG electrical input

mode to ON state.
(b) Use multimeter to measure the voltage between
connector SO27 terminal 22 and vehicle body
grounding
Yes
Step 7 Check harness fault between TPMS and gateway

mode to OFF state.
SO27
TP (c) Disconnect gateway harness connector CA08
(d) Use multimeter to measure the resistance between
connector SO27 terminal 2 and CA08 terminal 13
connector SO27 terminal 1 and CA08 terminal 3
standard value.

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Yes
Step 8 Replace TPMS control unit.

(b) Replace TPMS control unit. Please refer
"Replacement of TPMS control unit"
No

(b) Select "active test" on function test → "TPMS indicator
lamp"
(c) Check TPMS indicator lamp to see if it is working
properly
No
(a) Disconnect the negative battery cable. TP

(b) Replace the combination instrument unite, refer to
“Replacement of combination instrument”.
(c) Use a diagnostic scanner to eliminate DTCs.
Next Step
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Tire Pressure Monitoring System (TPMS) Indicator Lamp Does Not Light up When Tire Pressure
Is in Severe Shortage
Circuit schematic
Gateway
TP
Diagnostic steps:
Go to “The table of DTCs”, and repair

Yes
according to DTC.
No

Yes
Step 3 Check combination instrument fuse
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(b) Check whether fuse IF17 is blown out.
Overhaul the fuse circuit, and replace

Yes the original fuse with a fuse with rated
capacity
No
Step 4 Check the combination instrument connectors.

mode to OFF state.
(c) Check whether the connector is correctly connected
on the combination instrument assembly.
No Connect the connector properly
Yes
TP
Step 5 Check combination instrument power supply, grounding harness

mode to OFF state.
connector IP17.
IP17 Combination instrument harness connector (c) Operate the starter switch to turn the power supply
mode to ON state.
(d) Measure the voltage between combination instrument
harness connector IP17 terminal 1, 2 and vehicle body
grounding
(e) Operate starter switch to change the power supply
mode to OFF state.
(f) Measure the voltage between combination instrument
harness connector IP17 terminal 3, 4 and vehicle body
grounding
standard value.
Yes
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(b) Select "active test" on function test → "TPMS indicator
lamp"
(c) Check TPMS indicator lamp to see if it is working
properly.
No
Step 7 Replace the combination instrument.
(a) Replace combination instrument assembly. Refer to

"11.7.8.1 Replacement of combination instruments
assembly"
(b) Check TPMS indicator lamp to see if it is working
properly.
No
Step 8 Check TPMS fuse

mode to OFF state.
TP (b) Check whether fuse IF23 is blown out.
Overhaul the fuse circuit, and replace

Yes the original fuse with a fuse with rated
capacity
No
Step 9 Check power supply and grounding of TPMS control module
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mode to OFF state.
SO27 Tire pressure monitoring system harness (b) Disconnect TPMS control unit harness connector
connector
SO27
(d) Use multimeter to measure the voltage between
TPMS control unit harness connector SO27 terminal
17 and vehicle body grounding
standard value.
Yes
(a) Replace TPMS control module. Refer to

(b) Use diagnostic scanner to eliminate history DTCs
(c) Confirm the repair is completed. TP
Next Step
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DTC: B200216, B200316, B200416, B200516, B100631, B100731, B100831, B100931

DTC descriptiom:
DTC Description
B200216 Left front wheel sensor generates low voltage fault.
B200316 Right front wheel sensor generates low voltage fault.
B200416 Right rear wheel sensor generates low voltage fault.
B200516 Left rear wheel sensor generates low voltage fault.
B100631 Left front sensor high frequency signal loss fault.
B100731 Right front sensor high frequency signal loss fault.
B100831 Right rear sensor high frequency signal loss fault.
B100931 Left rear sensor high frequency signal loss fault.
Diagnostic steps:
Notice
Prior to executing this diagnostic procedure, observe the data list of the fault diagnostic scanner and analyze data accuracy for
quick troubleshooting!
Step 1 Use fault diagnostic scanner to access TPMS control unit

interface.
mode to ON state.
scanner.
(d) Read DTC, and eliminate DTC.
(e) Carry out road test for over 10min, and make sure if
the DTC still exists
TP
No The fault is eliminated.
Yes
Step 2 Replace tire pressure monitoring sensor
(a) Replace new tire pressure monitoring sensor

(b) Use fault diagnostic scanner to access TPMs control
unit, read and eliminate DTC
(c) Replace tire pressure monitoring sensor, and carry out
sensor learning
Next Step
Step 3 Clear DTC
Next Step
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DTC: U130055, U100016, U100017

DTC descriptiom
DTC Description
U100016 Receiver low voltage fault.
U100017 Receiver high voltage fault.
U130055 Receiver function configuration fault.
Circuit schematic:
Combination
instrument
TP
Gateway
Diagnostic steps:
Go to “The table of DTC”, and repair

Yes
according to DTC.
No
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Yes

(b) Disconnect TPMS control unit harness connector SO27
SO27 Tire pressure monitoring system harness connector (c) Connect the negative battery cable.
(d) Use multimeter to measure the voltage between TPMS
control unit harness connector SO27 terminal 17 and
vehicle body grounding
(f) Use multimeter to measure the resistance between
standard value.
Yes
TP
Step 4 Replace TPMS control unit
(a) Replace TPMS control module. Refer to

(b) Use fault diagnostic scanner to eliminate DTC.
Next Step
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DTC: U007300, B100106, U015587, U012187, U007388

DTC description
DTC Description
U007388 CAN internet communication fault.
B100106 Electric rewritable programmable read-only memory fault.
U015587 ICU communication lost fault.
U012187 ABS communication lost fault.
U007300 CAN main wire shutdown fault.
Circuit schematic:
TP
Gateway
Diagnostic steps:
Step 1 Use diagnostic scanner to access TPMS control unit.
Go to diagnostic trouble code (DTC)

Yes
table, repair according to DTC
No
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Yes

mode to OFF state.
SO27
(c) Use multimeter to measure the voltage between
TPMS control unit harness connector SO27 terminal
17 and vehicle body grounding
(d) Standard voltage value: 11~14V
standard value.
TP
Yes
Step 4 Check the communication line between TPMS control unit and gateway
(a) Measure the resistance between TPMS control unit

harness connector IP27 terminal 1 and gateway
harness connector CA08 terminal 3
SO27 Tire pressure monitoring system harness connector Standard resistance value: Less than 1 Ω
(b) Measure the resistance between TPMS control unit
harness connector IP27 terminal 2 and gateway
harness connector CA08 terminal 2
(c) Measure the resistance between TPMS control unit
harness connector IP27 terminal 1 and vehicle body
grounding, and resistance between IP27 terminal 2
and vehicle body grounding.
Standard resistance value: >10KΩ
value.
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Yes
(a) Replace the TPMS control module

(b) Use the fault diagnostic scanner to eliminate DTC
Next Step
TP
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TP-28 TPMS System -TPMS Controller Unit
TPMS Controller Unit

Component
Seat head pillow
Front seat assembly _ manual
Front seat right rear mounting bracket trim

cover
TP
Front seat left rear mounting bracket trim

cover
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TPMS System -TPMS Controller Unit TP-29
TPMS control unit
TPMS controller unit mounting bracket
TP
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Removal
3. Remove the left front seat, right front seat. Refer to "Front
seat"
4. Remove the auxiliary instrument panel. Refer to "Auxiliary
instrument panel"
5. Install the TPMS control unit
1) Connect the harness connector of TPMS control unit.
2) Remove 2 fixing screws of TPMS control unit

mounting bracket.
3) Take out the TPMS control unit mounting bracket.
TP
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TPMS System -TPMS Controller Unit TP-31
4) Separate the harness clip of TPMS control unit

mounting bracket.
5) Remove 2 fixing screws of TPMS control unit

mounting bracket.
6) Take out the TPMS control unit mounting bracket.
Installation TP
1. Install the TPMS control unit
1) Install the TPMS control unit mounting bracket onto
vehicle body, and tighten up the fixing bolt.
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2) Connect the harness clip of TPMS control unit

mounting bracket.
3) Install the TPMS control unit onto its mounting

bracket, and tighten up the fixing screw.
4) Connect the harness connector of TPMS control unit.

TP 2. Install the auxiliary instrument panel assembly.
3. Install the left front seat and right front seat
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TPMS System -TPMS Sensor TP-33
TPMS Sensor
Component
TPMS sensor assembly
Vehicle wheel nut
TP
Belt tire
Aluminum alloy wheel
TPMS sensor assembly Trim cover of wheel

hub
Tire valve assembly
Vehicle wheel nut
Belt tire
Aluminum alloy wheel
Trim cover of wheel hub

Tire valve assembly
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TP-34 TPMS System -TPMS Sensor
Removal
Notice
The same removal and installation methods are adopted for
TPMS sensor assemblies on four wheels
The following procedure is applicable to the TPMS sensor
assembly on tire
4. Remove the TPMS sensor assembly
1) Remove the valve cap from TPMS sensor, and
remove the hexagonal nut.
2) Deflate the tire.

3) Remove the right front tire
TP 4) Remove the TPMS sensor from rim.
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TPMS System -TPMS Sensor TP-35
Installation
1. Install the TPMS sensor.
1) Install the TPMS sensor onto rim.
Notice
Install the sealing rubber for sensor and rim, so as to ensure
the sealing property of tire.
2) Install the right front tire.

3) Inflate the right front tire.
4) Install the hexagonal nut and valve cap on TPMS
sensor.
2. Install the wheel.
3. Connect battery negative cables.
TP
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TP-36 TPMS System -TPMS Sensor
TP
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Steering System -6 Contents EP-1
EP Steering System
Steering System ................................................................................................................................................................... EP-3

Notices ......................................................................................................................................................................... EP-3
Component Position..................................................................................................................................................... EP-4
System Diagram .......................................................................................................................................................... EP-5
System Description ...................................................................................................................................................... EP-6
How to Carry out the Analysis for Elimination of Fault ................................................................................................. EP-7
Initialization .................................................................................................................................................................. EP-8
Table of Fault Symptoms ............................................................................................................................................. EP-9
EPS Terminal ............................................................................................................................................................. EP-10
Table of DTCs ............................................................................................................................................................ EP-15
DTC: C110117 C110216 C110921 U100016 U100017 .............................................................................................. EP-16
Diagnosis of Data Communication Fault .................................................................................................................... EP-20
Fault Diagnosis of Sensor .......................................................................................................................................... EP-25
Fault Diagnosis of Motor ............................................................................................................................................ EP-30
DTC: C160398 C160404 C170401 ............................................................................................................................ EP-34
Free Clearance of Steering Wheel ..................................................................................................................................... EP-40
Adjustment. ................................................................................................................................................................ EP-40
Steering Wheel (without Multi-functional Button)................................................................................................................ EP-41
Component ................................................................................................................................................................ EP-41
Removal..................................................................................................................................................................... EP-42
Installation .................................................................................................................................................................. EP-45
Steering Wheel (with Multi-functional Button)..................................................................................................................... EP-46
Component ................................................................................................................................................................ EP-46
EP
Removal..................................................................................................................................................................... EP-47
Installation .................................................................................................................................................................. EP-50
Electrical Power Steering Column & Intermediate Shaft Assembly .................................................................................... EP-51
Component ................................................................................................................................................................ EP-51
Removal..................................................................................................................................................................... EP-54
Installation .................................................................................................................................................................. EP-56
Mechanical Steering Gear with Tie Rod Assembly ............................................................................................................. EP-59
Component ................................................................................................................................................................ EP-59
Removal..................................................................................................................................................................... EP-65
Disassembling ........................................................................................................................................................... EP-67
Assembling ................................................................................................................................................................ EP-68
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EP-2 Steering System -6 Contents
Installation .................................................................................................................................................................. EP-69
EP
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Steering system -Steering System EP-3
Steering System
Notices
1. Notices for operation of airbag system
a. This vehicle is equipped with airbags. If the repair is not carried out in correct sequence, the airbag may be deployed
unexpectedly in the course of repair. This may cause serious accident. Before repair (including check, replacement,
removal or installation of part), be sure to read the notices about airbag system.
2. Notices on removal, installation and replacement of electrical steering components
(a) When removing and installing the power steering gear assembly, be sure to make the front wheels face at straight
direction. When disconnecting the steering sleeve yoke subassembly and power steering gear assembly, be sure to leave
the fitting mark before the operation.
3. Notices for operation
a. When handling any electronic component:
• Avoid getting any electronic component collided, such as controller. In case these components drop down or are
impacted violently, please replace the new components.
• Be sure not to expose any electronic component to hot and humid environment.
• Be sure not to touch any connector terminal.
b. When operating the steering column:
• Avoid getting the steering column collided, especially motor and torque sensor. In case these components drop down
or are impacted violently, please replace the new components.
• When moving the steering column, don’t pull the harness.
c. When disconnecting and re-connecting the connector:
• When disconnecting any connector relating to power steering system, please turn the ignition switch to position ON
(IG), return the steering wheel to straight position, turn the ignition switch to position OFF, and then disconnect the
connector.
4. Notices for CAN communication system
EP
a. The CAN communication circuit is used to receive the information from ESC and EMS, and send the warning to
combination instrument. In case there is any fault in CAN communication circuit, the DTC of CAN communication circuit will
be sent out.
b. When sending out the DTC of CAN communication system, be sure to eliminate the fault of communication circuit. Be sure
to eliminate the fault of power steering system only after confirming that the CAN communication system is in normal
condition.
c. Since the CAN communication circuit has its own length and route, it is impossible to carry out repair temporarily by using
bypass harness.
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EP-4 Steering System -Steering System
Component Position
Steering wheel assembly
Mechanical steering gear with tie rod

assembly
EP Electrical power steering column & intermediate shaft
assembly
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Steering System -Steering System EP-5
System Diagram
Steering control system
Motor
Diagnostic
interface Gateway
Torque & angle sensor (attached to EPS)

Combination
instrument
EP
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System Description
1. Overview
1. The power steering system uses a power steering motor, a torque & angle sensor and a reduction mechanism built in
steering column assembly to generate the torque, so as to assist the driver to operate the steering wheel.
2. Only when the driver turns the steering wheel, this system will switch on the power steering motor. Therefore, no energy
will be consumed when the vehicle is running straightly, so that the fuel economy will be improved.
2. Functions of main components
1. The functions of components of power steering system are detailed as follows:
Component Function
On the basis of the torsional deformation of torsion bar, the torque &
Torque & angle sensor
Power steering angle signals will be sent out.
column & On the basis of the signal received from ECU, the power will be
Motor
intermediate generated.
shaft assembly The turbine will be used to reduce the speed of motor, and then transmit
Reducing mechanism
it to lower shaft of steering column.
On the basis of the torque, angle, wheel speed and other relevant input
ECU
signals, the power current will be calculated and sent to motor.
The lamp will come on so as to remind the driver when the ECU detects
Warning lamp
any fault in EPS system.
EP
NL-3 01/2016

Please use the following steps to check your faults. If you carefully follow these steps, you will be able to identify most of
the EPS faults:
3. Check existing fault code (DTC) of the vehicle.
4. If fault symptom only appears occasionally and no fault code (DTC) appears, it indicates that it is an intermittent fault. Refer
to "2.2.7.4 Intermittent fault check".
5. When the fault conditions can be verified but without a fault code (DTC) or the system cannot communicate with the
diagnostic scanner.
8. If the Diagnostic trouble code (DTC) is set again, refer to “Table of DTCs”.
9. If the fault code (DTC) is not reset, they are intermittent faults, refer to "2.2.7.4 Intermittent fault check".
10. After repair, conduct the road test again, to confirm that fault has been eliminated.
EP
NL-3 01/2016
Initialization
Notice:
On the vehicle equipped with intelligent entry & ignition
system, after the battery is charged or the engine is started
with jumper cable, the start function will still be unavailable.
Under the circumstance that the battery voltage is lower than
9V, this situation is very common. The address of such
situation can be identified by the following steps.
1. Initialization steps
(a) Confirm whether a short-circuit pin is installed.
Notice:
In case no short-circuit pin is installed, and then install it.
(b) Move the gear shift lever to the position P (for vehicle with
automatic transmission) or the neutral position (for vehicle
with manual transmission).
(c) Adjust the ignition switch to ON state.
(d) Open the driver-side door.
Notice:
The opening of driver-side door will start the initialization step
between steering lock ECU and junction box of engine
compartment.
(e) Depress the brake pedal.
(f) Adjust the ignition switch to ON state.
EP
NL-3 01/2016
Table of fault symptoms

Tips:
• The table below can help identify the cause of fault. The descending sequence is used to indicate the possibility of
causes of fault. Check every suspected location in accordance with the sequence. If necessary, repair, replace or
adjust the part which has failed.
• Before checking the following suspected locations, please check the fuses and relays relating to the system.
1. Steering wheel fixing nut Tighten up or replace the nut Steering
(loose/damaged) wheel (without multi-functional button)
2. Connecting the bolt of electrical Tighten up or replace the bolt
steering column assembly Electrical power steering column &
(loosened/damaged) intermediate shaft assembly
3. Universal joint of upper and lower
Replace intermediate shaft assembly
intermediate shaft (worn)
4. Steering wheel spline housing Replace the steering wheel Steering
(worn) wheel (without multi-functional button)
Steering wheel is loose.
Replace the steering column Electrical
5. Steering column spline shaft (worn) power steering column & intermediate
shaft assembly
6. Upper and lower intermediate shaft
Replace intermediate shaft assembly
spline housing/shaft (worn)
Repair or replace the mechanical
7. Mechanical steering gear & tie rod steering gear & tie rod assembly
assembly Mechanical steering gear & tie rod
assembly
1. Electrical steering column fixing bolt
Tighten or replace
(loosened/damaged)
Re-weld the crossbeam bracket column
mounting base (crossbeam bracket
base)
The electrical steering column 2. Electric steering column assembly
Repair or replace the electrical steering
assembly is loosened mounting bearings (damaged)
column assembly Electrical power
steering column & intermediate shaft
assembly (column base)
3. Electrical steering column assembly Replace the electrical steering column EP
(damaged) assembly
1. Electric steering column assembly
Tighten or replace
mounting bolt (loose/damaged)
Replace the combination switch. Refer
2. Clock spring (loosened/damaged) to “Combination switch assembly”. After
(The clock spring is integrated in replacing the combination switch, be
combination switch) sure to carry out the four wheel
alignment
There is noise in electrical power 3. Electric steering column assembly
steering column assembly system connecting bolt (loose / Tighten or replace the bolt.
damaged)
Replace the electrical steering column
4. Shaft/bearing of electrical steering
assembly Electrical power steering
column assembly (worn)
column & intermediate shaft assembly
Apply the lubricating grease or replace
5. Upper and lower intermediate shaft
the upper and lower intermediate
universal joint (lack of lubrication/wear)
shafts.
NL-3 01/2016
EPS Terminal
IP14 EPS harness connector 1
IP14 EPS harness connector 1

1 IGN Starter switch On or Off
2 - - - -
3 - - - -
4 - - - -
5 - - - -
6 - - - -
P-CAN high-mounted
7 PCAN-H-1 on
bus
P-CAN low-mounted
8 PCAN-L-1 on
bus
EP
NL-3 01/2016
CA15 EPS harness connector 2
CA15 EPS harness connector 2

1 BATT2 Positive pole of battery All states Level voltage
2 GND Grounding All states Chassis grounding
EP
NL-3 01/2016
Diagnostic system
1. Instructions
(a) Diagnosis system
When using the diagnosis system to eliminate the fault on
vehicle, the only difference from elimination of common fault
is that, the fault diagnosis system will be connected to vehicle
and various data sent by steering lock ECU will be read. In
case the computer detects any fault in itself or system circuit,
the steering lock ECU will record the DTC. In order to verify
the diagnostic code, please connect the fault diagnostic
scanner to the diagnostic interface on vehicle. The fault
diagnostic scanner can eliminate the DTC, activate the
indicating lamp, and check the data sheet.
(b) Don’t use the diagnostic scanner to directly read
diagnosis information from steering lock ECU. Use the
controller area network (CAN) and ECU to send the diagnosis
information from steering lock ECU to diagnostic scanner.
2. Check the diagnostic interface
(a) The EMS adopts the ISO 15765-4 communication
IP12 OBD diagnosti

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2016 Geely NL-3 Service Manual

2016 Geely Automobile Co., Ltd.

Repair Manual for Geely NL-3

Preparatory Work PP-1

Specifications of Repair SS-1

JLD-4G20/24 Engine Control System ES-1

JLE-4G18TDB Engine Control System ES-1

JLD-4G20/24 Cooling System CO-2

JLE-4G18TDB Cooling System CO-2

JLD-4G20/24 Intake System AI-2

JLE-4G18TDB Intake System AI-2

JLD-4G20/24 Exhaust System EX-2

JLE-4G18TDB Exhaust System EX-2

JLD-4G20/24 Fuel System FU-2

JLE-4G18TDB Fuel System FU-2

JLD-4G20/24 Mechanical System EM-2

JLE-4G18TDB Mechanical System EM-2

JLD-4G20/24 Lubrication System LU-3

JLE-4G18TDB Lubrication System LU-3

JLD-4G20/24 Auxiliary Emission Control Device EC-3

JLE-4G18TDB Auxiliary Emission Control Device EC-3

JLD-4G20/24 Ignition System IG-3

JLE-4G18TDB Ignition System IG-3

JLD-4G20/24 Start System ST-3

JLE-4G18TDB Start System ST-3

JLD-4G20/24 Charging System CH-3

JLE-4G18TDB Charging System CH-3

DSI575F6 Transmission AT-3

6MTT250 Transmission MT-3

Clutch System CL-3

Brake System BR-3

Suspension System; SP-4

Constant-velocity Drive Shaft DS-4

Power Takeoff System TP-4

TPMS System TP-4

Steering System EP-4

Tire and Wheel TW-4

A/C System AC-4

Audio Entertainment System AV-5

Cruise Control System CC-5

Active Safety System AS-5

Emergency Power Supply BP-5

Intelligent Entry & Start System TD-5

Rearview Mirror MI-5

Combination Instrument ME-5

Lighting System LI-5

Horn System HO-5

Door Lock DL-5

Defrosting System DF-5

Wiper and Washer WW-5

Windshield & Window Glass WS-6

Sunroof System RF-6

Parking Assist System RR-6

Safety Control System SC-6

Seat Belt SB-6

Electrical Control System of Vehicle Body BE-6

On-board Network CA-6