Geely EC718 2009 Workshop Manual

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2009

Geely EC718 , EC718RV and

EC715, EC715RV Workshop

Manual

This workshop manual provides model year 2009 EC718/EC718RV and EC715/

EC715RV models specification, diagnostic and service information.

2009 Geely Automotive Co., Ltd.

Information as of the date of October 2009

Without written permission from Geely Automotive 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.

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Table of Contents

Summary of Contents for Geely EC718 2009

Page 1 Information as of the date of October 2009 Without written permission from Geely Automotive 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...
Page 2: Preface
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 Automotive Co., Ltd. to obtain the information about the products, part numbers or special tools referred in this manual.
Page 3: Warnings
– When replacing parts, please use parts approved by Geely Automotive Co., Ltd. with the same part numbers. Do not use inferior parts.
Page 5: Table Of Contents
Main table of contents Main table of contents Preface..............2 3.1 Warnings and Notices..........3-3 3.2 Clutch System............3-4 Warnings...............3 3.3 Manual Transmission..........3-27 Table of Contents..........5 Part Three Chassis Part One Vehicle Overview 4 Suspension System........4-1 1 Vehicle Overview..........1-1 4.1 Warnings and Notices..........4-3 4.2 Front Suspension............4-4 1.1 Warnings and Notices..........1-3 4.3 Rear Suspension............4-35...
Page 6 Main table of contents 11 Body Electric..........11-1 11.1 Warnings and Notices...........11-9 11.2 Audio Entertainment System......11-10 11.3 Navigation............11-37 11.4 Lighting System..........11-61 11.5 Glasses / Windows / Mirrors......11-153 11.6 Wipers / Washers System........11-215 11.7 Instrument / Driver Information System....11-272 11.8 Sunroof.............11-301 11.9 Central Locking..........11-326 11.10 Remote Anti-theft System.......11-371 11.11 Electric Seats..........11-398 11.12 Defrosting............11-432...
Page 7: Table Of Contents
Vehicle Overview Table of Contents 1 Vehicle Overview 1.1 Warnings and Notices.....1-3 1.6.1.4 Air-Conditioning Refrigerant......1-29 1.6.1.5 Adhesives and Sealants........1-29 1.1.1 Description and Operation......1-3 1.6.1.6 Engine Coolant..........1-29 1.1.1.1 Warnings and Notices........1-3 1.6.1.7 Asbestos............1-29 1.6.1.8 Battery Acid Fluid..........1-29 1.2 Vehicle Inspection......1-11 1.6.1.9 Brake Fluid............1-29 1.2.1 Description and Operation......1-11 1.6.1.10 Chemical Materials.........1-29 1.6.1.11 Dust..............1-30...
Page 8 Table of Contents Vehicle Overview 1.10 Noise, Vibration and Abnormal Sound ............1-66 1.10.1 Description and Operation....1-66 1.10.1.1 Diagnostic Information and Procedures..1-66 1.10.1.2 Repair.............1-67 1.11 Water Leaks........1-69 1.11.1 Description and Operation....1-69 1.11.1.1 Diagnostic Information and Procedures..1-69 1.11.1.2 Repair.............1-69 1.12 Special Tools.......1-71 1.12.1 Special Tools and Equipment....1-71 1.12.1.1 Power Train Special Tools......1-71 1.12.1.2 Chassis and Body Special Tools....1-76...
Page 9: Vehicle Overview
Provide additional information for completing a procedure Diagnostic and repair procedures include general and specific, – Clarify the recommended procedures for operational two types of "Warning", "Notice" and "Note". Geely is reasons committed to provide information to assist service technicians –...
Page 10 Warnings and Notices Vehicle Overview Battery Disconnect Warning Breathing R-134a Warning Warning: Unless directed otherwise, the ignition and start Warning: Avoid breathing the A/C Refrigerant 134a (R-134a) switch must be in the OFF or LOCK position, and all electrical and the lubricant vapor or the mist. Exposure may irritate the loads must be OFF before servicing any electrical component.
Page 11 Vehicle Overview Warnings and Notices Foam Sound Deadener Warning Fuel Vapors Evaporative Emission Components Warning Warning: Foam sound deadener must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body Warning: Do not breathe the air through the EVAP component repairs.
Page 12 Warnings and Notices Vehicle Overview Protective Goggles and Glove Warning – Personal injury Warning: Approved safety glasses and gloves should be worn – Unnecessary SIR system repairs when performing this procedure to reduce the chance of Warning: In order to avoid the above conditions, observe the personal injury.
Page 13 Vehicle Overview Warnings and Notices Warning: When storing an undeployed inflator module, make damage painted surfaces and cause corrosion to electrical sure the airbag opening point away from the surface on which components. If any brake fluid comes in contact with painted the inflator module rests.
Page 14: Warnings And Notices
Warnings and Notices Vehicle Overview Excessive Adhesive on Flywheel Bolts Notice Fuel Pressure Notice Notice: Apply the proper amount of the sealant to the fastener Notice: Do not allow the fuel pressure to exceed the specified when assembling this component. Excessive use of the sealant value because damage to the fuel pressure regulator or the fuel can prohibit the component from being assembled properly or pressure gage may result.
Page 15 Vehicle Overview Warnings and Notices Power Steering Hose Disconnected Notice Notice: This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to Notice: Do not start the vehicle with any power steering gear repair the wires, connectors, or terminals could result in the inlet or outlet hoses disconnected.
Page 16 1-10 Warnings and Notices Vehicle Overview Test Probe Notice Notice: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use approved terminal test kit in order to front probe terminals.
Page 17: Vehicle Inspection
Vehicle Overview Vehicle Inspection 1-11 1.2 Vehicle Inspection 3. Wipe clean the dipstick and then insert it back. 4. Pull out the dipstick and inspect the oil level. 1.2.1 Description and Operation 5. If necessary, add engine oil, so that the oil level maintained 1.2.1.1 Inspection Items Before Operating The between MIN (minimum) line and the MAX (maximum) line.
Page 18: Inspection Items At Least Once A Year
1-12 Vehicle Inspection Vehicle Overview Brake Master Cylinder Fluid Level Exhaust System Inspect the brake fluid level and maintain the correct fluid level. Inspect the entire exhaust system, including the catalytic If the fluid level is too low, it indicates that the brake pads have converter.
Page 19 Vehicle Overview Vehicle Inspection 1-13 Wash The Vehicle Underbody Firstly, loose deposited dust, and then rinse the bottom of the vehicle body with water. In winter, wash the bottom of the vehicle body at least once a year. Washing the bottom of the vehicle body can remove snow, ice and dust-proof corrosive substances.
Page 20: Lifting And Jacking The Vehicle
1-14 Lifting and Jacking the Vehicle Vehicle Overview 1.3 Lifting and Jacking the Vehicle pads do not contact the catalytic converter, the brake pipes or the fuel lines. If such contact occurs, vehicle 1.3.1 Description and Operation damage or unsatisfactory vehicle performance may 1.3.1.1 Lifting and Jacking the Vehicle result.
Page 21 Vehicle Overview Lifting and Jacking the Vehicle 1-15 Vehicle Jacking Locations EC718/EC718RV EC715/EC715RV 10/2009...
Page 22 1-16 Lifting and Jacking the Vehicle Vehicle Overview Vehicle Lifting - Frame Contact Hoist Rear Hoist Pads FE01-0002b Note Position the rear hoist pads as follows: – Under the junction between the rear frame rails and the side The rear hoist pads and arms must not contact the rocker frame rails.
Page 23 Vehicle Overview Lifting and Jacking the Vehicle 1-17 Front Hoist Pads Note The front hoist pads and arms must not contact the rocker panels, the front mud guards, or the floor pan. Position the front hoist pads as follows: – Under the front frame box section.
Page 24: Maintenance
1-18 Maintenance Vehicle Overview 1.4 Maintenance 1.4.1 Specifications 1.4.1.1 Oil and Fluid Capacity Application Specification Brake Fluid and Clutch Fluid 0.68 L (1.20 pt) Engine Oil (JLγ4G18-D) 4 L (7.04 pt) Engine Coolant (JLγ4G18-D) 6.5 L (11.44 pt) Manual Transmission Fluid 2.2 L (3.87 pt) Power Steering Fluid 0.9 L (1.58 pt)
Page 25: Description And Operation
Vehicle Overview Maintenance 1-19 1.4.2 Description and Operation – * 2 Only use "Genuine Geely ultra-long-effective type engine coolant" or the same level of high-quality 1.4.2.1 Oil Maintenance Schedule ethylene glycol based engine coolant. Do not use ordinary clean water.
Page 26 1-20 Maintenance Vehicle Overview Maintenance Schedule Odomete (Odometer readings or 112. readings 75 82.5 90 120 127.5 the number × 1,000 months, whichever comes first) 5. Cooling and Heating System Hoses Connectors * 2 * 3 6. Engine coolant * 5 * 6 7.VVT oil filters * 4 8.
Page 27: Harsh Driving Condition Service Schedule
Vehicle Overview Maintenance 1-21 Maintenance Schedule Odomete (Odometer readings or 112. readings 75 82.5 90 120 127.5 the number × 1,000 months, whichever comes first) Steering Wheel, Steering Linkage 21. Drive Shaft Dust Cover 22. Ball Joints and Dust Cover 23.
Page 28: Regular Service Instructions
1-22 Maintenance Vehicle Overview Inspection Items Time or Odometer Reading - Replace engine oil Every 5,000 km or 6 months - Replace oil filter Every 5,000 km or 6 months - Check or replace the air cleaner filter I: Every 2,500 km or 3 months R: Every 1,000 km or 6 months - Check brake pads and brake disc Every 5,000 km or 3 months...
Page 29: Tire Rotation Description
Note the location of each tire and wheel assembly in Spark Plug Replacement relation to the original position on the vehicle. Use only genuine Geely parts for replacements. Refer to 3. Remove the tire and wheel assembly. Refer to 4.4.5.1 Wheel 1.4.2.2 Normal Driving Condition Service...
Page 30 1-24 Maintenance Vehicle Overview FE01-0004b Note For 'Directional' tires carry out rotation as shown below. EC718/EC718RV EC715/EC715RV 10/2009...
Page 31 Vehicle Overview Maintenance 1-25 FE01-0020b 5. Install the tire and wheel assemblies. Refer to 4.4.5.1 Wheel Replacement. 6. Remove the safety stands. 7. Lower the vehicle. 8. Check and adjust the tire inflation pressure. EC718/EC718RV EC715/EC715RV 10/2009...
Page 32: Service Information System
1-26 Service Information System Vehicle Overview 1.5 Service Information System 1.5.1 Description and Operation 1.5.1.1 Abbreviations Used In This Manual Abbreviations Description Anti-lock Brake Control System Airbag Control Module Body Control Module Controller Area Network Crankshaft Position Sensor Camshaft Position Sensor Data Link Connector Engine Control Module Engine Coolant Temperature Sensor...
Page 33: Arrows And Symbols Description
Vehicle Overview Service Information System 1-27 1.5.1.2 Arrows and Symbols Description FE01-0023b Legend 1. Arrow 2. Motion or Direction 3. Rotation Direction of the Arrow 4. Part Number 5. Enlarged Area EC718/EC718RV EC715/EC715RV 10/2009...
Page 34: Health And Safety
1-28 Health and Safety Vehicle Overview 1.6 Health and Safety contact with the propellant. If the gas containers happen to break, wear full protective clothing when handling the overflow 1.6.1 Description and Operation materials. 1.6.1.1 Description After deploying airbags, wear safety goggles and gloves when handling the airbags.
Page 35: Air-Conditioning Refrigerant
Vehicle Overview Health and Safety 1-29 – Do not touch the component or the gas generator within 10 When heated, engine coolant (ethylene glycol) may produce min of airbag being deployed. steam. Avoid inhaling the vapor. – Do not use electrical probe in the return circuit. After direct contact with engine coolant through the skin, directly absorbed dose may reach toxic or harmful dose.
Page 36: Dust
1-30 Health and Safety Vehicle Overview – Carefully read and follow the warnings on the containers of Flammable fine dust may cause explosion. Keep them away raw materials and any accompanying leaflets, posters or from an explosion or a fire. other instructions.
Page 37: Fire
Vehicle Overview Health and Safety 1-31 1.6.1.15 Fire Remember Do not inhale vapor or spray. These materials must be used at Many materials related to vehicle maintenance are extremely a well ventilated place or with respiratory protection measures. flammable. Some materials will produce toxic and harmful Do not immediately remove the mask after spraying.
Page 38: Lubricants And Grease
1-32 Health and Safety Vehicle Overview Oxygen, acetylene, argon and propane-like gas, is usually Do not be used engine oil as a lubricant, or any other purpose stored under 13.8 Mp (2,001 psi) pressure in the gas cylinder. that has direct contact with the skin. When handling these cylinders, you must be really careful.
Page 39: Standards And Metrics
Vehicle Overview Standards and Metrics 1-33 1.7 Standards and Metrics 1.7.1 Description and Operation 1.7.1.1 Equivalent - Decimal and Metric Fraction (in) Decimal (in) Metric (mm) 1 / 64 0.015625 0.39688 1 / 32 0.03125 0.79375 3 / 64 0.046875 1.19062 1 / 16 0.0625...
Page 40 1-34 Standards and Metrics Vehicle Overview Fraction (in) Decimal (in) Metric (mm) 15/32 0.46875 11.90625 31/64 0.484375 12.30312 1 / 2 12.7 33/64 0.515625 13.09687 17/32 0.53125 13.49375 35/64 0.546875 13.89062 9 / 16 0.5625 14.2875 37/64 0.578125 14.68437 19/32 0.59375 15.08125 39/64...
Page 41: Us English/Metric Units Conversion
Vehicle Overview Standards and Metrics 1-35 Fraction (in) Decimal (in) Metric (mm) 31/32 0.96875 24.60625 63/64 0.984375 25.00312 25.4 1.7.1.2 US English/Metric Units Conversion US English Multiply / Divide Metric US English measurement units calculation, divided by the number in the middle column . Metric measurement units calculation, multiplied by the number in the middle column .
Page 42 1-36 Standards and Metrics Vehicle Overview US English Multiply / Divide Metric Pound Force (lbf) 4.448 Newton (N) Acceleration 0.3048 ft / sec (ft / s m / sec (m / s 0.0254 ft / sec (ft / s m / sec (m / s Torque Pound Inch (lb-in)
Page 43: Vehicle Specifications
Vehicle Overview Vehicle Specifications 1-37 1.8 Vehicle Specifications 1.8.1 Specifications 1.8.1.1 Body Size Front View (Sedan) Front Wheel Distance 1,502 mm (59 in) Body Width 1,789 mm (70 in) FE01-0007b EC718/EC718RV EC715/EC715RV 10/2009...
Page 44 1-38 Vehicle Specifications Vehicle Overview Front View (Hatchback) Front Wheel Distance 1,502 mm (59 in) Body Width 1,789 mm (70 in) FE01-0007c EC718/EC718RV EC715/EC715RV 10/2009...
Page 45 Vehicle Overview Vehicle Specifications 1-39 Side View (Sedan) Body Length 4,635 mm (182 in) Approach Angle Minimum Clearance 167 mm (6 in) Departure Angle 21° 17°10'46" Wheel Base 2,650 mm (104 in) FE01-0008b EC718/EC718RV EC715/EC715RV 10/2009...
Page 46 1-40 Vehicle Specifications Vehicle Overview Side View (Hatchback) Body Length 4,397 mm (173 in) Approach Angle 16° Minimum Clearance 167 mm (6 in) Departure Angle 27° Wheel Base 2,650 mm (104 in) FE01-0008c EC718/EC718RV EC715/EC715RV 10/2009...
Page 47 Vehicle Overview Vehicle Specifications 1-41 Rear View (Sedan) Body Height 1,480 mm (58 in) Rear Wheel Distance 1,483 mm (58 in) FE01-0009b EC718/EC718RV EC715/EC715RV 10/2009...
Page 48 1-42 Vehicle Specifications Vehicle Overview Rear View (Hatchback) Body Height 1,470 mm (57 in) Rear Wheel Distance 1,492 mm (58 in) FE01-0009c EC718/EC718RV EC715/EC715RV 10/2009...
Page 49: Fastener Specifications
1.8.1.2 Fastener Specifications Fastener Specifications Table FE01-0010b Geely Automotive engineering standards have adopted some while maintaining the best thread quality for each size. As parts of the definition of the standard ISO metric fastener size, Metric bolts shown above, the intensity level increases with the aimed at reducing the number of different size fasteners used, number.
Page 50 1-44 Vehicle Specifications Vehicle Overview Torque Range Part name Application Specifications Metric (Nm) US English (lb-ft) Hex Head Bolt and Spring Washer Starter M10 × 1.25 × 60 38-45 28-33.2 Assembly Connecting the Engine Hexagon Flange Bolts M12 × 1.25 × 55 96-110 70.8-81.1 and Gearbox...
Page 51 Vehicle Overview Vehicle Specifications 1-45 Torque Range Part name Application Specifications Metric (Nm) US English (lb-ft) Hex Head Bolt Washer Air Cleaner Assembly M6 × 30 8-12 5.9-8.9 Assembly Hex Head Bolt Washer Fuel Tank M10 × 1.25 × 30 38-46 28-33.9 Assembly...
Page 52 1-46 Vehicle Specifications Vehicle Overview Torque Range Part name Application Specifications Metric (Nm) US English (lb-ft) Cross Slot Pockets Brake and Clutch Pedal Hexagon Head Bolts M8 × 16 16-26 11.8-19.2 Mounting Bracket and Washer Assembly Screw Driving Double Master Cylinder φ17 Steel Wire Hoop Hex Head Bolt, Spring...
Page 53 Vehicle Overview Vehicle Specifications 1-47 Torque Range Part name Application Specifications Metric (Nm) US English (lb-ft) Hex Head Bolt and Body and Sub-frame M6 × 14 26-32 19.2-23.6 Washer Assembly Hex Head Bolt and Body M6 × 30 26-32 19.2-23.6 Washer Assembly Hex Head Bolt and Power Steering Pump...
Page 54 1-48 Vehicle Specifications Vehicle Overview Torque Range Part name Application Specifications Metric (Nm) US English (lb-ft) Hex Head Bolt and Body M10 × 18 65-85 47.9-62.7 Washer Assembly Front Shock Absorber Hexagon Flange Bolt M14 × 55 32-38 23.6-28 and Steering Knuckle Hexagon Flange Bolt Front Sub-frame and M14 ×...
Page 55 Vehicle Overview Vehicle Specifications 1-49 Torque Range Part name Application Specifications Metric (Nm) US English (lb-ft) Hexagon Flange Nut Body 23-26 17-19.2 Hexagon Flange Bolt Body M8 × 20 29-35 21.4-25.8 Hexagon Flange Nut Body 23-26 17-19.2 Hexagon Flange Bolt Body M8 ×...
Page 56 1-50 Vehicle Specifications Vehicle Overview Torque Range Part name Application Specifications Metric (Nm) US English (lb-ft) Hexagon Flange Bolt Instrument Panel M8 × 100 8-12 5.9-8.9 Hexagon Head Bolt Instrument Panel M8 × 22 8-12 5.9-8.9 Instrument Panel Hexagon Flange Nut 8-12 5.9-8.9 Subassembly...
Page 57 Vehicle Overview Vehicle Specifications 1-51 Torque Range Part name Application Specifications Metric (Nm) US English (lb-ft) Cross Slot Pan Head Left Rear Door Trim ST4.8 × 1.6 5.5-6.3 4.1-4.7 Screw Panel Assembly Cross Slot Pan Head Right Rear Door Trim ST4.8 ×...
Page 58 1-52 Vehicle Specifications Vehicle Overview Torque Range Part name Application Specifications Metric (Nm) US English (lb-ft) Cross Slot Head Screw Right center Pillar Upper M6 × 16 3.5-5.5 3-4.4 and Washer Assembly Trim Panel Cross Slot Head Screw Left Quarter Upper Trim M6 ×...
Page 59 Vehicle Overview Vehicle Specifications 1-53 Torque Range Part name Application Specifications Metric (Nm) US English (lb-ft) Hexagon Flange Nut Hood Assembly 3.5-5.5 2.6-4.1 Cross Slot Pan Head Front Fender ST4.8 × 16 3-4.4 Screw Cross Slot Pan Head Rear Wheelhouse Liner ST4.8 ×...
Page 60 1-54 Vehicle Specifications Vehicle Overview Torque Range Part name Application Specifications Metric (Nm) US English (lb-ft) Hexagon Head Bolt and Front Seat M10 × 36 44-58 32.6-43 Washer Assembly Hexagon Flange Bolt Rear Seat M8 × 20 22-29 16.3-21.5 Hexagon Flange Bolt 7 / Child Seat Hook Inch 7 / 16 ×...
Page 61 Vehicle Overview Vehicle Specifications 1-55 Torque Range Part name Application Specifications Metric (Nm) US English (lb-ft) Hexagon Head Nut and Rear Compartment Lid Conical Washer 8-11 5.9-8.1 Hinge Assembly Hexagon Head Bolt and Instrument Panel M8 × 16 9-12 6.6-8.9 Washer Assembly Hexagon Head Bolt and Instrument Panel...
Page 62 1-56 Vehicle Specifications Vehicle Overview Torque Range Part name Application Specifications Metric (Nm) US English (lb-ft) Hexagon Nut and Air-Conditioning Inlet 3.7-5.2 Washer Assembly Pipe Hexagon Nut and Air-Conditioning M6 × 20 8-10 5.9-7.4 Washer Assembly Assembly Hexagon Flange Bolt Compressor M8 ×...
Page 63 Vehicle Overview Vehicle Specifications 1-57 Torque Range Part name Application Specifications Metric (Nm) US English (lb-ft) Cross Slot Pan Head Dome lamp With M5 × 8 2.2-3 Screw Sunroof Assembly Cross Slot Pan Head Dome lamp Assembly M5 × 8 2.2-3 Screw Cross Slot Pan Head...
Page 64: Vehicle Identification Number
A vehicle identification number (VIN) is stamped on the top right Plant Vehicle Type of the firewall. FE01-0021b Vehicle identification number L6T7844S68N138894, for example, the meaning of each figure represents the following table: Position Description Number/Letter Meaning Worldwide Manufacturer Zhejiang Geely Automotive Identification Code Co., Ltd. EC718/EC718RV EC715/EC715RV 10/2009...
Page 65 LJU - Shanghai Huapu Automotive Co., Ltd. LB3 - Zhejiang Haoqing Automotive Manufacturing Co., Ltd. First part (first - third digit) of vehicle identification number, of which: L6T - Zhejiang Geely Automotive Co., Ltd. The Fourth-Digit Serial Number Vehicle Type...
Page 66 1-60 Vehicle Identification Number Vehicle Overview Passenger Car / Bus Truck / Special Purpose Vehicle >3.7-3.8 >4.6-4.8 >2,000-2,500 >4,500-5,000 >3.8-4.0 >4.8 >2,500-3,000 >5,000 The Sixth-Digit Engine Displacement, Serial Number Engine Location Fuel Code ≤1 Front Gasoline >1-1.3 >1.3-1.5 >1.5-1.7 Gasoline >1.7-1.9 >1.9-2.1 Front...
Page 67 Vehicle Overview Vehicle Identification Number 1-61 The Seventh-Digit Body Type / Door Serial Number Bearing type Roof Open Roof Code Number Hatchback / 2 Door Hatchback / 5 Door Hatchback / 4 Door Sedan / 4 Door Load Type Hatchback / 2 Door Hatchback / 5 Door Hatchback / 4 Door Sedan / 4 Door...
Page 68 The 11th-Digit It is used to distinguish different assembly plants. Serial Number Name Code Zhejiang Haoqing Automotive Manufacturing Co., Ltd. Zhejiang Haoqing Automotive Manufacturing Co., Ltd (Bridge Branch) Geely Automotive Co., Ltd. Huapu Automotive Co., Ltd. Cixi Branch EC718/EC718RV EC715/EC715RV 10/2009...
Page 69: Compliance Label
Refer to the following table: Serial Number Month Code Serial Number Month Code 1.9.1.3 Compliance Label China Zhejiang Geely Automotive Co.Ltd China Zhejiang Geely Automotive Co.Ltd Brand:Geely Meiri Model: MR7180 L6T7844S68N138894 Number of Passengers: 5 Engine Type:JL 4G18-D Mass:1610kg Engine Rated Power:102KW...
Page 70: Tire Placard
1.9.1.6 Manual Transmission Serial Number capacity are specified on a tire placard. and its Location 1.9.1.5 Engine Serial Number and its Location Manual Transmission Serial Number Label (JL-S170B) Engine Serial Number (JLγ4G18-D) Zhejiang Geely Automotive Co.Ltd Product Certificate Product Model: JL-S170B Product Name: Transmission...
Page 71 Vehicle Overview Vehicle Identification Number 1-65 Manual Transmission Drive Axle Identification Number Location EC718/EC718RV EC715/EC715RV 10/2009...
Page 72: Noise, Vibration And Abnormal Sound
1-66 Noise, Vibration and Abnormal Sound Vehicle Overview 1.10 Noise, Vibration and Abnormal – Internal wind noise is caused by air escaping from the car. The repair should take the following approaches: Sound • When trying to determine the leak location, attach tapes 1.10.1 Description and Operation to the body pressure relief valve.
Page 73: Diagnostic Information And Procedures
Vehicle Overview Noise, Vibration and Abnormal Sound 1-67 Abnormal Sound Check the manual shift assembly. – Switch between gears and verify the squeak. At high engine speed, inspect whether the insulation shield comes into contact with the bottom of the body. –...
Page 74 1-68 Noise, Vibration and Abnormal Sound Vehicle Overview Before remove the tire, mark the position of the valve to make sure it can be installed back to the original position. Abnormal Sound Abnormal Sound Repair Abnormal sound mainly comes from parts that should not have relative motion.
Page 75: Water Leaks
Vehicle Overview Water Leaks 1-69 1.11 Water Leaks 1. Let an assistant inside the vehicle to confirm the exact location of water leaks. 1.11.1 Description and Operation 2. Start testing from the bottom of the window or the 1.11.1.1 Diagnostic Information windshield.
Page 76 1-70 Water Leaks Vehicle Overview 3. If it is fixed windows side-leakage, use a dedicated seam adhesive to repair or replace the windshield. EC718/EC718RV EC715/EC715RV 10/2009...
Page 77: Special Tools
Vehicle Overview Special Tools 1-71 1.12 Special Tools 1.12.1 Special Tools and Equipment 1.12.1.1 Power Train Special Tools Serial Illustration Tool Number Description Number GL201-001 Input Shaft Holding Fixture FE01-2001b GL201-002 Input Shaft Seal Installer FE01-2002b GL201-003 Input and Output Shaft Parts Installer FE01-2003b Transmission Input Shaft Bearing GL201-004...
Page 78 1-72 Special Tools Vehicle Overview Serial Illustration Tool Number Description Number GL201-005 Output Shaft Bearing Cup Remover FE01-2005b GL201-006 Output Shaft Bearing Cup Installer FE01-2006b GL201-007 Output Shaft Bearing Remover FE01-2007b GL201-008 Output Shaft Adjuster FE01-2008b Differential Clutch Housing Oil Seal GL201-009 Remover FE01-2009b...
Page 79 Vehicle Overview Special Tools 1-73 Serial Illustration Tool Number Description Number Differential Gearbox Housing Oil Seal GL201-010 Remover FE01-2010b GL201-011 Differential Bearing Remover FE01-2011b GL201-014 Manual Shift Assembly Oil Seal Installer FE01-2028b GT301-002 Driver Handle FE01-2014b GT301-006 Valve Oil Seal Remover FE01-2015b EC718/EC718RV EC715/EC715RV 10/2009...
Page 80 1-74 Special Tools Vehicle Overview Serial Illustration Tool Number Description Number GT301-008 Valve Oil Seal Installer FE01-2016b GT301-009 Valve Tube Remover FE01-2017b GT301-013 Crankshaft Front Oil Seal Installer FE01-2018b GT301-015 Crankshaft Rear Oil Seal Installer FE01-2019b GT301-016 Piston Pin Remover FE01-2020b EC718/EC718RV EC715/EC715RV 10/2009...
Page 81 Vehicle Overview Special Tools 1-75 Serial Illustration Tool Number Description Number GT301-017 Clutch Installer FE01-2021b GT301-018 Camshaft Positioning Tool FE01-2022b GT301-020 Camshaft Locking Tool GT301-021 Flywheel Holding Tool FE01-2023b GT301-022 Timing Chain Retention Tool FE01-2024b EC718/EC718RV EC715/EC715RV 10/2009...
Page 82: Chassis And Body Special Tools
1-76 Special Tools Vehicle Overview 1.12.1.2 Chassis and Body Special Tools Serial Illustration Tool Number Description Number GL401-001 Front Axle Wheel Hub Bearing Remover FE01-2025b GL401-002 Drive Shaft Ball Bearing Remover FE01-2026b GL401-003 Rear Axle Sleeve Remover FE01-2027b EC718/EC718RV EC715/EC715RV 10/2009...
Page 83: Engine
Engine Table of Contents 2 Engine 2.1 Warnings and Notices.....2-9 2.2.7.7 DTC Code (DTC) list........2-50 2.2.7.8 DTC Fail-Safe Table.........2-54 2.1.1 Warnings and Notices...........2-9 2.2.7.9 Data Stream List..........2-57 2.2 Control System JL4G18-D....2-11 2.2.7.10 Action Test Table...........2-62 2.2.7.11 DTC Code Index..........2-64 2.2.1 Specifications.........2-11 2.2.7.12 DTC P0010 P2088 P2089......2-69 2.2.1.1 Fastener Tightening Specifications....2-11 2.2.7.13 DTC P000A P0012.........2-73...
Page 84 Table of Contents Engine 2.3.8 Removal and Installation......2-249 2.2.7.46 Idle Speed Reading Procedure....2-203 2.3.8.1 Fuel Pressure Release Procedure....2-249 2.2.8 Removal and Installation......2-205 2.3.8.2 Fuel Filter Replacement.........2-249 2.2.8.1 Idle Air Control Valve Replacement....2-205 2.3.8.3 Fuel Pump Assembly Replacement....2-250 2.2.8.2 Fuel Injector Replacement......2-207 2.3.8.4 Fuel Level Sensor Replacement....2-254 2.2.8.3 Throttle Position Sensor Replacement...2-212 2.4 Auxiliary Emission Control JL4G18-D.
Page 85 Engine Table of Contents 2.5 Engine Anti-theft System JL4G18-D. 2- 2.6.1.3 Intake and Exhaust Valves Lifter Specifications Table................2-302 2.6.1.4 Intake and Exhaust Valves Lifter Selection Table... 2.5.1 Specifications........2-274 2-304 2.5.1.1 Fastener Tightening Specifications....2-274 2.6.2 Description and Operation....2-306 2.5.2 Description and Operation....2-275 2.6.2.1 Description and Operation......2-306 2.5.2.1 Description and Operation......2-275 2.6.3 System Working Principle.....2-307...
Page 86 Table of Contents Engine 2.6.8.6 Intake Manifold Assembly Replacement..2-343 2.7.5.4 Exhaust System Leakage.......2-438 2.6.8.7 Engine Mount Replacement......2-347 2.7.5.5 Exhaust System Noise........2-439 2.6.8.8 Timing Chain Tensioner Replacement...2-350 2.7.5.6 Exhaust System Repair Notes.......2-439 2.6.8.9 Timing Chain Cover Replacement....2-353 2.7.6 Removal and Installation......2-441 2.6.8.10 Timing Chain Replacement......2-360 2.7.6.1 Exhaust Manifold Replacement......2-441 2.6.8.11 Timing Chain Inspection.......2-366...
Page 87 Engine Table of Contents 2.10.2 Description and Operation....2-518 2.8.8.2 Coolant Recovery Reservoir Replacement..2- 2.10.2.1 Description and Operation......2-518 2.8.8.3 Cooling Fan Replacement......2-485 2.10.3 System Working Principle....2-519 2.8.8.4 Thermostat Replacement.......2-489 2.8.8.5 Radiator Replacement........2-492 2.10.3.1 System Working Principle......2-519 2.8.8.6 Water Pump Replacement......2-494 2.10.4 Component Locator......2-520 2.9 Lubricating System JL4G18-D..2-499 2.10.4.1 Component Locator........2-520 2.9.1 Specifications........2-499...
Page 88 Table of Contents Engine 2.11.3 System Working Principle....2-551 2.12.3 System Working Principle....2-593 2.11.3.1 Starting System Working Principle....2-551 2.12.3.1 Electronic Throttle Body (ETC) Working Principle. 2.11.3.2 Charging System Working Principle.....2-551 2-593 2.12.3.2 ECM Controlled Fuel Supply System...2-594 2.11.4 Component Locator......2-553 2.12.3.3 ECM Controlled Ignition System....2-595 2.11.4.1 Generator and Starter........2-553 2.12.3.4 Electronic Throttle Body Function Restrictions...2- 2.11.5 Disassemble View......2-554...
Page 89 Engine Table of Contents 2.13.1 Diagnostic Information and Procedures. . .2- 2.12.7.22 DTC P0131 P0132 P0133 P0134....2-670 2.12.7.23 DTC P0135..........2-677 2.12.7.24 DTC P0137 P0138 P0140......2-680 2.13.1.1 Fuel Pump Inoperative.........2-798 2.12.7.25 DTC P0141..........2-686 2.13.1.2 All Fuel Injectors Inoperative......2-803 2.12.7.26 DTC P0171 P0172 P1167 P1171 P2187 P2188. 2.13.2 Removal and Installation....2-807 2-689 2.12.7.27 DTC P0222 P0223........2-692...
Page 90 Table of Contents Engine 2.20.5 Removal and Installation....2-864 2.17 Exhaust System JL4G15-D..2-835 2.20.5.1 Camshaft Position Sensor Replacement..2-864 2.17.1 4G15-D Engine Exhaust System Overview..2-835 2.20.5.2 Ignition Coil Replacement......2-866 2.17.1 Specifications........2-836 2.20.5.3 High-voltage Damping Line Replacement..2- 2.17.1.1 Fastener Tightening Specifications....2-836 2.18 Engine Cooling System JL4G15-D. 2- 2.21 Starting / Charging System JL4G15-D ............2-871 2.18.1 4G15-D Engine Cooling System Overview..2-837...
Page 91: Warnings And Notices
Engine Warnings and Notices 2.1 Warnings and Notices Fuel Gage Leak Warning Warning! 2.1.1 Warnings and Notices Warning: Wrap a shop towel around the fuel pressure Battery Disconnect Warning connection in order to reduce the risk of fire and personal Warning! injury.
Page 92 2-10 Warnings and Notices Engine Lower O-Ring Removal Warning Warning! Warning: Verify that the lower (small) O-ring of each injector does not remain in the lower manifold in order to reduce the risk of fire and personal injury. If the O-ring is not removed with the injector, the replacement injector with new O-rings will not seat properly in the injector socket.
Page 93: Control System Jl4G18-D
Engine Control System JL4G18-D 2-11 2.2 Control System JL4G18-D 2.2.1 Specifications 2.2.1.1 Fastener Tightening Specifications Specifications Applications Model Metric (Nm) US English (lb-ft) Camshaft Position Sensor Retaining Bolts M6X14 8-10 6.0-7.4 Crankshaft Position Sensor Retaining Bolts M6X12 8-10 6.0-7.4 Ignition Coil Retaining Bolts M6X35 7-11 5.2-7.8...
Page 94 2-12 Control System JL4G18-D Engine Temperature (°C) / ( ºF) Resistance (Ω) -5/23 7,000 0/32 5,600 5/41 4,600 10/50 3,600 15/59 3,000 20/68 2,400 25/77 2,000 30/86 1,700 35/95 1,400 40/104 1,180 45/113 50/122 55/131 60/140 65/149 70/158 80/176 90/194 100/212 110/230 120/248...
Page 95 Engine Control System JL4G18-D 2-13 Altitude (m)/(ft) Atmospheric Pressure (kPa)/(psi) 2,100/6,890 74/10.7 1,800/5,906 77/11.2 1,500/4,921 80/11.6 1,200/3,937 83/12 900/2,953 87/12.6 600/1,969 90/13.1 300/984 93/13.5 100/14.5 2.2.1.4 Intake Air Pressure Sensor Voltage and Pressure Diagram Voltage Absolute Pressure FE02-2001b EC718/EC718RV EC715/EC715RV 10/2009...
Page 96 2-14 Control System JL4G18-D Engine 2.2.2 Description and Operation 2.2.2.2 Input Components 2.2.2.1 Overview 1. Crankshaft Position Sensor (CKP) The engine use an electronic control system manufactured by UAES(United Automotive Electronic Systems Co., Ltd.). It consists of the engine control module (ECM), ECM working circuit, system input and output parts.
Page 97 Engine Control System JL4G18-D 2-15 2. Camshaft Position Sensor (CMP) Intake air pressure and temperature sensor has an intake pressure sensing element and a thermistor. When the engine is working, the engine intake pressure sensing element produces the intake air pressure signal, negative temperature coefficient thermistor produces intake air temperature signal.
Page 98 2-16 Control System JL4G18-D Engine 6. Engine Coolant Temperature Sensor (ECT) Knock sensor is a frequency response sensor, installed in the engine block the most sensitive to knocking part, the lower intake manifold. ECM uses knock sensor to detect knock intensity, and then to adjust the ignition advance angle, to effectively control knocking and optimize the engine power, fuel economy and emission levels.
Page 99 Engine Control System JL4G18-D 2-17 The vehicle speed sensor is installed in the front transmission changes near the theoretical Air-Fuel ratio (λ=1). Sensor case, connected with differential speed sensor drive gear. signals pass through ECM harness connector EN01 terminal Speed sensor is a Hall-style. The main relay controlled by ECM No.45 to ECM.
Page 100 2-18 Control System JL4G18-D Engine 2.2.2.3 Output Components 12. Defrost Heating Enable Input The signal is provided by the BCM through a dedicated circuit 1. Idle Speed Control Valve (IAC) and is a voltage signal. The rear defrosting heating block is essentially a resistance wire with fairly high heating power.
Page 101 Engine Control System JL4G18-D 2-19 2.Cylinder No.1,2,3,4 Fuel Injectors ECM controls the fuel injectors through ECM harness connector EN01 terminals No.50,63,49,64. If a fuel injector or circuit is fault, DTC code P0201, P0202, P0203, P0204, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271 will be recorded.
Page 102 2-20 Control System JL4G18-D Engine 4. Variable Valve Timing Solenoid Valve (VVT) participate in combustion. Canister control valve consists of the electromagnetic coils, armature and valves. Canister inlet port has a filter. On one hand, air flow through the Canister control valve is related to ECM to the Canister control valve output electrical pulse duty cycle, on the other hand, it is related to the pressure difference between the Canister inlet port and outlet...
Page 103 Engine Control System JL4G18-D 2-21 8. High-Speed Cooling Fan Relay (A), Low-Speed Main relay is controlled by ECM, when turning the ignition switch to "ON" position, battery voltage passes through the Cooling Fan Relay (B) ignition switch to ECM 10 A fuse, and finally to ECM harness connector EN01 terminal No.17.
Page 104 2-22 Control System JL4G18-D Engine 11. Serial Data Cable Output The most typical serial data cable output application is the information exchange with the Anti-theft module. Scan tool diagnosis, data flow reading and other operations are also through the serial data cable. ECM harness connector EN01 terminals No.15,23 are for serial data communication.
Page 105 Engine Control System JL4G18-D 2-23 2.2.3 System Working Principle – Heavy Load-Enrich Mixture: The engine power output is maximum, in order to ensure the engine work properly, 2.2.3.1 System Working Principle ECM increases fuel injection duration according to throttle position, engine speed, flow,...
Page 106 2-24 Control System JL4G18-D Engine 2.2.3.3 Fault Self-Diagnostic and Protection Function In order to discover the engine electronically controlled gasoline injection system fault in time, and maintain the vehicle basic driving ability when a fault occurs, ECM has a fault diagnostic and self-protection function.
Page 107 Engine Control System JL4G18-D 2-25 2.2.4 Component Locator 2.2.4.1 Fuel Injector, Idle Speed Control Valve and VVT Solenoid Valve FE02-2002b Legend 1. Fuel Rail Injector Subassembly 3. VVT Solenoid Valve 2. Idle Speed Control Valve EC718/EC718RV EC715/EC715RV 10/2009...
Page 108 2-26 Control System JL4G18-D Engine 2.2.4.2 Throttle Position Sensor, Engine Solenoid Valve and Intake Air Pressure and Coolant Temperature Sensor, Canister Temperature Sensor Legend 1. Throttle Position Sensor 4. Intake Air Pressure and Temperature Sensor 2. Engine Coolant Temperature Sensor 3.
Page 109 Engine Control System JL4G18-D 2-27 2.2.5 Disassemble View 2.2.5.1 Throttle Body Assembly Legend 1. Idle Air Intake Channel 5. Throttle Limit Screw 2. Idle Speed Control Valve 6. Throttle Cable Mounting Bracket 3. Throttle Butterfly Valve Control Components 4. Throttle Position Sensor EC718/EC718RV EC715/EC715RV 10/2009...
Page 110 2-28 Control System JL4G18-D Engine 2.2.6 Schematic 2.2.6.1 Schematic 1. Ignition Switch 1. Idle Air Control Motor 2. Crankshaft Position Sensor 2. 1-2-3-4 Cylinder Fuel Injector 3. Camshaft Position Sensor 3. Ignition Coil 4. Intake Air Pressure Temperature Sensor 4. Variable Valve Timing Solenoid 5.
Page 111 Engine Control System JL4G18-D 2-29 Engine Control Module Fuel Pump Relay Main Relay Evaporative Canister Solenoid To Rearview Mirror VVT Solenoid Heater To Ignition Coil Ignition Relay Anti-theft Module Ignition Switch FE02-2101b EC718/EC718RV EC715/EC715RV 10/2009...
Page 112 2-30 Control System JL4G18-D Engine Ignition Relay Engine Control Module 1,4 Ignition Coil To Air Conditioning Pressure Switch 2,3 Ignition Coil Power Steering Switch Fan Low Speed Relay Fan High Speed Relay Idle Speed Control Valve Assembly Engine Coolant Temperature Sensor Evaporator Temperature Sensor A/C Relay Intake Air Temperature Sensor...
Page 113 Engine Control System JL4G18-D 2-31 Engine Control Module Pre-catalytic Oxygen Sensor Post-catalytic Oxygen Sensor Vehicle Speed Sensor FE02-2103b EC718/EC718RV EC715/EC715RV 10/2009...
Page 114 2-32 Control System JL4G18-D Engine 2.2.7 Diagnostic Information and Procedures 2.2.7.1 Diagnostic Description Before diagnose the control system, please refer to 2.2.2.1 Overviewand2.2.3.1 System Working Principle. Understand and become familiar with control system working principle and then start systematic diagnosis, so that in the event of faults it will help determine the correct Diagnostic Steps, more importantly, it will also help to determine whether the customer described situation is normal or not.
Page 115 Engine Control System JL4G18-D 2-33 Refer to 2.11.7.4 Engine Can Not Start Step 5 Select engine control module DTC code reading function. Is there any system DTC code? Refer to 2.2.7.3 Intermittent Fault Check Record and clear the DTC code. Step 6 Next Step 7...
Page 116 2-34 Control System JL4G18-D Engine Turn the ignition switch to "ON" position. Measure the voltage between datalink connector IP12 terminal 16 and a reliable ground. Datalink Connector IP12 Standard Voltage: 11-14 V Is the voltage normal? Check if the circuit between terminal 16 and the IF21 fuse open.
Page 117 Engine Control System JL4G18-D 2-35 Disconnect engine immobilizer control module IP25 wiring harness connector. Test the terminal continuity using an ohmmeter. Datalink Connector IP12 Connecting Multimeter Standard Value IP12(7) - IP25(7) Less than 1 Ω Reconnect the engine immobilizer control module IP25 wiring harness connector.
Page 118 2-36 Control System JL4G18-D Engine According to the Measure value, choose the appropriate diagnostic step. Results To Step 11 V or higher Less than 11 V Check the battery. Refer to 2.11.2.1 Battery Description and Operation Check visually and physically. Step 2 This step is an important method to initially identify the fault location:...
Page 119 Engine Control System JL4G18-D 2-37 Next Reproduce the fault and use instruments to record engine control module data. Step 4 Connect a scan tool and use the data record function to record road test data. After pressing the vehicle data recorder button, the scan tool can record engine control module data in the event of intermittent fault occurring, and then the data can be used to identify the fault location.
Page 120 2-38 Control System JL4G18-D Engine Symptoms Suspected Fault Items Relevant Sections 2. Starter Fault Definition: When the 3. Start Relay ignition switch in the "ST" 4. Ignition Switch position, the engine crankshaft is not rotating. 5. BCM "Engine Immobilizer System" in the2.5.7 Diagnostic Information and Procedures.
Page 121 Engine Control System JL4G18-D 2-39 Symptoms Suspected Fault Items Relevant Sections This section2.2.8.1 Idle Air Control Valve 6. Idle Air Control Valve Replacement. "Auxiliary Emissions Control Device" in 7. Crankcase Ventilation Valve the2.4.6 Diagnostic Information and Procedures. 8. Evaporative Emission (EVAP) "Auxiliary Emissions Control Device"...
Page 122 2-40 Control System JL4G18-D Engine Symptoms Suspected Fault Items Relevant Sections engine speed is not stable or 3.ECM This section2.2.8.8 Engine Control Module engine stall. Replacement. 1.ECM Power Supply Circuit This section2.2.7.37 DTC P0560 P0562 P0563. 2. Fuel Pressure Abnormal "Fuel System"...
Page 123 Engine Control System JL4G18-D 2-41 Symptoms Suspected Fault Items Relevant Sections 9. Air Leakage In Intake System and Crankcase System "Auxiliary Emissions Control Devices" in the2.4.6 Diagnostic Information and Procedures. 10. Crankcase Ventilation Valve Stagnant 11. Knock Sensor (KS) system ignition delay too great 12.
Page 124 2-42 Control System JL4G18-D Engine Symptoms Suspected Fault Items Relevant Sections 1. ECM Power Supply Circuit This section2.2.7.37 DTC P0560 P0562 P0563. 2. Air-conditioner Compressor "Air-Conditioning System" in the8.2.7 Diagnostic Information and Procedures. 3. Heated Oxygen Sensor Abnormal This section2.2.7.37 DTC P0560 P0562 P0563.
Page 125 Engine Control System JL4G18-D 2-43 Symptoms Suspected Fault Items Relevant Sections 12. Crankshaft Position Sensor This section2.2.7.29 DTC P0321 P0322. 13. Excessive Engine Oil in Combustion Chamber or Valve Seals Leakage 14. Cylinder Compression Pressure Incorrect 15. Valve Stagnant, Valve Spring "Engine Mechanical System"...
Page 126 2-44 Control System JL4G18-D Engine Symptoms Suspected Fault Items Relevant Sections 1. ECM Power Supply Circuit This section2.2.7.37 DTC P0560 P0562 P0563. 2. Intake Manifold Absolute Pressure This section2.2.7.17 DTC P0105 P0106 P0107 P0108. (MAP) Sensor Retardation, Engine Speed 3. Fuel Pressure Abnormal "Fuel System"...
Page 127 Engine Control System JL4G18-D 2-45 Symptoms Suspected Fault Items Relevant Sections 13. Cylinder Compression Pressure Incorrect 14. Valve Stagnant or Leakage 15. Camshaft Convex Corner Wear 16. Valve Timing Incorrect 17. Valve Spring Broken 18. Excessive Carbon Residue in Combustion Chamber Lack of Fuel Supply, Misfire Fault Definition: After the 19.
Page 128 2-46 Control System JL4G18-D Engine 2.2.7.5 ECM Connector Terminal Table FE02-5003b Note: 1. UB represents the battery voltage. 2. If there is no instructions, GND is 0 V or close to 0 V. Terminal Name Wire Terminal Description Status Specified Condition Number Intake Variable Cam Timing GND (<0.85 V)-UB of...
Page 129 Engine Control System JL4G18-D 2-47 Terminal Name Wire Terminal Description Status Specified Condition Number GND (<1.8 V)-UB of The Ignition Coil 2, Cylinder 3 AP-ZUE2I 0.85 Y Idle PWM Wave, Clamping Control Voltage (Nominal) 400 V Power Supply Controlled by U-U-UBR 1.5 B/R Ignition Switch "ON"...
Page 130 2-48 Control System JL4G18-D Engine Terminal Name Wire Terminal Description Status Specified Condition Number E-A-KS1B 0.5 L/W Knock Sensor B-Side Idle A-S-HR 0.5 B/R Main Relay Ignition Switch "ON" <1.8 V B-D-CANH 0.5 L/R CAN Bus Interface B-D-CANL 0.5 Y/R CAN Bus Interface Idle Air Control Valve Phase GND (<0.45 V)-UB of...
Page 131 Engine Control System JL4G18-D 2-49 Terminal Name Wire Terminal Description Status Specified Condition Number The water temperature High-Speed Fan Relay reaches the temperature A-S-FAN2 0.5 Lg/R GND or UB Control that turns on High-Speed fan. When the Vehicle is GND-UB of The PWM E-F-vfZ 0.5 Y Vehicle Speed Signal...
Page 132 2-50 Control System JL4G18-D Engine The MIL lamp will be lit in 2.5s when a fault occurs. If the fault has been repaired after 3 consecutive Type 4 driving cycles, the MIL lamp will be off. The fault will be deleted after 40 continuous trouble-free warmed- up driving cycles.
Page 133 Engine Control System JL4G18-D 2-51 DTC Code Description Type Fault Lamp Post-Catalytic Heated Oxygen Sensor Internal Resistance P0054 Unreasonable P0105 Intake Air Pressure Sensor Signal No Change (Frozen) P0106 Intake Air Pressure Sensor Malfunction P0107 Intake Air Pressure Sensor Circuit Short to Ground P0108 Intake Air Pressure Sensor Circuit Short to Power Supply P0112...
Page 134 2-52 Control System JL4G18-D Engine DTC Code Description Type Fault Lamp P0203 Cylinder No.3 Fuel Injector Control Circuit Open P0204 Cylinder No.4 Fuel Injector Control Circuit Open P0261 Cylinder No.1 Fuel Injector Control Circuit Short to Ground P0262 Cylinder No.1 Fuel Injector Control Circuit Short to Power Supply P0264 Cylinder No.2 Fuel Injector Control Circuit Short to Ground P0265...
Page 135 Engine Control System JL4G18-D 2-53 DTC Code Description Type Fault Lamp P0507 Idle Control Speed Higher Than Target P0508 Stepper Motor Driver Pin Short to Ground P0509 Stepper Motor Driver Pin Short to Power Supply P0511 Stepper Motor Driver Pin Open Circuit P0560 System Battery Voltage Signal Unreasonable P0562...
Page 136 2-54 Control System JL4G18-D Engine DTC Code Description Type Fault Lamp P2195 Pre-Catalytic Oxygen Sensor Aging (Too Lean) P2196 Pre-Catalytic Oxygen Sensor Aging (Too Rich) P2270 Post-Catalytic Oxygen Sensor Aging (Too Lean) P2271 Post-Catalytic Oxygen Sensor Aging (Too Rich) U0001 CAN High-Speed Data Communication Cable Malfunction U0121 Communication with ABS Controller Interrupted...
Page 137 Engine Control System JL4G18-D 2-55 DTC code Component Fail-Safe Operation Fail-Safe Lifting Condition P0262, P0261, P0201, P0268, Eligible Requirements P0267, P0203, P0271, P0270, Injectors 1,2,3,4 Prolonged Fault, Misfire Detected P0204, P0265, P0264, P0202 Pre-Catalytic Oxygen Sensor Oxygen Sensor Internal Eligible Requirements P0030, P0031 and P0032 Circuit Resistance Diagnosis Stop...
Page 138 2-56 Control System JL4G18-D Engine DTC code Component Fail-Safe Operation Fail-Safe Lifting Condition Misfire cylinder can not be Crankshaft and Camshaft Eligible Requirements P0016 determined. Cylinder group Relative Installation Position Detected fuel injection. Eligible Requirements P0010, P2088, P2089 VVT Circuit Stop VVT diagnosis.
Page 139 Engine Control System JL4G18-D 2-57 2.2.7.9 Data Stream List By reading the "Data Stream List" on the scan tool, you can check switches, sensors, actuators working state without removing any parts. Before the control system diagnosis, observing and analyzing data is the first step, so that the diagnose time could be shortened.
Page 140 2-58 Control System JL4G18-D Engine Ignition Switch 2,500 rpm Data Stream Name Idle Speed Diagnosis Description "ON" When ignition timing according to the air density. The intake air temperature is also compared with the ECT to identify the start up of the heating wire of Intake Air the heated oxygen sensor and diagnosis of 23°C (73.4 ºF)
Page 141 Engine Control System JL4G18-D 2-59 Ignition Switch 2,500 rpm Data Stream Name Idle Speed Diagnosis Description "ON" When Scan tool shows 0-16ms. It indicates that in each engine cycle, the number of the engine control module command connected to each injector. The greater the fuel injector pulse width, the more the fuel is injected.
Page 142 2-60 Control System JL4G18-D Engine Ignition Switch 2,500 rpm Data Stream Name Idle Speed Diagnosis Description "ON" When Under normal operating conditions, HO S output is 0.1-0.9V voltage. ECM receives this voltage signal and measures whether the Air-Fuel ratio is Group 1 Oxygen lean or rich.
Page 143 Engine Control System JL4G18-D 2-61 Ignition Switch 2,500 rpm Data Stream Name Idle Speed Diagnosis Description "ON" When adding more fuel or decrease fuel amount is need to control idle speed. Different from long-term idle, when the engine load is 30-75% and the air volume is 40-200kg/h, it monitors the long-term engine load and uses multiple-tuning to control idle speed.
Page 144 2-62 Control System JL4G18-D Engine Ignition Switch 2,500 rpm Data Stream Name Idle Speed Diagnosis Description "ON" When parameter shows the evaporative emission control module commands (EVAP) solenoid Canister Control valve Canister clean-up power supply time or 100% Valve Duty Cycle duty cycle.
Page 145 Engine Control System JL4G18-D 2-63 Scan Tool Display Test Component Control Range Diagnosis Description Item Note This test can only be carried out when the vehicle speed is equal to zero and vehicle Fuel Pump Relay Enable the fuel pump relay. ON/OFF speed sensor has no fault.
Page 146 2-64 Control System JL4G18-D Engine Scan Tool Display Test Component Control Range Diagnosis Description Item Delay the ignition advance Ignition Delay angle. • 600 rpm • 700 rpm • 800 rpm Control engine speed to the Idle Speed Control Control engine speed to the required speed. •...
Page 147 Engine Control System JL4G18-D 2-65 DTC Code Description Diagnostic Procedures Pre-Catalytic Heated Oxygen Sensor P0053 Refer to 2.2.7.15 DTC P0030 P0031 P0032 P0053. Internal Heating Resistance Unreasonable Post-Catalytic Heated Oxygen Sensor P0054 Refer to 2.2.7.16 DTC P0036 P0037 P0038 P0054. Internal Heating Resistance Unreasonable Intake Air Pressure Sensor Signal No P0105...
Page 148 2-66 Control System JL4G18-D Engine DTC Code Description Diagnostic Procedures Post-Catalytic Heated Oxygen Sensor P0140 Signal Malfunction Post-Catalytic Air-Fuel Ratio Closed-loop P0170 Control self learn Unreasonable Post-Catalytic Air-Fuel Ratio Closed-loop Refer to 2.2.7.23 DTC P0170 P0171 P0172 P2177 P2178 P2187 P0171 Control self learn Too Lean P2188.
Page 149 Engine Control System JL4G18-D 2-67 DTC Code Description Diagnostic Procedures P0321 Speed Reference Point Fault Refer to 2.2.7.29 DTC P0321 P0322. No CKP sensor Pulse Signal (Open or Short P0322 Circuit) Knock Sensor Signal Circuit Voltage Too P0327 Refer to 2.2.7.30 DTC P0327 P0328.
Page 150 2-68 Control System JL4G18-D Engine DTC Code Description Diagnostic Procedures P0562 System Battery Voltage Too Low P0563 System Battery Voltage Too High P0602 Electronic Control Unit Code Fault Refer to 2.2.7.38 DTC P0602. P0627 Pump Relay Control Circuit Open P0628 Pump Relay Control Circuit Short to Ground Refer to 2.2.7.39 DTC P0627 P0628...
Page 151 Engine Control System JL4G18-D 2-69 DTC Code Description Diagnostic Procedures Air-Fuel Ratio Closed-loop Control self learn P2187 Higher Than Maximum Limit (Low-Load Zone) Refer to 2.2.7.23 DTC P0170 P0171 P0172 P2177 P2178 P2187 P2188. Air-Fuel Ratio Closed-loop Control self learn P2188 Lower Than Minimum Limit (Low-Load Zone)
Page 152 2-70 Control System JL4G18-D Engine 2. Conditions For Setting DTC and The Fault Location: Conditions For Setting The DTC DTC Code DTC Detection Strategy Fault Locations (Control Strategy) 1. Circuit Open. 1. Solenoid Valve Circuit P0010 2. Circuit Short to Ground. 2.
Page 153 Engine Control System JL4G18-D 2-71 Disconnect VVT solenoid valve wiring harness connector EN10. VVT Solenoid Measure VVT solenoid valve resistance between the two terminals. Standard Resistance: 9.4-10.6 Ω (68 ºF) when 20°C Connect VVT solenoid valve wiring harness connector. Replace VVT solenoid valve assembly. Go to step 6 FE02-5005b Measure VVT solenoid valve working power supply voltage.
Page 154 2-72 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect VVT solenoid valve wiring harness connector VVT Solenoid Harness Connector EN10 EN10. Disconnect ECM harness connector EN01. Use multimeter to measure the resistance between VVT solenoid valve wiring harness connector EN10 terminal No. 2 and ECM harness connector EN01 terminal No.2.
Page 155 Engine Control System JL4G18-D 2-73 Road test the vehicle for at least 10 min. Read DTC control system code again to confirm that there is no DTC code. Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 7 5.
Page 156 2-74 Control System JL4G18-D Engine Conditions For Setting The DTC DTC Code DTC Detection Strategy Fault Locations (Control Strategy) 1. VVT actual angle and target angle difference is greater than or equal to 20°. 2. Camshaft completed self learn. 3. The engine running time is less than or equal to 1.5 s.
Page 157 Engine Control System JL4G18-D 2-75 Check engine oil level. The engine oil level should be within the range. Check if engine oil needs to be replaced or contains additives or engine oil viscosity is not correct. All normal? Replace the engine oil and oil filter, when necessary, clean the engine lubrication system.
Page 158 2-76 Control System JL4G18-D Engine Check VVT solenoid valve filter. Step 5 Remove VVT solenoid valve filter. Check whether filter is blocked. Check whether filter is damaged. Re-install VVT solenoid valve filter. Does VVT solenoid valve filter work properly? Clean VVT solenoid valve filter, if necessary, replace the VVT solenoid valve filter.
Page 159 Engine Control System JL4G18-D 2-77 Next Check control system DTC code. Step 8 Connect scan tool to datalink connector. Turn the ignition switch to "ON" position. Press scan tool power button. Select the following menu items: Engine/Read DTC codes. Read DTC codes. Are there DTC codes? Intermittent Fault.
Page 160 2-78 Control System JL4G18-D Engine 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis. Check valve timing system. Step 1 Check whether camshaft, crankshaft and timing chain is correct.
Page 161 Engine Control System JL4G18-D 2-79 Clear DTC code. Start and run the engine at idle speed to warm up the engine for at least 5 min. Road test the vehicle for at least 5 min. Read control system DTC code again to confirm that the system has no DTC code.
Page 162 2-80 Control System JL4G18-D Engine 3. Schematic: Main Relay Engine Pre-catalytic Oxygen Sensor Control Module To Post-catalytic Oxygen Sensor From Battery FE02-5008b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 163 Engine Control System JL4G18-D 2-81 Turn the ignition switch to "OFF" position. Disconnect oxygen sensor wiring harness connector. Pre-catalytic Oxygen Sensor Measure heater resistance between the Pre-Catalytic oxygen sensor terminal No.1 and terminal No.2. Standard Resistance: 9 Ω(68 ºF) at 20°C Connect the Pre-Catalytic oxygen sensor wiring harness connector.
Page 164 2-82 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect the Pre-Catalytic oxygen sensor wiring harness Pre-catalytic Oxygen Sensor Harness connector EN02. Connector EN02 Disconnect ECM harness connector EN01. Test continuity between the Pre-Catalytic oxygen sensor wiring harness connector EN02 terminal No.2 and ECM harness connector EN01 terminal No.6.
Page 165 Engine Control System JL4G18-D 2-83 Diagnostic completed. Step 8 5. Repair Instructions: Replace the Pre-Catalytic oxygen sensor. Refer to 2.4.7.2 Pre-Catalytic Oxygen Sensor Replacement. 2.2.7.16 DTC P0036 P0037 P0038 P0054 1. DTC Descriptor: P0036 Post-Catalytic Oxygen Sensor Heating Control Circuit Open P0037 Post-Catalytic Oxygen Sensor Heating Control Circuit Short to Ground P0038...
Page 166 2-84 Control System JL4G18-D Engine 3. Schematic: Main Relay Engine Control Post-catalytic Oxygen Sensor Module From Pre-catalytic Oxygen Sensor From Battery FE02-5012b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 167 Engine Control System JL4G18-D 2-85 Turn the ignition switch to "OFF" position. Disconnect the post-catalytic oxygen sensor wiring harness Post-catalytic Oxygen Sensor connector. Measure the Post-Catalytic oxygen sensor heater resistance. Standard Resistance: Between connector No.1 and No.2, 9 Ω (68 ºF) at 20°C Connect the post-catalytic oxygen sensor wiring harness connector.
Page 168 2-86 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect the post-catalytic oxygen sensor wiring harness Post-catalytic Oxygen Sensor Harness connector EN03. Connector EN03 Disconnect ECM harness connector EN01. Measure the continuity between the post-catalytic oxygen sensor wiring harness connector EN03 terminal No.2 and ECM harness connector EN01 terminal No.4.
Page 169 Engine Control System JL4G18-D 2-87 Diagnostic completed. Step 8 5. Repair Instructions: Replace the post-catalytic oxygen sensor. Refer to 2.4.7.1 Post-Catalytic Oxygen Sensor Replacement. 2.2.7.17 DTC P0105 P0106 P0107 P0108 1. DTC Descriptor: P0105 Intake Air Pressure Sensor Signal No Change (Frozen) P0106 Intake Air Pressure Sensor Unreasonable P0107...
Page 170 2-88 Control System JL4G18-D Engine Circuit Inspection, Lower Than P0108 Pressure sensor voltage is greater than 4.9 V. the Maximum Limit 3. Schematic: Engine To Temperature Sensor Control Module FE02-5016b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 171 Engine Control System JL4G18-D 2-89 Step 2 Measure intake manifold absolute pressure sensor 5 V reference voltage. Turn the ignition switch to "OFF" position. Disconnect intake manifold absolute pressure sensor wiring Intake Air Pressure Temperature harness connector EN16. Sensor Harness Connector EN16 Turn the ignition switch to "ON"...
Page 172 2-90 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect intake manifold absolute pressure sensor wiring harness connector EN16. Intake Air Pressure Temperature Turn the ignition switch to "ON" position. Sensor Harness Connector EN16 Measure resistance between intake manifold absolute pressure sensor wiring harness connector EN16 terminal No.
Page 173 Engine Control System JL4G18-D 2-91 Step 7 Check sensor signal circuit. Turn the ignition switch to "OFF" position. Disconnect intake manifold absolute pressure sensor wiring Intake Air Pressure Temperature harness connector EN16. Sensor Harness Connector EN16 Disconnect ECM harness connector EN01. Measure resistance between intake manifold absolute pressure sensor harness connector EN16 terminal No.4 and ECM harness connector terminal No.59.
Page 174 2-92 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect intake manifold absolute pressure sensor wiring Intake Air Pressure Temperature harness connector EN16. Sensor Harness Connector EN16 Disconnect ECM harness connector EN01. Measure resistance between intake manifold absolute pressure sensor harness connector EN16 terminal No.1 and ECM harness connector terminal No.40.
Page 175 Engine Control System JL4G18-D 2-93 Diagnostic completed. Step 12 5. Repair Instructions: Replace the MAP sensor. Refer to 2.2.8.7 Intake Air Pressure and Temperature Sensor Replacement. Refer to 2.2.8.8 Engine Control Module ReplacementReplace ECM. 2.2.7.18 DTC P0112 P0113 1. DTC Descriptor: P0112 Intake Air Temperature Sensor Signal Voltage Too Low P0113...
Page 176 2-94 Control System JL4G18-D Engine Sensor Wiring Harness Connector Loose Next Note It is not allowed to connect intake manifold absolute pressure sensor 5 V reference voltage circuit and other components of the vehicle, as this will damage the sensors and ECM. Step 2 Measure intake air temperature sensor resistance.
Page 177 Engine Control System JL4G18-D 2-95 Turn the ignition switch to "OFF" position. Disconnect intake air pressure and temperature sensor wiring harness connector EN16. Intake Air Pressure Temperature Turn the ignition switch to "ON" position. Harness Connector EN16 Measure resistance between intake air pressure and temperature sensor wiring harness connector EN16 terminal No.1 and a reliable ground.
Page 178 2-96 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect intake air pressure and temperature sensor Intake Air Pressure Temperature wiring harness connector EN16. Harness Connector EN16 Disconnect ECM harness connector EN01. Measure resistance between intake air pressure and temperature sensor wiring harness connector EN16 terminal No.1 and ECM harness connector terminal No.40.
Page 179 Engine Control System JL4G18-D 2-97 Diagnostic completed. Step 10 5. Repair Instructions: Replace intake air pressure and temperature sensor. Refer to 2.2.8.7 Intake Air Pressure and Temperature Sensor Replacement. 2.2.7.19 DTC P0117 P0118 1. DTC Descriptor: P0117 Engine Coolant Temperature Sensor Circuit Voltage Too Low P0118 Engine Coolant Temperature Sensor Circuit Voltage Too High ECT sensor is a variable resistor with negative temperature coefficient and is used to measure engine coolant temperature.
Page 180: Engine Coolant Temperature Sensor
2-98 Control System JL4G18-D Engine 3. Schematic: Engine Control Engine Coolant Temperature Sensor Module FE02-5029b 4. Diagnostic Steps: Warning! Refer to "Cooling System Servicing Warning" in "Warnings and Notices". Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 181: Engine Coolant Temperature
Engine Control System JL4G18-D 2-99 Turn the ignition switch to "OFF" position. Disconnect the engine coolant temperature sensor wiring Engine Coolant Temperature harness connector EN23. Measure engine coolant temperature sensor resistance. Standard Resistance (Refer to the specific parameters2.2.1.2 Temperature Sensor Temperature and Resistance Correlation): 2400 Ω...
Page 182 2-100 Control System JL4G18-D Engine Go to step 7 Check the engine coolant temperature sensor signal circuit. Step 5 Turn the ignition switch to "OFF" position. Disconnect the engine coolant temperature sensor wiring Engine Coolant Temperature Sensor harness connector EN23. Harness Connector EN23 Disconnect ECM harness connector EN01.
Page 183 Engine Control System JL4G18-D 2-101 Turn the ignition switch to "OFF" position. Disconnect the engine coolant temperature sensor wiring Engine Coolant Temperature Sensor harness connector EN23. Harness Connector EN23 Disconnect ECM harness connector EN01. Measure resistance between engine coolant temperature sensor wiring harness connector EN23 terminal C and ECM harness connector terminal No.40.
Page 184 2-102 Control System JL4G18-D Engine Diagnostic completed. Step 10 5. Repair Instructions: Replace the engine coolant temperature sensor. Refer to 2.2.8.6 Engine Coolant Temperature Sensor Replacement. 2.2.7.20 DTC P0122 P0123 1. DTC Descriptor: P0122 Throttle Position Sensor Circuit Voltage Lower Than Minimum P0123 Throttle Position Sensor Circuit Voltage Higher Than Maximum The actual throttle position will be compared with throttle position determined by the engine load.
Page 185 Engine Control System JL4G18-D 2-103 3. Schematic: Engine Control Throttle Body Position Sensor Module FE02-5035b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 186 2-104 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect throttle position sensor wiring harness connector EN27. Throttle Body Position Sensor Measure throttle position sensor resistance. Standard Resistance Test Items Value Terminal 1 and Terminal 2 3,000 Ω Changes between Terminal 2 and Terminal 3 1,300 Ω...
Page 187 Engine Control System JL4G18-D 2-105 Turn the ignition switch to "OFF" position. Disconnect throttle position sensor wiring harness connector Throttle Body Position Sensor EN27. Harness Connector EN27 Turn the ignition switch to "ON" position. Connect a 5A fuse between EN27 terminal No.2 and No.3. Use scan tool to read "the actual throttle position sensor voltage"...
Page 188 2-106 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect throttle position sensor wiring harness connector Throttle Body Position Sensor Harness Connector EN27 EN27. Disconnect ECM harness connector EN01. Measure resistance between throttle position sensor wiring harness connector EN27 terminal No.2 and ECM harness connector terminal No.18.
Page 189 Engine Control System JL4G18-D 2-107 Turn the ignition switch to "OFF" position. Disconnect throttle position sensor wiring harness connector Throttle Body Position Sensor Harness Connector EN27 EN27. Disconnect ECM harness connector EN01. Measure resistance between throttle position sensor wiring harness connector EN27 terminal No.3 and ECM harness connector terminal No.26.
Page 190 2-108 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect throttle position sensor wiring harness connector Throttle Body Position Sensor Harness Connector EN27 EN27. Disconnect ECM harness connector EN01. Measure resistance between throttle position sensor wiring harness connector EN27 terminal No.1 and ECM harness connector terminal No.39.
Page 191 Engine Control System JL4G18-D 2-109 Diagnostic completed. Step 12 5. Repair Instructions: Replace throttle position sensor. Refer to 2.2.8.3 Throttle Position Sensor Replacement. 2.2.7.21 DTC P0130 P0131 P0132 P0133 P0134 P2195 P2196 1. DTC Descriptor: P0130 Pre-Catalytic Oxygen Sensor Signal Unreasonable P0131 Pre-Catalytic Oxygen Sensor Circuit Voltage Too Low P0132...
Page 192 2-110 Control System JL4G18-D Engine DTC Detection Strategy Conditions For Setting The DTC (Control Strategy) Fault Locations Code 1. Pre-Catalytic oxygen sensor output voltage is greater than 1.5 V. 2. Pre-Catalytic oxygen sensor output voltage is less 1. Pre-Catalytic Sensor Voltage than 0.06 V.
Page 193 Engine Control System JL4G18-D 2-111 3. Schematic: Main Relay Engine Pre-catalytic Oxygen Sensor Control Module To Post-catalytic Oxygen Sensor From Battery FE02-5008b 4. Diagnostic Steps: Connect scan tool. Step 1 Next Step 2 Start engine and turn on the scan tool. Next Step 3 Maintain engine speed at 2,500 rpm for more than 2 min to warm up the engine, until the engine coolant...
Page 194 2-112 Control System JL4G18-D Engine Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Test the oxygen sensor signal. Step 6 If the voltage data is consistently below 0.45 V (mixture too lean), then carry out inspection steps as following: • Spray proper amount of propane gas into the intake port.
Page 195 Engine Control System JL4G18-D 2-113 Measure pre-catalytic oxygen sensor signal circuit. Step 8 Turn the ignition switch to "OFF" position. Disconnect oxygen sensor wiring harness connector EN02. Turn the ignition switch to "ON" position. Pre-catalytic Oxygen Sensor Measure voltage between Pre-Catalytic oxygen sensor Harness Connector EN02 wiring harness connector EN02 terminal No.4 and a reliable ground.
Page 196 2-114 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect oxygen sensor wiring harness connector EN02. Pre-catalytic Oxygen Sensor Disconnect ECM harness connector EN01. Harness Connector EN02 Measure resistance between pre-catalytic oxygen sensor wiring harness connector EN02 terminal No.4 and ECM harness connector terminal No.45.
Page 197 Engine Control System JL4G18-D 2-115 Turn the ignition switch to "OFF" position. Disconnect oxygen sensor wiring harness connector EN02. Pre-catalytic Oxygen Sensor Disconnect ECM harness connector EN01. Harness Connector EN02 Measure resistance between the oxygen sensor wiring harness connector EN02 terminal No.3 and ECM harness connector terminal No.39.
Page 198 2-116 Control System JL4G18-D Engine Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 16 5. Repair Instructions: Replace the pre-catalytic oxygen sensor. Refer to 2.4.7.2 Pre-Catalytic Oxygen Sensor Replacement. 2.2.7.22 DTC P0136 P0137 P0138 P0140 P2270 P2271 1.
Page 199 Engine Control System JL4G18-D 2-117 Conditions For Setting The DTC DTC Code DTC Detection Strategy Fault Locations (Control Strategy) 1. Post-Catalytic oxygen voltage signal is greater than 1.5 V. 2. Battery voltage is greater than 10.98 V. 3. Engine speed is greater than 25 rpm.
Page 200 2-118 Control System JL4G18-D Engine 3. Schematic Main Relay Engine Control Post-catalytic Oxygen Sensor Module From Pre-catalytic Oxygen Sensor From Battery FE02-5012b 4. Diagnostic Steps: Connect scan tool. Step 1 Next Step 2 Start engine and turn on the scan tool. Next Step 3 Maintain the engine speed at 2,500 rpm for more than 2 min to warm up the engine, until the engine coolant...
Page 201 Engine Control System JL4G18-D 2-119 Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Test the oxygen sensor signal. Step 6 If the voltage data is consistently below 0.45 V (mixture too lean), carry out steps as following: • Spray proper amount of propane gas into the intake. •...
Page 202 2-120 Control System JL4G18-D Engine DTC Codes Shown To Step P0136, P0137, P0138, P0140, P2270, P2271DTC, P0136, P0137, P0138, P0140, P2270, P2271 Refer to 2.2.7.11 DTC Code Index Inspect the exhaust system seal. Step 8 Check the three-way catalytic converter appearance (signs of excessive heat, gasket missing, etc.).
Page 203 Engine Control System JL4G18-D 2-121 Turn the ignition switch to "OFF" position. Disconnect the oxygen sensor wiring harness connector EN03. Post-Catalytic Oxygen Sensor Turn the ignition switch to "ON" position. Harness Connector EN03 Measure resistance between Post-Catalytic oxygen sensor connector EN03 terminal No.3 and a reliable ground. Standard Resistance: Less than 1 Ω...
Page 204 2-122 Control System JL4G18-D Engine Step 13 Check oxygen sensor ground circuit. Turn the ignition switch to "OFF" position. Disconnect the oxygen sensor wiring harness connector Post-Catalytic Oxygen Sensor EN03. Disconnect ECM harness connector EN01. Harness Connector EN03 Measure resistance between post-catalytic oxygen sensor wiring harness connector EN03 terminal No.3 and ECM harness connector terminal No.39.
Page 205 Engine Control System JL4G18-D 2-123 Read control system DTC code again to confirm that the system has no DTC code. Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 17 5. Repair Instructions: Replace post-catalytic oxygen sensor. Refer to 2.4.7.1 Post-Catalytic Oxygen Sensor Replacement.
Page 206 2-124 Control System JL4G18-D Engine 2. Conditions For Setting DTC and The Fault Location: Conditions For Setting The DTC DTC Code DTC Detection Strategy Fault Locations (Control Strategy) 1. Fuel Adjustment Value Higher Than Maximum Limit 1. Excessive air coefficient is higher 1.
Page 207 Engine Control System JL4G18-D 2-125 Refer to 2.2.7.17 DTC P0105 P0106 P0107 P0108 Read the throttle position sensor data. Step 3 Start the vehicle. Warm up the engine with normal idle speed and throttle opening is less than 10%. Use scan tool to read throttle position sensor data. Is throttle position sensor data normal? Refer to 2.2.7.20 DTC P0122 P0123...
Page 208 2-126 Control System JL4G18-D Engine Check whether there is excessive fuel in the crankcase. Check evaporative emission control systems working condition. (m) Check other fault lights in I/P working condition. Is engine System normal? System normal Step 7 Repair engine and its components. Next Step 8 System normal.
Page 209 Engine Control System JL4G18-D 2-127 3. Schematic: Main Relay Cylinder No.1 Fuel Injector Engine Control Module From Battery FE02-5051b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 210 2-128 Control System JL4G18-D Engine Disconnect the fuel injector wiring harness connector EN11. Measure resistance between the two fuel injector terminals. Standard Resistance: 20°C (68 ºF) 11.5-12.5 Ω Cylinder No.1 Fuel Injector Connect the fuel injector wiring harness connector EN11. Replace fuel injector assembly.
Page 211 Engine Control System JL4G18-D 2-129 Step 5 Check and repair cylinder No.1 fuel injector power supply circuit. Turn the ignition switch to "OFF" position. Disconnect the fuel injector wiring harness connector EN11. Remove the engine main relay. Cylinder No.1 Fuel Injector Harness Measure resistance between cylinder No.1 fuel injector Connector EN11 wiring harness connector EN11 terminal No.1 and engine...
Page 212 2-130 Control System JL4G18-D Engine Voltage Between EN11 (1) and a Reliable Ground Execute next step as per normal. Next Step 7 Check ECM power supply circuit. Check whether ECM power supply circuit is normal. Check whether ECM ground circuit is normal. Repair the faulty part.
Page 213 Engine Control System JL4G18-D 2-131 Fuel injector operating voltage is provided by The Main Relay which is controlled by ECM. Battery voltage passes through the main relay terminal No.3 to all fuel injector wiring harness connectors terminal No.1. ECM controls fuel injector ground circuit by ECM harness connector EN01 terminal No.63.
Page 214 2-132 Control System JL4G18-D Engine Check the fuel injector wiring harness connector for damage, poor connection, aging or signs of loosening. Next Measure the resistance of fuel injector assembly. Step 2 Disconnect the fuel injector wiring harness connector EN12. Measure resistance between the two fuel injector terminals. Standard Resistance: 20°C (68 ºF) 11.5-12.5 Ω...
Page 215 Engine Control System JL4G18-D 2-133 Turn the ignition switch to "OFF" position. Disconnect cylinder No.1 fuel injector wiring harness connector EN12. Cylinder No.2 Fuel Injector Harness Connect test lamp made from light-emitting diodes to the fuel Connector EN12 injector wiring harness connector EN12 terminal No.1 and No.2.
Page 216 2-134 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect cylinder No.2 fuel injector wiring harness connector EN12. Cylinder No.2 Fuel Injector Harness Disconnect ECM harness connector EN01. Connector EN12 Measure resistance between cylinder No.2 fuel injector wiring harness connector EN12 terminal No.1 and ECM harness connector terminal No.63.
Page 217 Engine Control System JL4G18-D 2-135 Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 10 5. Repair Instructions: Replace the fuel injector. Refer to 2.2.8.2 Fuel Injector Replacement. 2.2.7.26 DTC P0203 P0267 P0268 1. DTC Descriptor: P0203 Cylinder No.3 Fuel Injection Control Circuit Open P0267 Cylinder No.3 Fuel Injector Control Circuit Short to Ground P0268...
Page 218 2-136 Control System JL4G18-D Engine 3. Schematic Main Relay Engine Cylinder No.3 Fuel Injector Control Module From Battery FE02-5063b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 219 Engine Control System JL4G18-D 2-137 Disconnect the fuel injector wiring harness connector EN13. Measure resistance between the two fuel injector terminals. Standard Resistance: 20°C (68 ºF) 11.5-12.5 Ω Cylinder No.3 Fuel Injector Connect the fuel injector wiring harness connector EN13. Replace fuel injector assembly.
Page 220 2-138 Control System JL4G18-D Engine Step 5 Check and repair cylinder No.3 fuel injector power supply circuit. Turn the ignition switch to "OFF" position. Disconnect the fuel injector wiring harness connector EN13. Remove the engine main relay. Cylinder No.3 Fuel Injector Harness Measure resistance between cylinder No.3 fuel injector Connector EN13 wiring harness connector EN13 terminal No.1 and engine...
Page 221 Engine Control System JL4G18-D 2-139 Voltage Between EN13 (1) and a Reliable Ground Execute next step as per normal. Next Step 7 Check ECM power supply circuit. Check whether ECM power supply circuit is normal. Check whether ECM ground circuit is normal. Repair the faulty part.
Page 222 2-140 Control System JL4G18-D Engine Fuel injector operating voltage is provided by The Main Relay which is controlled by ECM. Battery voltage passes through the main relay terminal No.3 to all fuel injector wiring harness connectors terminal No.1. ECM controls fuel injector ground circuit by ECM harness connector EN01 terminal No.64.
Page 223 Engine Control System JL4G18-D 2-141 Check the fuel injector wiring harness connector for damage, poor connection, aging or signs of loosening. Next Measure the resistance of fuel injector assembly. Step 2 Disconnect the fuel injector wiring harness connector EN14. Measure resistance between the two fuel injector terminals. Standard Resistance: 20°C (68 ºF) 11.5-12.5 Ω...
Page 224 2-142 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect cylinder No.1 fuel injector wiring harness connector EN14. Cylinder No.4 Fuel Injector Harness Connect test lamp made from light-emitting diodes to the fuel Connector EN14 injector wiring harness connector EN14 terminal No.1 and No.2.
Page 225 Engine Control System JL4G18-D 2-143 Turn the ignition switch to "OFF" position. Disconnect cylinder No.4 fuel injector wiring harness Cylinder No.4 Fuel Injector Harness connector EN14. Disconnect ECM harness connector EN01. Connector EN14 Measure resistance between cylinder No.4 fuel injector wiring harness connector EN14 terminal No.1 and ECM harness connector terminal No.64.
Page 226 2-144 Control System JL4G18-D Engine Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 10 5. Repair Instructions: Replace the fuel injector. Refer to 2.2.8.2 Fuel Injector Replacement. 2.2.7.28 DTC P0300-P0304 1. DTC Descriptor: P0300 Multi-Cylinder Misfire P0301 Cylinder No.1 Misfire P0302 Cylinder No.2 Misfire...
Page 227 Engine Control System JL4G18-D 2-145 2. DTC Code Set Up and Removal Conditions: Conditions For Setting The DTC DTC Code DTC Detection Strategy Fault Locations (Control Strategy) 1. Each Cylinder Catalytic 1. Connector Loose or Poor Converter Damage Related Connection Misfire Counters.
Page 228 2-146 Control System JL4G18-D Engine 3. Schematic: Ignition System Main Relay IF30 Engine Control 1,4 Cylinder Ignition Coil Module Ignition Switch IG1 2,3 Cylinder Ignition Coil From Battery FE02-5075b EC718/EC718RV EC715/EC715RV 10/2009...
Page 229 Engine Control System JL4G18-D 2-147 Fuel Injector Main Relay Cylinder No.1 Fuel Injector Cylinder No.2 Fuel Injector Engine Cylinder No.3 Fuel Injector Control Module Cylinder No.4 Fuel Injector From Battery FE02-5076b 4. Diagnostic Steps: Note – If the control system stores DTC other than misfire, diagnose these DTC first and eliminate the faults. –...
Page 230 2-148 Control System JL4G18-D Engine Check the vacuum tube for damaged, loose, leakage and so Next Check for other DTC codes. Step 2 Connect scan tool to the datalink connector. Turn the ignition switch to "ON" position. Press the scan tool power button. Select the following menu items: Engine/Read DTC codes.
Page 231 Engine Control System JL4G18-D 2-149 Replace the spark plug. Refer to 2.10.8.4 Spark Plug Replacement. Go to step Note Prior to the implementation of this program, the following conditions must be met: 1. Disconnect all fuel injector connectors. 2. Engine running time must not be longer than 5 s. Check whether the spark plug arcing is normal.
Page 232 2-150 Control System JL4G18-D Engine 2. Run the engine for no longer than 5s. Step 9 Use a properly working spark plug and check whether there is misfire cylinder arcing. Replace the installed spark plug with a spark plug that works properly.
Page 233 Engine Control System JL4G18-D 2-151 Check valve timing system. Step 12 Refer to the "Engine Mechanical System" in the2.6.8.9 Timing Chain Cover Replacement, Is valve timing normal? Adjust the valve timing. Go to step 17 Check the fuel pressure. Step 13 Refer to "Fuel System"...
Page 234 2-152 Control System JL4G18-D Engine Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 18 5. Repair Instructions: Replace the spark plug. Refer to 2.10.8.4 Spark Plug Replacement. 2.2.7.29 DTC P0321 P0322 1. DTC Descriptor: P0321 Speed Reference Point Fault P0322 No CKP Sensor Pulse Signal (Open or Short Circuit) CKP sensor signal provides ECM with current crankshaft speed and position.
Page 235 Engine Control System JL4G18-D 2-153 3. Schematic: Crankshaft Position Sensor Engine Control Camshaft Position Sensor Module Oxygen Sensor Throttle Body Position Sensor FE02-5078b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 236: Crankshaft Position Sensor
2-154 Control System JL4G18-D Engine Standard Value: Normal data. Refer to 2.2.7.9 Data Stream List If the engine does not start, check the data with the engine running. If the engine speed is shown as "0", it indicates the circuit between the crankshaft position sensor and ECM wiring harness open or short.
Page 237 Engine Control System JL4G18-D 2-155 Turn the ignition switch to "OFF" position. Disconnect the crankshaft position sensor wiring harness Crankshaft Position Sensor Harness Connector EN26 connector EN26. Disconnect ECM harness connector EN01. Measure resistance between crankshaft position sensor wiring harness connector EN26 terminal No.1 and ECM harness connector EN01 terminal No.47.
Page 238 2-156 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect the crankshaft position sensor wiring harness Crankshaft Position Sensor Harness connector EN26. Connector EN26 Disconnect ECM harness connector EN01. Measure resistance between crankshaft position sensor wiring harness connector EN26 terminal No.2 and ECM harness connector EN01 terminal No.46.
Page 239 Engine Control System JL4G18-D 2-157 Next Use scan tool to confirm whether the DTC code is stored again. Step 10 Connect scan tool to the datalink connector. Turn the ignition switch to "ON" position. Clear DTC code. Start and run the engine at idle speed to warm up the engine for at least 5 min.
Page 240 2-158 Control System JL4G18-D Engine 1. Knock identification reference voltage is 0.35-0.60 V. 2. It occurs for more than 30 times successively. 3. Engine coolant temperature is greater P0327 Signal Range Too Low than 40°C (104 ºF). 4. Engine speed is greater than 2,600 rpm.
Page 241 Engine Control System JL4G18-D 2-159 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis. Initial Inspection Step 1 Check whether there is KS sensor physical damage.
Page 242 2-160 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect Knock Sensor harness connector EN08. Knock Sensor Measure knock sensor resistance. Standard Resistance: 49 kΩ at 20°C (68 ºF) Connect Knock Sensor harness connector EN08. Is resistance normal? Replace the knock sensor.
Page 243 Engine Control System JL4G18-D 2-161 Turn the ignition switch to "OFF" position. Disconnect Knock sensor harness connector EN08. Knock Sensor Harness Connector EN08 Disconnect ECM harness connector EN01. Measure resistance between knock sensor harness connector EN08 terminal No.2 and ECM harness connector EN01 terminal No.31.
Page 244 2-162 Control System JL4G18-D Engine Diagnostic completed. Step 10 5. Repair Instructions: Replaced the knock sensor. Refer to 2.10.8.5 Knock Sensor Replacement. 2.2.7.31 DTC P0340-P0343 1. DTC Descriptor: P0340 Camshaft Position Sensor Incorrectly Installed P0341 Camshaft Position Sensor Poor Connection P0342 Camshaft Position Sensor Circuit Short to Ground P0343...
Page 245 Engine Control System JL4G18-D 2-163 3. Schematic: Refer to 2.2.7.29 DTC P0321 P0322. 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis. Initial Inspection Step 1 Check the sensor wiring harness connector EN15 whether...
Page 246 2-164 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect camshaft position sensor wiring harness connector EN15. Camshaft Position Sensor Harness Connector EN15 Turn the ignition switch to "ON" position. Measure voltage between camshaft position sensor wiring harness connector EN15 terminal No.2 and a reliable ground.
Page 247 Engine Control System JL4G18-D 2-165 Turn the ignition switch to "OFF" position. Disconnect camshaft position sensor wiring harness connector EN15. Camshaft Position Sensor Harness Connector EN15 Disconnect ECM harness connector EN01. Measure resistance between camshaft position sensor harness connector EN015 terminal No.3 and ECM harness connector EN01 terminal No.18.
Page 248 2-166 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect camshaft position sensor wiring harness connector EN15. Camshaft Position Sensor Harness Connector EN15 Disconnect ECM harness connector EN01. Measure resistance between camshaft position sensor harness connector EN015 terminal No.2 and ECM harness connector EN01 terminal No.42.
Page 249 Engine Control System JL4G18-D 2-167 Turn the ignition switch to "OFF" position. Disconnect camshaft position sensor wiring harness connector EN15. Camshaft Position Sensor Harness Connector EN15 Disconnect ECM harness connector EN01. Measure resistance between camshaft position sensor wiring harness connector EN15 terminal No.1 and ECM harness connector EN01 terminal No.39.
Page 250 2-168 Control System JL4G18-D Engine Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 13 5. Repair Instructions: Replace the CMP sensor. Refer to 2.10.8.1 Camshaft Position Sensor Replacement. 2.2.7.32 DTC P0420 1. DTC Descriptor: P0420 Three-way Catalytic Converter Oxygen Storage Capacity Aging (Emission Over the Limit) ECM uses two oxygen sensors (Pre-Catalytic oxygen sensor and Post-Catalytic oxygen sensor) installed before and after the three- way catalytic converters to monitor the conversion efficiency of the three-way catalytic converter (TWC).
Page 251 Engine Control System JL4G18-D 2-169 DTC Codes Shown To Step DTC P0420 DTC Code Other Than DTC P0420 Refer to 2.2.7.11 DTC Code Index Start the engine and turn on the scan tool. Step 2 Next Keep the engine speed at 2,500 rpm for more than 2 min to warm up the engine, until the engine coolant Step 3 temperature reaches 80°C (176 ºF).
Page 252 2-170 Control System JL4G18-D Engine Step 5 Observe Pre-Catalytic oxygen sensor and Post-Catalytic oxygen sensor output voltages. Whether Pre-Catalytic oxygen sensor and Post-Catalytic oxygen sensor signal voltage is matching "Normal TWC" in the figure? Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Warning! Propane gas is a flammable gas.
Page 253 Engine Control System JL4G18-D 2-171 Step 9 Check whether there is exhaust leakage. Repair the faulty part. Go to step 11 Replace the post-catalytic oxygen sensor. Refer to 2.4.7.1 Post-Catalytic Oxygen Sensor Replacement. Step 10 Next Use scan tool to confirm whether the DTC code is stored again. Step 11 Connect scan tool to the datalink connector.
Page 254 2-172 Control System JL4G18-D Engine 2. Conditions For Setting DTC and The Fault Location: Conditions For Setting The DTC DTC Code DTC Detection Strategy Fault Locations (Control Strategy) 1. Circuit Open. 1. Canister Solenoid Valve P0444 Circuit 2. Circuit Short to Ground. P0458 Hardware Circuit Checks 2.
Page 255 Engine Control System JL4G18-D 2-173 Select the following menu: "Engine"/"Action Test"/"Canister Solenoid Valve". Use scan tool to enable the use of "Canister Control Valve". Place a finger over the vacuum port solenoid valve and check whether there is suction. Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Measure canister solenoid valve resistance.
Page 256 2-174 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect canister solenoid valve harness connector EN24. Evaporative Canister Solenoid Harness Connector EN24 Disconnect ECM harness connector EN01. Measure resistance between canister solenoid valve wiring harness connector EN24 terminal No.2 and ECM harness connector EN01 terminal No.37.
Page 257 Engine Control System JL4G18-D 2-175 Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 8 5. Repair Instructions: Replace EVAP solenoid valve. Refer to 2.4.7.3 Canister Solenoid Valve Replacement. 2.2.7.34 DTC P0480 P0481 P0691 P0692 P0693 P0694 1. DTC Descriptor: P0480 Cooling Fan Relay Control Circuit Open (Low Speed) P0482...
Page 258 2-176 Control System JL4G18-D Engine 5. Repair Instructions: Replace the cooling fan. Refer to 2.8.8.3 Cooling Fan Replacement. 2.2.7.35 DTC P0501 1. DTC Descriptor: P0501 Unreasonable Vehicle Speed Sensor Signal The vehicle speed signal is used to monitor the vehicle speed. The vehicle speed signal is one of the fuel control reference signals during an urgent deceleration.
Page 259 Engine Control System JL4G18-D 2-177 3. Schematic: Main Relay Engine Control Vehicle Module Speed Sensor To Meter From Battery FE02-5097b 4. Diagnostic Steps: Road test the vehicle. Is the vehicle speed meter display working properly? Step 1 If the instrument panel displays the vehicle speed as per normal, the vehicle speed sensor is working correctly.
Page 260 2-178 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect speed sensor wiring harness connector EN21. Disconnect ECM harness connector EN01. Vehicle Speed Sensor Harness Connector EN21 Measure resistance between the vehicle speed sensor harness connector EN21 terminal No.3 and ECM harness connector EN01 terminal No.57.
Page 261 Engine Control System JL4G18-D 2-179 Turn the ignition switch to "OFF" position. Disconnect speed sensor wiring harness connector EN21. Vehicle Speed Sensor Harness Connector EN21 Measure resistance between vehicle speed sensor harness connector EN21 terminal No.2 and a reliable ground. Check whether the circuit is short to ground.
Page 262 2-180 Control System JL4G18-D Engine 2.2.7.36 DTC P0506-P0509 P0511 1. DTC Descriptor: P0506 Controlled Idle Speed Lower Than Target Idle Speed P0507 Controlled Idle Speed Higher Than Target Idle Speed P0508 Stepper Motor Driver Pin Short to Ground P0509 Stepper Motor Driver Pin Short to Power Supply P0511 Stepper Motor Driver Pin Circuit Open ECM controls the engine idle speed by regulating the IAC valve core shaft position.
Page 263 Engine Control System JL4G18-D 2-181 DTC Detection Strategy Conditions For Setting The DTC (Control Strategy) Fault Locations Code 1. Static target idle speed and the actual idle speed difference is less than 100 rpm. 2. Idle speed integral part is equal to the maximum. 3.
Page 264 2-182 Control System JL4G18-D Engine 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis. Use scan tool to carry out idle air control valve action test. Step 1 Connect scan tool to the datalink connector.
Page 265 Engine Control System JL4G18-D 2-183 Replace idle speed control valve. Refer to 2.2.8.1 Idle Air Control Valve Replacement. Go to step 10 Step 4 Check idle speed control Valve terminal A circuit. Turn the ignition switch to "OFF" position. Disconnect idle speed control valve wiring harness connector EN17.
Page 266 2-184 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect idle speed control valve wiring harness connector EN17. Idle Control Valve Harness Connector EN17 Disconnect ECM harness connector EN01. Measure resistance between idle speed control valve wiring harness connector EN17 terminal B and ECM harness connector EN01 terminal No.21.
Page 267 Engine Control System JL4G18-D 2-185 Turn the ignition switch to "OFF" position. Disconnect idle speed control valve wiring harness connector EN17. Idle Control Valve Harness Connector EN17 Disconnect ECM harness connector EN01. Measure resistance between idle speed control valve wiring harness connector EN17 terminal C and ECM harness connector EN01 terminal No.35.
Page 268 2-186 Control System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect idle speed control valve wiring harness connector EN17. Idle Control Valve Harness Connector EN17 Disconnect ECM harness connector EN01. Measure resistance between idle speed control valve wiring harness connector EN17 terminal D and ECM harness connector EN01 terminal No.36.
Page 269 Engine Control System JL4G18-D 2-187 Read control system DTC code again to confirm that the system has no DTC code. Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 11 5. Repair Instructions: Replace idle speed control valve. Refer to 2.2.8.1 Idle Air Control Valve Replacement.
Page 270 2-188 Control System JL4G18-D Engine 3. Schematic: Main Relay Ignition Switch IG2 Engine Control Module FE02-5107b 4. Diagnostic Steps: Check ECM fuses EF04 and EF18. Step 1 Turn the ignition switch to "OFF" position. Remove fuses EF04, EF18 from the I/P fuse block. Use multimeter to measure whether there is conduction between the two terminals.
Page 271 Engine Control System JL4G18-D 2-189 Turn the ignition switch to "OFF" position. Remove IF12 from the I/P fuse block. Use multimeter to measure whether there is conduction between the two terminals. IF24 Conducted? IF20 IF14 IF27 IF19 Check whether there are short circuits. IF13 IF25 IF23...
Page 272 2-190 Control System JL4G18-D Engine Check charging system. Step 5 Check the battery voltage. Standard Voltage: 11-14 V Check the generator charging voltage. Standard Resistance: 11.5-14.5 V Normal? Repair the faulty part. Go to step 8 Check EF04 fuse to ECM circuit. Step 6 Turn the ignition switch to "OFF"...
Page 273 Engine Control System JL4G18-D 2-191 Turn the ignition switch to "OFF" position. Disconnect ECM harness connector EN01. Measure continuity between ECM harness connector EN01 IF24 terminal No.17 and fuse IF12. IF20 IF14 Measure resistance between ECM harness connector EN01 IF27 IF19 IF13 IF25...
Page 274 2-192 Control System JL4G18-D Engine 2. Conditions For Setting DTC and The Fault Location: Conditions For Setting The DTC DTC Code DTC Detection Strategy Fault Locations (Control Strategy) P0602 ECM Internal Monitoring 4. Diagnostic Steps: Check whether there is control system DTC code other than DTC P0602. Step 1 Connect scan tool to the datalink connector.
Page 275 Engine Control System JL4G18-D 2-193 P0629 Circuit Short to Power Supply. 3. Schematic: Main Relay Fuel Pump Relay Engine Fuel Pump Control Module From Battery FE02-5108b 4. Diagnostic Steps: Check fuel pump relay circuit. Refer to 2.3.7.3 Fuel Pump Inoperative. 2.2.7.40 DTC P0645-P0647 1.
Page 276 2-194 Control System JL4G18-D Engine 2. Conditions For Setting DTC and The Fault Location: Conditions For Setting The DTC DTC Code DTC Detection Strategy Fault Locations (Control Strategy) 1. Circuit Open. P0645 1. Air-Conditioning Relay 2. Circuit Short to Ground. P0646 Hardware Circuit Checks 2.
Page 277 Engine Control System JL4G18-D 2-195 P1614 Anti-theft Malfunction ECM communicates with the anti-theft control module via ECM harness connector EN01 terminal No.15 W-LIN and terminal No.23 R-LIN-line. For working details. Refer to. 2. Conditions For Setting DTC and The Fault Location: Conditions For Setting The DTC DTC Code DTC Detection Strategy...
Page 278 2-196 Control System JL4G18-D Engine 5. Repair Instructions: Repair the anti-theft system. Refer to2.5.7 Diagnostic Information and Procedures. 2.2.7.43 DTC P1523 U0001 U0121 U0140 U0151 1. DTC Descriptor: P1523 airbag control module to ECU Signals Interrupted or Incorrect U0001 CAN High-Speed Line Fault U0121 Communications with ABS Controller Interrupted U0140...
Page 279 Engine Control System JL4G18-D 2-197 3. Schematic: IP35 IP35 CA13 CA13 IP03 IP03 IP12 IP12 FE02-5116b 4. Diagnostic Steps: Refer to 11.17.7.6 CAN Bus Signal Diagnostic. 2.2.7.44 Engine Fault Lamp (MIL)/Check Vehicle Lamp Malfunction Description: CAN network is used in vehicles. Fault lamps are controlled via the instrument panel circuit. When ECM DTC code is set to light fault lamps, ECM sends a "Light the fault lamp"...
Page 280 2-198 Control System JL4G18-D Engine Repair instrument cluster ground circuit. Refer to 11.7.6.7 DTC U129C U129D. Fault solved? System normal Check the instrument DTC codes. Step 3 Connect scan tool. Turn the ignition switch to "ON" position. Scan instrument DTC. Is there DTC U1430? Go to step 5 Test the fault indicator lamp.
Page 281 Engine Control System JL4G18-D 2-199 Repair ECM power supply circuit. Step 7 Repair ECM power supply circuit. Refer to 2.2.7.37 DTC P0560 P0562 P0563. Fault solved? System normal Replace ECM. Step 8 Connect scan tool. Turn the ignition switch to "ON" position. Scan ECM DTC codes, identify ECM fault.
Page 282 2-200 Control System JL4G18-D Engine Scan ECM for DTC codes. Step 2 Connect scan tool. Turn the ignition switch to "ON" position. Scan ECM for DTC codes. Check DTC P0627 and any fuel system related DTC codes and repair the faulty part. Refer to 2.2.7.11 DTC Code Index.
Page 283 Engine Control System JL4G18-D 2-201 Turn the ignition switch to "OFF" position. Disconnect fuel pump harness connector SO29. Connect scan tool. Fuel Pump Harness Connector SO29 Turn the ignition switch to "ON" position. Select scan tool "Fuel Pump Relay" in the "Action Test" to drive the fuel pump relay.
Page 284 2-202 Control System JL4G18-D Engine Replace fuel pump assembly. Refer to 2.3.8.3 Fuel Pump Assembly Replacement. Start the engine, fault solved? System normal Inspect (repair) fuel injectors. Step 9 Inspect (repair) fuel injectors. Refer to the DTC code2.2.7.24 DTC P0201 P0261 P0262in the repair procedures.
Page 285 Engine Control System JL4G18-D 2-203 System normal Step 13 Test the cylinder pressure. Test the cylinder pressure. Refer to the "Engine Mechanical System" in the. Standard Cylinder Pressure: 800 kPa All cylinders compression pressure equal to or higher than the specified value? Go to step 16 Step 14...
Page 286 2-204 Control System JL4G18-D Engine – Engine control module is disconnected or replaced. – The fuse between the ignition voltage IGN1 or battery positive voltage and the engine control module is removed. – The idle air control valve has been removed or replaced. –...
Page 287 Engine Control System JL4G18-D 2-205 2.2.8 Removal and Installation 2.2.8.1 Idle Air Control Valve Replacement Removal Procedure: Note Refer to "Battery Disconnection Warning" in the "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Disconnect idle speed control valve wiring harness connector.
Page 288 2-206 Control System JL4G18-D Engine Remove the idle speed control valve from the throttle body. Note Do not drop the idle speed control valve O-ring. FE02-0003b Installation Procedure: Clean carbon residue in the throttle body idle speed control valve air bypass. FE02-0004b Install and tighten idle speed control valve retaining bolts.
Page 289 Engine Control System JL4G18-D 2-207 Connect the idle speed control valve wiring harness connector. Connect the battery negative cable. 2.2.8.2 Fuel Injector Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in the "Warnings and Notices". Release fuel system pressure. Refer to 2.3.8.1 Fuel Pressure Release Procedure.
Page 290 2-208 Control System JL4G18-D Engine Remove the fuel pipe from the fuel rail. FE02-0025b Remove the fuel rail retaining bolts. FE02-0026b Remove the fuel rail and fuel injector assembly. Note Plug four fuel injector holes immediately after removal to prevent debris falling into the cylinder causing engine damage.
Page 291 Engine Control System JL4G18-D 2-209 Remove fuel injectors retaining clips. 10. Pull fuel injectors out of the fuel rail. Installation Procedure: Apply a small amount of engine oil to lubricate the fuel injector O-ring. Install the fuel injectors to the fuel rail. Note The fuel injector terminals should face outside.
Page 292 2-210 Control System JL4G18-D Engine Install fuel injector retaining clips to ensure that the fuel injector wiring harness connector and the fuel rail mounting hole are in the same direction. FE02-0031b Install the fuel rail. Install the fuel rail retaining bolts. Torque: 9 Nm (Metric) 6.66 lb-ft (US English) FE02-0033b EC718/EC718RV EC715/EC715RV 10/2009...
Page 293 Engine Control System JL4G18-D 2-211 Connect the fuel pipe. Note The fuel pipe must be inserted into the fuel rail after the second boss and then tightened with the clips. FE02-0034b Connect the fuel injector wiring harness connector. FE02-0035b Restore the self-locking device. FE02-0036b EC718/EC718RV EC715/EC715RV 10/2009...
Page 294 2-212 Control System JL4G18-D Engine Install the crankcase ventilation tube. 10. Connect the battery negative cable. Note Start the engine. Check fuel and fuel injectors for fuel leaks and vacuum leaks. 11. Install the engine hood. FE02-0037b 2.2.8.3 Throttle Position Sensor Replacement Removal Procedure: Note Refer to "Battery Disconnection Warning"...
Page 295 Engine Control System JL4G18-D 2-213 Installation Procedure: Install and tighten the throttle position sensor retaining bolts. Note During the installation procedure align the throttle shaft groove with the sensor boss. Install the throttle body assembly. Connect the battery negative cable. FE02-0039b 2.2.8.4 VVT Solenoid Valve Replacement and Filter Cleaning...
Page 296 2-214 Control System JL4G18-D Engine Remove VVT solenoid valve retaining bolts and remove the VVT solenoid valve. Installation Procedure: Note After replacing the VVT solenoid valve, you must carry out the "Clean Solenoid Valve Filter" procedure, other it cause electromagnetic valve damage. Make sure the new VVT solenoid valve seals are intact.
Page 297 Engine Control System JL4G18-D 2-215 Connect the VVT solenoid valve wiring harness connector. FE02-0044b Clean the solenoid valve filter: Remove the generator. Refer to 2.11.8.3 Generator Replacement. Remove the VVT solenoid valve filter sealing bolts. Remove the VVT solenoid valve filter with a plier. EC718/EC718RV EC715/EC715RV 10/2009...
Page 298 2-216 Control System JL4G18-D Engine Clean the filter and make sure the solenoid valve is not damaged or deformed, otherwise it must be replaced. Install the VVT solenoid valve filter. FE02-0047b Install the solenoid valve filter and tighten the bolts. Torque: 16.5 Nm (Metric) 12.2 lb-ft (US English) Install the generator.
Page 299 Engine Control System JL4G18-D 2-217 Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Remove VVT solenoid valve. Refer to 2.2.8.4 VVT Solenoid Valve Replacement and Filter Cleaning. Clean the VVT solenoid valve hole, return hole, the chamber. Note During the cleaning process, keep the VVT solenoid valve and wiring harness connector upright, otherwise the cleaning agent will easily enter the...
Page 300 2-218 Control System JL4G18-D Engine 2.2.8.6 Engine Coolant Temperature Sensor Replacement Removal Procedure: Warning! Refer to "Cooling System Service Warning" in "Warnings and Notices". Release cooling system pressure. Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Disconnect the engine coolant temperature sensor wiring harness connector.
Page 301 Engine Control System JL4G18-D 2-219 2.2.8.7 Intake Air Pressure and Temperature Sensor Replacement Removal Procedure: Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Disconnect intake air pressure and temperature sensor wiring harness connector. Remove the intake manifold assembly. Refer to 2.6.8.6 Intake Manifold Assembly Replacement.
Page 302 2-220 Control System JL4G18-D Engine Installation Procedure: Clean the intake air pressure and temperature sensor installation position and apply new seals. Note The seal is single used only. After removal, a new seal must be installed. FE02-0054b Install the sensor retaining bolt. Torque: 9 Nm (Metric) 6.66 lb-ft (US English) FE02-0055b Install the intake manifold assembly.
Page 303 Engine Control System JL4G18-D 2-221 2.2.8.8 Engine Control Module Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices" Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Remove the glove box. Refer to 12.8.3.2 Glove Box Replacement.
Page 304: Fuel System Jl4G18-D
2-222 Fuel System JL4G18-D Engine 2.3 Fuel System JL4G18-D 2.3.1 Specifications 2.3.1.1 Fastener Tightening Specifications Specifications Applications Model Metric (Nm) US English (lb-ft) Fuel Tank Retaining Bolt M10 × 1.25 × 30 38-46 28.2-34.0 Fuel Filter Mounting Bracket M6 × 16 8-10 6.0-7.4 Retaining Bolt...
Page 305: Fuel Tank
Engine Fuel System JL4G18-D 2-223 2.3.2 Description and Operation the fuel pipe fuel flow and to control the fuel injectors pressure. When the ignition switch is at ON position and the engine is 2.3.2.1 Description and Operation shut down, the system fuel pressure should be about 400 kPa. The fuel supply system provides a suitable amount of fuel to 5.
Page 306: Fuel Injectors
2-224 Fuel System JL4G18-D Engine 9. Fuel Injectors Fuel injector is a solenoid valve device controlled by the engine control module. When the engine control module provides power supply to the fuel injector coil, normally closed ball valve opens, allowing fuel flow through the diffuser plate to fuel injector outlet.
Page 307: Acceleration Mode
Engine Fuel System JL4G18-D 2-225 2.3.3 System Working Principle can not shut down. In addition, if the reference pulse is not received, there will be no fuel supply, in order to prevent fuel 2.3.3.1 System Working Principle overflow. Intake manifold absolute pressure sensor senses and measures intake manifold vacuum.
Page 308 2-226 Fuel System JL4G18-D Engine 2.3.4 Component Locator 2.3.4.1 Fuel Filler FE02-2018b EC718/EC718RV EC715/EC715RV 10/2009...
Page 309 Engine Fuel System JL4G18-D 2-227 2.3.4.2 Fuel Supply System Legend 1. Filling Tube 6. Fuel Pipe and Evaporative Pipe 2. Canister 7. Canister Solenoid Valve 3. Filter 4. Tank 5. Fuel Pump With a Fuel Sensor Assembly EC718/EC718RV EC715/EC715RV 10/2009...
Page 310 2-228 Fuel System JL4G18-D Engine 2.3.4.3 Fuel Tank Assembly Legend 1. Fuel Vapor Vacuum Hose 5. Fuel Vapor Ventilation Valve 2. EVAP Hose 3. Fuel Pump Outlet Pipe 4. Fuel Pump Return Pipe EC718/EC718RV EC715/EC715RV 10/2009...
Page 311 Engine Fuel System JL4G18-D 2-229 2.3.4.4 Fuel Pump Assembly FE02-2021b Legend 1. Fuel Level Sensor 4. Fuel Pump Return Port 2. Fuel Pressure Regulator 3. Fuel Pump Outlet Port EC718/EC718RV EC715/EC715RV 10/2009...
Page 312 2-230 Fuel System JL4G18-D Engine 2.3.4.5 Fuel Injectors EC718/EC718RV EC715/EC715RV 10/2009...
Page 313 Engine Fuel System JL4G18-D 2-231 2.3.5 Disassemble View 2.3.5.1 Disassemble View Oil Rail and Jet Assembly Disassemble View FE02-2023b Legend 1. Fuel Rail 3. Spring Clip 2. Fuel Injectors EC718/EC718RV EC715/EC715RV 10/2009...
Page 314 2-232 Fuel System JL4G18-D Engine 2.3.6 Schematic 2.3.6.1 Schematic Cylinder No.4 Fuel Injector Cylinder No.3 Fuel Injector Cylinder No.2 Fuel Injector Battery Main Ignition Switch Voltage Relay Cylinder No.1 Fuel Injector Fuel Disable/Enable Pump Fuel Signal Relay Fuel Pump FE02-2024b EC718/EC718RV EC715/EC715RV 10/2009...
Page 315 Engine Fuel System JL4G18-D 2-233 2.3.7 Diagnostic Information and Procedures 2.3.7.1 Diagnostic Descriptions Refer to 2.3.2.1 Description and OperationGet familiar with the system functions and operations before start system diagnostics, so that it will help to determine the correct diagnostic steps in the event of fault, more importantly, it will also help to determine whether the customer described situations are normal.
Page 316 2-234 Fuel System JL4G18-D Engine Is the fuel pump fuse EF05 blown? Go to step 3 1413 12 11 10 FE02-5403b Repair fuel pump fuse EF05 circuit. Step 2 Check fuel pump fuse EF05 circuit. Repair fuel pump power circuit short to ground fault. Replace the fuse EF05.
Page 317 Engine Fuel System JL4G18-D 2-235 System normal Step 5 Check fuel pump relay terminal 2 voltage. Check fuel pump relay terminal 2 voltage with a multimeter. Standard Voltage: 11-14 V Go to step 7 EF28 EF27 EF08 EF01 FE02-5405b Repair the main relay circuit fault. Step 6 Repair the main relay circuit fault.
Page 318 2-236 Fuel System JL4G18-D Engine Turn on the ignition switch. Connect a test lamp between ECM harness connector EN01 terminal 61 and the body ground circuit. Use scan tool to carry out pump relay "Action Test". Is test lamp lit? Go to step 9 FE02-5406b Step 8...
Page 319 Engine Fuel System JL4G18-D 2-237 Replace the fuel pump relay. Step 10 Replace the fuel pump relay. Is fuel pump working properly? System normal Step 11 Check the fuel pump wiring harness connector SO29 terminal 3 voltage. Check the fuel pump wiring harness connector SO29 terminal 3 voltage with a multimeter.
Page 320 2-238 Fuel System JL4G18-D Engine Check circuit between fuel pump wiring harness connector SO29 terminal 3 and the fuel pump relay terminals 5. Repair open circuit fault between fuel pump wiring harness Fuel Pump Harness Connector SO29 connector SO29 terminal 3 and the fuel pump relay terminals Is fuel pump working properly? System normal EF28...
Page 321 Engine Fuel System JL4G18-D 2-239 Replace the fuel pump. Step 15 Replace the fuel pump. Refer to 2.3.8.3 Fuel Pump Assembly Replacement. Confirm repair completed. Next Step 16 System normal. 2.3.7.4 All Fuel Injectors Inoperative Schematic: To Ignition Switch Main Relay Fuel Injector 1 Fuel Injector 2 Engine...
Page 322 2-240 Fuel System JL4G18-D Engine Repair the engine anti-theft system. Step 2 Repair the engine anti-theft system. Refer to 2.5.7.12 Engine Anti-theft Warning Lamp Flashing, Vehicle Can Not Start. Is fuel injector working properly? System normal Check ECM fuse. Step 3 Is ECM fuse IF12 blown? Go to step 6 IF24...
Page 323 Engine Fuel System JL4G18-D 2-241 Repair ECM power supply short to body ground fault. Replace fuse IF12. Is fuel injector working properly? System normal FE02-5413b Step 5 Inspect and repair ECM ground circuit. Check ECM ground circuit. Repair ECM EN01 terminals 5,43,48 to the body open circuit fault.
Page 324 2-242 Fuel System JL4G18-D Engine Check the fuel injector wiring harness connector terminal 1 voltage. Step 6 Turn on point switch. Measure fuel injectors wiring harness connector terminal 1 voltage with a multimeter . Cylinder No.1 Fuel Injector Harness Connector EN11 Standard Voltage: 11-14 V Is voltage the Standard Value? Go to step 8...
Page 325 Engine Fuel System JL4G18-D 2-243 System normal Step 10 Replace the fuel injector. Replace the fuel injector. Refer to 2.2.8.2 Fuel Injector Replacement. Confirm repair completed. Next System normal. Step 11 2.3.7.5 Fuel Gage Inaccurate Refer to 11.7.6.6 DTC U1303 U1304.
Page 326 2-244 Fuel System JL4G18-D Engine Check the fuel pressure, is it normal? Step 4 Refer to 2.3.7.7 Fuel Pressure Testing Procedure. Check whether the pipeline is blocked, if necessary, replace the failed component. Use the scan tool "Fuel Injector Cleaning and Testing Machine" function, test the performance of the cylinder Step 5 fuel injector.
Page 327 Engine Fuel System JL4G18-D 2-245 • Observe whether there is a significant change in the pre- catalytic oxygen sensor voltage data, as the signal voltage will increase rapidly. During the above test, the oxygen sensor signal voltage should have a significant change. Significant voltage change? Signal Voltage No Response Signal Voltage Remains High...
Page 328 2-246 Fuel System JL4G18-D Engine "Air-Conditioning System" in the8.2.7 Diagnostic Information Procedures. Repair the faulty part. Check whether the exhaust system is normal? Step 12 Inspect the exhaust system for blocking. Refer to the "Engine Exhaust System" in the2.7.5.3 Exhaust System Blockage.
Page 329 Engine Fuel System JL4G18-D 2-247 2.3.7.7 Fuel Pressure Testing Procedure Warning! Gasoline and gasoline vapor is highly flammable. In order to avoid fire or explosion, please select keep away from a fire. It is prohibited to use mobile phones during this procedure. Do not use open containers to store gasoline exhaust emissions.
Page 330 2-248 Fuel System JL4G18-D Engine Next End. Step 10 EC718/EC718RV EC715/EC715RV 10/2009...
Page 331 Engine Fuel System JL4G18-D 2-249 2.3.8 Removal and Installation 2.3.8.1 Fuel Pressure Release Procedure Open the fuel tank cap. Open the hood, pull out fuel pump fuse EF05 (15 A). Start the engine until the engine stops running automatically. Start the engine again, so that the crankshaft continues to rotate about 10 s.
Page 332 2-250 Fuel System JL4G18-D Engine Loosen filter retaining bolts on the bracket. Disconnect the fuel inlet and outlet pipes. Note If sand enters into the pipe joints, removal may become difficult. With a wood handle gently knock the filter housing to remove the sand, and then push the pipe toward the filter direction.
Page 333 Engine Fuel System JL4G18-D 2-251 Release fuel pressure. Refer to 2.3.8.1 Fuel Pressure Release Procedure. Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Remove the rear seat cushion. Refer to 12.7.3.4 Rear Seat Cushion Replacement. Remove fuel pump inspection cover. FE02-0070b Disconnect fuel pump harness connector.
Page 334 2-252 Fuel System JL4G18-D Engine Unscrew counter-clockwise and remove the fuel pump lock ring. FE02-0073b Remove fuel pump assembly. Note Pay attention to not to drop gasoline on the floor and the interior, otherwise it will corrode sealant and the interior.
Page 335 Engine Fuel System JL4G18-D 2-253 Install fuel pump clockwise to tighten fuel pump lock ring. Note During installation, make ensure the outlet pipe and return pipe face the rear of the vehicle body. FE02-0076b Connect the fuel pump outlet pipe. Warning! Refer to "Fuel Pipe Joints Warning"...
Page 336 2-254 Fuel System JL4G18-D Engine Connect the fuel pump wiring harness connector. FE02-0079b Install fuel pump inspection cover, note that the arrow is pointing to the vehicle body front. Install the rear seat. 10. Connect the battery negative cable. FE02-0080b 2.3.8.4 Fuel Level Sensor Replacement Removal Procedure: Warning!
Page 337 Engine Fuel System JL4G18-D 2-255 Release fuel system pressure. Refer to 2.3.8.1 Fuel Pressure Release Procedure. Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Remove the rear seat cushion. Refer to 12.7.3.4 Rear Seat Cushion Replacement. Remove fuel pump assembly. Refer to 2.3.8.3 Fuel Pump Assembly Replacement.
Page 338 2-256 Fuel System JL4G18-D Engine Connect the black wires to the fuel level sensor. FE02-0084b Connect the black wires to the fuel level sensor. Fix the fuel gage wiring harness with a cable tie. Install the fuel pump. Install the rear seat cushion. Connect the battery negative cable.
Page 339: Auxiliary Emission Control Jl4G18-D
Engine Auxiliary Emission Control JL4G18-D 2-257 2.4 Auxiliary Emission Control JL4G18- 2.4.1 Specifications 2.4.1.1 Fastener Tightening Specifications Specifications Applications Model Metric (Nm) US English (lb-ft) Canister Ventilation Filter Mounting Bracket Retaining M6 × 1.25 × 20 5.2-6.7 Bolt Canister Solenoid Valve M6 ×...
Page 340: Evaporative Emission Control System
2-258 Auxiliary Emission Control JL4G18-D Engine 2.4.2 Description and Operation 2.4.2.2 Evaporative Emission Control System 2.4.2.1 Heated Oxygen Sensor (HO Evaporative emission control system uses the basic principle of Canister storage method. This method transfers fuel vapor Heated Oxygen Sensors (HO S) are installed before and after from fuel tank to the carbon storage devices in order to save the three-way catalytic converter.
Page 341 Engine Auxiliary Emission Control JL4G18-D 2-259 1. Operation The main control device is the crankcase ventilation (PCV) valve. purged crankcase ventilation valve calculate the channeling air flow according to manifold vacuum signal. Lower crankcase ventilation valve parts below the O-ring are exposed to a vacuum in the intake manifold, parts located between the lower and upper O-ring are exposed to the crankcase gases.
Page 342 2-260 Auxiliary Emission Control JL4G18-D Engine 2.4.3 System Working Principle 4. When the engine coolant temperature, engine running time and engine load etc. meet the preset requirements, ECM 2.4.3.1 Heated Type Oxygen Sensor Working will instruct Canister solenoid valve to start working. In the Principle following situations canister solenoid valve will not work: –...
Page 343 Engine Auxiliary Emission Control JL4G18-D 2-261 2.4.4 Component Locator 2.4.4.1 Canister Location FE11-2025b Legend 1. Canister Assembly 2. Canister Ventilation Filter EC718/EC718RV EC715/EC715RV 10/2009...
Page 344 2-262 Auxiliary Emission Control JL4G18-D Engine 2.4.4.2 Canister Solenoid Valve Location FE02-2026b EC718/EC718RV EC715/EC715RV 10/2009...
Page 345 Engine Auxiliary Emission Control JL4G18-D 2-263 2.4.5 Schematic 2.4.5.1 Schematic Emission Control Diagram Air Intake Exhaust Sensor Engine Air Intake Feedback Fuel Injection Signal Voltage Signal Voltage FE02-5801b EC718/EC718RV EC715/EC715RV 10/2009...
Page 346 2-264 Auxiliary Emission Control JL4G18-D Engine 2.4.6 Diagnostic Information and Procedures 2.4.6.1 Diagnostic Description Refer to2.4.2 Description and Operationget familiar with the system functions and operations then start system diagnostics, so that it will help with the correct diagnostic steps, more importantly, it will also help to determine whether the customer described the situation is normal.
Page 347 Engine Auxiliary Emission Control JL4G18-D 2-265 Diagnostic Steps: Check engine emission malfunction warning lamp. Step 1 Start the engine. Check whether the engine emission malfunction warning lamp is lit. Go to step 3 Repair the engine control system fault. Step 2 Repair the engine control system fault.
Page 348 2-266 Auxiliary Emission Control JL4G18-D Engine Turn off the ignition switch. Evaporative Canister Solenoid Harness Connector EN24 Check resistance between solenoid valve wiring harness connector EN24 terminal 2 and ECM harness connector EN01 terminal No.37 with the multimeter and confirm the circuit continuity.
Page 349 Engine Auxiliary Emission Control JL4G18-D 2-267 Replace the canister solenoid valve. Step 8 Turn off the ignition switch. Replace the canister solenoid valve. Refer to 2.4.7.3 Canister Solenoid Valve Replacement. Confirm the repairs completed. Next System normal. Step 9 2.4.6.4 Crankcase Ventilation (PCV) System Check / Diagnostic Check crankcase ventilation hose whether there is a vacuum.
Page 350 2-268 Auxiliary Emission Control JL4G18-D Engine – Engine stalls or idle speed is too low. – Engine oil leakd. – Engine oil enters the intake. – Engine sludges. 2. Ventilation hood or hose leak may lead to the following faults: –...
Page 351 Engine Auxiliary Emission Control JL4G18-D 2-269 2.4.7 Removal and Installation 2.4.7.1 Post-Catalytic Oxygen Sensor Replacement Removal Procedure: Warning! Refer to "Exhaust Service Warning", and "Vehicle Lifting Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection.
Page 352 2-270 Auxiliary Emission Control JL4G18-D Engine Installation Procedure: Install the heated post-catalytic oxygen sensor. Lower the vehicle. Connect the post-catalytic oxygen sensor wiring harness connector. Connect the battery negative cable. FE02-0311b 2.4.7.2 Pre-Catalytic Oxygen Sensor Replacement Removal Procedure: Warning! Refer to "Exhaust Service Warning" in "Warnings and Notices".
Page 353 Engine Auxiliary Emission Control JL4G18-D 2-271 Installation Procedure: Install the heated pre-catalytic oxygen sensor. FE02-0438b Tighten the heated pre-catalytic oxygen sensor. Install the three-way catalytic converter. Connect the battery negative cable. FE02-0437b 2.4.7.3 Canister Solenoid Valve Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning"...
Page 354 2-272 Auxiliary Emission Control JL4G18-D Engine Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Remove the canister solenoid valve from the mounting bracket. FE02-0439b Disconnect the canister solenoid valve vacuum tube. FE02-0440b Disconnect canister solenoid valve wiring harness connector.
Page 355 Engine Auxiliary Emission Control JL4G18-D 2-273 Installation Procedure: Connect canister solenoid valve wiring harness connector. FE02-0442b Connect canister solenoid valve vacuum tube. FE02-0443b Install the canister solenoid valve to the mounting bracket. Connect the battery negative cable. FE02-0444b EC718/EC718RV EC715/EC715RV 10/2009...
Page 356: Engine Anti-Theft System Jl4G18-D
2-274 Engine Anti-theft System JL4G18-D Engine 2.5 Engine Anti-theft System JL4G18-D 2.5.1 Specifications 2.5.1.1 Fastener Tightening Specifications Specifications Applications Model Metric (Nm) US English (lb-ft) Engine Anti-theft System 8-10 6-7.4 Control Module Bracket Bolts EC718/EC718RV EC715/EC715RV 10/2009...
Page 357: Engine Control Module
Engine Engine Anti-theft System JL4G18-D 2-275 2.5.2 Description and Operation Note 2.5.2.1 Description and Operation If the anti-theft system can not get the ignition key transponder information, it will not send any signal to the Engine Anti-theft system feature is realized by the engine engine control module.
Page 358 2-276 Engine Anti-theft System JL4G18-D Engine 2.5.3 System Working Principle 2.5.3.1 System Working Principle When the ignition key is inserted into the ignition cylinder and ignition switch is at ON position, the transponder will be excited by electronic Anti-theft ignition cylinder coil. the transponder will send a signal containing its own information.
Page 359 Engine Engine Anti-theft System JL4G18-D 2-277 2.5.4 Component Locator 2.5.4.1 Component Locator Electronic Anti-theft Coil, Engine Anti-theft System Control Module FE02-2027b Legend 1. Engine Anti-theft System Control Module 2. Electronic Anti-theft Coil EC718/EC718RV EC715/EC715RV 10/2009...
Page 360 2-278 Engine Anti-theft System JL4G18-D Engine 2.5.5 Disassemble View 2.5.5.1 Disassemble View Repeater Legend 1. Remote Keyless Entry Transmitter 2. Transponder EC718/EC718RV EC715/EC715RV 10/2009...
Page 361 Engine Engine Anti-theft System JL4G18-D 2-279 2.5.6 Schematic 2.5.6.1 Schematic Ignition Engine Switch Anti-Theft Control Module Scan Tool Starter Anti-Theft Coil FE02-6601b EC718/EC718RV EC715/EC715RV 10/2009...
Page 362 2-280 Engine Anti-theft System JL4G18-D Engine 2.5.7 Diagnostic Information and Procedures 2.5.7.1 Diagnosis Description Refer to 2.5.2.1 Description and Operationget familiar with the system functions and operations then start system diagnostics, so that it will help with the correct diagnostic steps, more importantly, it will also help to determine whether the customer described the situation is normal.
Page 363 Engine Engine Anti-theft System JL4G18-D 2-281 Anti-theft Engine Control Module Wiring Harness Connector 2 Engine Anti-Theft Control Module Harness Connector IP26 FE02-6604b Terminal Terminal Working Terminal Wire Rated Working Voltage Definition Current Instructions Coil Connector 1 125 KHz Modulation Waveform Antenna Signal Coil Connector 2 Gr/O...
Page 364 2-282 Engine Anti-theft System JL4G18-D Engine B3060 Anti-theft transponder verification failed. B3061 EFI controller verification failed. Note DTC (DTC code) is set based on the above-mentioned output sequence. But at the same time it only shows a maximum of 7 DTC. Note DTC code history is code recorded before shown by the scan tool.
Page 365 Engine Engine Anti-theft System JL4G18-D 2-283 Symptoms Suspect Part Refer to Page 3. Anti-theft Module 4. ECM 5. Instrument Cluster 6. Wiring Harness Connector 1. Anti-theft Coil Anti-theft system can not detect the valid key. 2. Anti-theft Module 1. Anti-theft Coil Keys do not match 2.
Page 366 2-284 Engine Anti-theft System JL4G18-D Engine Next Note Before enter the security code please contact the manufacturers technical department, as the Anti-theft computer will be locked after the wrong security code entered seven consecutive times. Enter the security code. Step 4 Next Learn the key.
Page 367 Engine Engine Anti-theft System JL4G18-D 2-285 Next Enter the security code. Step 4 Next Erase the key: select the recorded key location and erase. If you select all, all the keys will be removed. Step 5 Next Step 6 Place the ignition switch at "OFF" position and wait about 5min or so. Next Step 7 Key erase successful .
Page 368 2-286 Engine Anti-theft System JL4G18-D Engine Next Read the security module from ECM. Step 6 Next Reprogram the keys. Refer to 2.5.7.7 Replaced Key Programming. Step 7 2.5.7.10 Replaced ECM Programming Step 1 Insert a new key. Next Turn the ignition switch to "ON" position. Step 2 Next Enter into the anti-theft system.
Page 369 Engine Engine Anti-theft System JL4G18-D 2-287 Next Enter into the anti-theft system. Step 3 FE02-7002b Next Step 4 Set security code (Provided that the anti-theft module is new and without preset security code). Next Step 5 Enter the security code (preset the four-digit security code). Next Read anti-theft module to ECM.
Page 370 2-288 Engine Anti-theft System JL4G18-D Engine 2.5.7.12 Engine Anti-theft Warning Lamp Flashing, Vehicle Can Not Start Schematic: Engine Control Module To Ignition Switch Engine Anti-Theft Control Module Datalink Connector Anti -Theft Coil To Battery FE02-6602b Diagnostic Steps: Check the fuses IF26 and IF21. Step 1 Check whether the fuses IF26 and IF21 are blown.
Page 371 Engine Engine Anti-theft System JL4G18-D 2-289 Repair fuse IF26 and IF21 circuits. Step 2 Check the fuse IF26 circuit and repair the short circuit fault. Check the fuse IF21 circuit and repair the short circuit fault. Replace the fuse. Can the vehicle start as per normal? System normal Check engine anti-theft system control module ground status.
Page 372 2-290 Engine Anti-theft System JL4G18-D Engine Disconnect the electronic anti-theft coil harness connector. Measure coil resistance with a multimeter. Standard Resistance Value: 5 Ω at room temperature 20°C(68 ºF) Engine Anti-Theft Coil Is EAS coil resistance the standard value? Go to step 7 FE02-6609b Replace the electronic anti-theft coil.
Page 373 Engine Engine Anti-theft System JL4G18-D 2-291 Go to step 9 Step 8 Repair the circuit fault between electronic anti-theft wiring harness connector coil and engine anti-theft system control module wiring harness connector. Repair the open circuit between the anti-theft coil harness connector IP21 terminal No.1 and engine anti-theft system control module wiring harness connector IP26 terminal No.1.
Page 374 2-292 Engine Anti-theft System JL4G18-D Engine 5 and the engine control module connector EN01 terminal No.23. Repair the serial communication open circuit between engine anti-theft system control module connector IP25 terminal No. 8 and the engine control module connector EN01 terminal No.15.
Page 375 Engine Engine Anti-theft System JL4G18-D 2-293 2.5.8 Removal and Installation 2.5.8.1 EAS Coil Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Turn the steering wheel to the left 90 ° and remove the left upper steering column shield retaining screw.
Page 376 2-294 Engine Anti-theft System JL4G18-D Engine Remove the lower steering column shield screw. FE02-0447b Remove the lower steering column shield. FE02-0448b Remove the upper steering column shield. EC718/EC718RV EC715/EC715RV 10/2009...
Page 377 Engine Engine Anti-theft System JL4G18-D 2-295 Disconnect the electronic anti-theft wiring harness coil connector. FE02-0450b Remove the electronic anti-theft engine coil. FE02-0451b Installation Procedure: Install the electronic anti-theft engine coil. FE02-0452b EC718/EC718RV EC715/EC715RV 10/2009...
Page 378 2-296 Engine Anti-theft System JL4G18-D Engine Connect the electronic anti-theft wiring harness coil connector. FE02-0453b Install the upper steering column shield. Install the lower steering column shield. Install and tighten the left upper steering column shield retaining screw. Torque: 2 Nm (Metric) 1.5 lb-ft (US English) Install and tighten the right upper steering column shield retaining screw.
Page 379 Engine Engine Anti-theft System JL4G18-D 2-297 2.5.8.2 Anti-theft System Control Module Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Remove instrument panel trim under the driver's side. Refer to 11.10.8.1 BCM Replacement.
Page 380 2-298 Engine Anti-theft System JL4G18-D Engine Installation Procedure: Install the anti-theft system control module. Torque: 10 Nm (Metric) 7.4 lb-ft (US English) Connect anti-theft system control module wiring harness connector. Install instrument panel trim under the driver's side. Connect the battery negative cable. FE02-0458b EC718/EC718RV EC715/EC715RV 10/2009...
Page 381: Engine Mechanical System Jl4G18-D
Engine Engine Mechanical System JL4G18-D 2-299 2.6 Engine Mechanical System JL4G18- 2.6.1 Specifications 2.6.1.1 Fastener Tightening Specifications Specifications Applications Model Metric (Nm) US English (lb-ft) Spark Plug Bolt M14 × 1.25 20-30 14.8-22.2 Cylinder Head Cover (Short Bolt) 7-11 5.2-8.2 Cylinder Head Cover (Long Bolts, 9-13 6.7-9.6...
Page 382 2-300 Engine Mechanical System JL4G18-D Engine Specifications Applications Model Metric (Nm) US English (lb-ft) Generator Screw M10 × 1.25 × 72 43.2-64.8 32-48 Generator Bolt M8 × 30 20-30 14.8-22.2 Clutch Assembly Mounting Bolt 21.6-32.4 16-24 Coolant Valve Bolt 25 and Above 18.5 and Above Oil Pump Mounting Bolt 7.2-10.8...
Page 383 Engine Engine Mechanical System JL4G18-D 2-301 Items Specifications Meet GB11121 standard, API quality grade SJ-class, SL-class Lubricant Specification / Grades exports to the EU statement, viscosity: SAE5W-30, 10W-30, 10W-40, 15W-40 Spark Plug Type K6RTC Spark Plug Gap (mm/in) 1.0-1.1/0.03-0.04 Without starter, with the engine oil, coolant, with wiring harness, Dry Mass (kg/lb) with the clutch 117 ±...
Page 384 2-302 Engine Mechanical System JL4G18-D Engine Items Specifications Pistons Gap With The Cylinder (mm/in) 0.060-0.083/0.0023-0.0033 Diameter (mm/in) 78.9/3.11 Piston Pin Gap With The Piston (mm/in) 0.005-(-0.001) / 0.0002-(-0.00003) Gap With The Rod (mm/in) 0.005-0.011/0.0002-0.0004 Diameter (mm/in) 20/0.787 Length (mm/in) 50/1.969 Piston Pin Offset - Thrust (mm/in) 0.6/0.0236 Oil Pump...
Page 385 Engine Engine Mechanical System JL4G18-D 2-303 Packet No. Thickness (mm/in) Packet No. Thickness (mm/in) 5.10 (0.2008) 5.46 (0.2150) 5.12 (0.2016) 5.48 (0.2157) 5.14 (0.2024) 5.50 (0.2165) 5.16 (0.2031) 5.52 (0.2173) 5.18 (0.2039) 5.54 (0.2181) 5.20 (0.2047) 5.56 (0.2189) 5.22 (0.2055) 5.58 (0.2197) 5.24 (0.2063) 5.60 (0.2205)
Page 386 2-304 Engine Mechanical System JL4G18-D Engine 2.6.1.4 Intake and Exhaust Valves Lifter Selection Table Intake Valve Selection Table Lifter No. and Thickness EC718/EC718RV EC715/EC715RV 10/2009...
Page 387 Engine Engine Mechanical System JL4G18-D 2-305 Exhaust Valve Selection Table Lifter No. and Thickness EC718/EC718RV EC715/EC715RV 10/2009...
Page 388 2-306 Engine Mechanical System JL4G18-D Engine 2.6.2 Description and Operation 2.6.2.1 Description and Operation 1. Cylinder Head Cylinder head is made from aluminum alloy casting process. cylinder valve stem is a mechanical system. valve clearance can not be automatically adjust, which is very important. The cylinder valve is an integrated part.
Page 389 Engine Engine Mechanical System JL4G18-D 2-307 2.6.3 System Working Principle the mixture within the cylinder and reduce the power consumed in the intake process. Because intake and exhaust valves have 2.6.3.1 System Working Principle a certain overlap angles, namely, at a certain crank angle 1.
Page 390 2-308 Engine Mechanical System JL4G18-D Engine (2). VVT Control Strategy is 5 °, so the intake valve opens at idle with actual angle of 13 °. Driving Intake Valve Cause (4). Lag Process Conditions Timing Steady Low-Load Combustion High Load, High Increased Output Speed Characteristics...
Page 391 Engine Engine Mechanical System JL4G18-D 2-309 2.6.4 Component Locator 2.6.4.1 Component Locator VVT System Component Locator Legend 1. VVT Actuator 3. VVT Solenoid Valve Filter 2. VVT Solenoid Valve EC718/EC718RV EC715/EC715RV 10/2009...
Page 392 2-310 Engine Mechanical System JL4G18-D Engine 2.6.5 Disassemble View 2.6.5.1 Cylinder Head Covers FE02-2069b Legend 1. Cylinder Head Covers 6. Cylinder Head Covers Retaining Nut 2. Cylinder Head Cover Gasket 7. Purged Crankcase Ventilation Valve 3. Engine Oil Cap 8. Hood Retaining Bolts 4.
Page 393 Engine Engine Mechanical System JL4G18-D 2-311 2.6.5.2 Camshaft and Accessories FE02-2070b Legend 1. Intake Camshaft 8. Timing Chain Guide Rail 2. Exhaust Camshaft 9. Timing Chain Guide Rail Retaining Bolts 3. VVT Actuator 10. Timing Chain Tensioner Rail Bolt 4. Exhaust Camshaft Drive Sprocket 11.
Page 394 2-312 Engine Mechanical System JL4G18-D Engine 2.6.5.3 Cylinder Head FE02-2071b Legend 1. Exhaust Valve 12. Intake Valve Lifter 2. Intake Valve 13. Exhaust Valve Lifter 3. Exhaust Valve Seating Ring 14. Exhaust Locking Piece 4. Intake Valve Seating Ring 15. Exhaust Valve Spring Seat 5.
Page 395 Engine Engine Mechanical System JL4G18-D 2-313 2.6.5.4 Cylinder Block Legend 1. Piston Rod Component 5. Crankcase Bolt 2. Cylinder Block 6. Crankshaft Bearing Tightening Bolt 3. Flywheel 7. Filters 4. Crankcase 8. Oil Sump EC718/EC718RV EC715/EC715RV 10/2009...
Page 396 2-314 Engine Mechanical System JL4G18-D Engine 9. Oil Pan Bolts 15. Crankshaft Belt Drive 10. Crankshaft Thrust 16. Crankshaft Timing Sprocket 11. Crankshaft Bearings 17. Engine Oil Pump 12. Crankshaft 18. Timing Chain Cover 13. Timing Chain Tensioner 14. Crankshaft Belt Tightening Bolt EC718/EC718RV EC715/EC715RV 10/2009...
Page 397 Engine Engine Mechanical System JL4G18-D 2-315 2.6.6 Schematic 2.6.6.1 Schematic Throttle Body Position Sensor Crankshaft Position Sensor Camshaft Position Sensor Engine Control Module VVT Solenoid Intake Air Pressure Temperature Sensor Vehicle Speed Sensor Engine Coolant Temperature Sensor FE02-2073b EC718/EC718RV EC715/EC715RV 10/2009...
Page 398 2-316 Engine Mechanical System JL4G18-D Engine 2.6.7 Diagnostic Information and Procedures 2.6.7.1 Diagnosis Description Refer to 2.6.3.1 System Working PrincipleGet familiar with the system functions and operations before start system diagnostics, so that it will facilitate the correct diagnostic steps, more importantly, it will also help to determine whether the customer described the situation is normal.
Page 399 Engine Engine Mechanical System JL4G18-D 2-317 Turn the ignition switch to "OFF" position. Connect scan tool to the datalink connector. Start and run the engine to normal working temperature. Turn off A/C switch. Select in sequence: Engine / Data List / Cylinder No.1 ignition advance angle.
Page 400 2-318 Engine Mechanical System JL4G18-D Engine Accelerate the engine, observe the engine ignition timing, which should be moving ahead as shown. FE02-7004b Next Step 5 Remove the timing light to restore high-voltage resistor wire. Next Step 6 End of the test. 7.
Page 401 Engine Engine Mechanical System JL4G18-D 2-319 Next Turn the ignition switch to the "ST" position, so that each cylinder runs 4 to 5 compression strokes. Step 4 Next Individual cylinder pressure readings should not be less than 75% of the maximum and any cylinder pressure Step 5 gage reading should not be less than 750 kPa.
Page 402 2-320 Engine Mechanical System JL4G18-D Engine Check the existence of the flywheel cracking, deformation and other components intervention. Is the flywheel Step 3 normal? Replace the flywheel assembly. Confirm whether the fault is fixed. Step 4 Check whether the main bearing clearance is too large. Does it exceed the specified value? Standard Value: 0.006-0.022 mm (0.0002-0.0008 in) Replace the main bearings.
Page 403 Engine Engine Mechanical System JL4G18-D 2-321 Confirm diagnostic completed. Step 4 2.6.7.7 Vibration at idle and when engine is warming up Step 1 Check drive belt tension. Is it too loose or worn. Any fault? If necessary, replace the drive belt. Confirm whether the fault is fixed.
Page 404 2-322 Engine Mechanical System JL4G18-D Engine Replace failed parts. Confirm whether the fault is fixed. Check the piston pin offset. Does it exceed the specified value? Step 8 Standard Value: 0.6 mm (0.0236 in) Replace failed parts. Confirm whether the fault is fixed.
Page 405 Engine Engine Mechanical System JL4G18-D 2-323 Check whether there are excessive cam wear or obvious fults? Step 6 Repair the faulty part. Refer to 2.6.8.12 Camshaft Replacement Step 7 Check valve for the existence of cracks, excessive wear and tear and other faults? Repair the faulty part.
Page 406 2-324 Engine Mechanical System JL4G18-D Engine 1. Inspect when the engine is cool or has been turned off for 30 min. 2. Visual Inspect whether there is V-drive belt excessive wear or cord wear. If faults are found, replace the V-drive belt. 3.
Page 407 Engine Engine Mechanical System JL4G18-D 2-325 Refer to 2.6.7.9 Drive Belt Inspection Replace the drive belt. Refer to 2.6.8.3 Drive Belt Replacement Check whether the drive pulley is installed correctly? (Misaligned, etc?) Step 4 Reinstall the drive pulley, if necessary, replace the drive belt.
Page 408 2-326 Engine Mechanical System JL4G18-D Engine Does the scream disappear? Refer to 2.6.7.4 Engine Noise Diagnosis Check whether all attached drive pulley bearings are normal? Step 3 Pulley bearings do not appear stuck, loose and so on. Replace the damaged pulley or bearing. Step 4 Check whether drive belt tensioner device is working properly? Tensioner pulley bearing device does not appear stuck, loose.
Page 409 Engine Engine Mechanical System JL4G18-D 2-327 2.6.7.12 Drive Belt Hum Sound Diagnostic Diagnostic Tips: Drive belt should not produce hum sound. If there is an intermittent noise, check the attached parts by changing the load. Make sure that components run until the maximum load. These conditions may be due to (but are not limited to) over filling the air-conditioning system, power steering system blocked or steering fluid incorrect, as well as the generator failure.
Page 410 2-328 Engine Mechanical System JL4G18-D Engine Next Check whether the pulley is bent or depressed. Repair the faulty part. Step 3 Next Check whether the drive belt tensioner device bracket is bent or cracked. Repair the faulty part. Step 4 Next Step 5 Check whether the drive belt tensioner device is working properly.
Page 411 Engine Engine Mechanical System JL4G18-D 2-329 2.6.8 Removal and Installation 2.6.8.1 Plastic Engine Shield Replacement Removal Procedure: Remove the engine plastic shield retaining nuts. Remove the plastic engine shield. Installation Procedure: Install the engine plastic shield retaining nuts onto the engine plastic shield.
Page 412 2-330 Engine Mechanical System JL4G18-D Engine Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Remove the engine plastic shield. Refer to 2.6.8.1 Plastic Engine Shield Replacement. Remove the ignition coil and ignition wire. Refer to 2.10.8.3 Ignition Coil Replacement.
Page 413 Engine Engine Mechanical System JL4G18-D 2-331 Remove the cylinder head cover. FE02-0012b Remove the cylinder head gasket from the cylinder head cover. FE02-0013b EC718/EC718RV EC715/EC715RV 10/2009...
Page 414 2-332 Engine Mechanical System JL4G18-D Engine Installation Procedure: Install the cylinder head cover gasket. Apply sealant evenly in the cylinder head gasket. Install the cylinder head cover. EC718/EC718RV EC715/EC715RV 10/2009...
Page 415 Engine Engine Mechanical System JL4G18-D 2-333 Tighten the cylinder head cover bolts. Note When tightening, tighten a single bolt several times, in accordance with the specified torque. Short Bolts: Torque: 9 Nm (Metric) 6.7 lb-ft (US English) Long Bolts, Nuts, Special Bolts: Torque: 11 Nm (Metric) 8.2 lb-ft (US English) Install the crankcase ventilation vacuum tube.
Page 416 2-334 Engine Mechanical System JL4G18-D Engine Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Rotate the drive belt tensioner anti-clockwise with a wrench to remove the drive belt. Note In the removal process, prevent the wrench slipping causing injury to the operator. Installation Procedure: Wrap the drive belt as shown.
Page 417 Engine Engine Mechanical System JL4G18-D 2-335 Release the Drive Belt Tensioner device to the normal position. Note Before releasing the tensioner device, confirm the drive belt aligned drive pulley groove, otherwise the drive belt may be damaged. Connect the battery negative cable. 2.6.8.4 Drive Belt Tensioner Replacement Removal Procedure: Disconnect the battery negative cable.
Page 418 2-336 Engine Mechanical System JL4G18-D Engine Remove the drive belt tensioner pulley bracket bolt. FE02-0088b Installation Procedure: Install drive belt tensioner bracket bolts. Torque: 69 Nm (Metric) 51.1 lb-ft (US English) Install drive belt tensioner bracket retaining nut. Torque: 29 Nm (Metric) 21.5 lb-ft (US English) Install the drive belt.
Page 419 Engine Engine Mechanical System JL4G18-D 2-337 2.6.8.5 Throttle Body Assembly Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Remove the throttle pull cable. FE02-0091b Remove the throttle body from the intake manifold. FE02-0092b Disconnect throttle position sensor wiring harness connector.
Page 420 2-338 Engine Mechanical System JL4G18-D Engine Disconnect idle speed control valve wiring harness connector. FE02-0095b Remove the crankcase ventilation hose. FE02-0096b Remove throttle body preheated water inlet pipe. FE02-0097b EC718/EC718RV EC715/EC715RV 10/2009...
Page 421 Engine Engine Mechanical System JL4G18-D 2-339 Remove throttle body preheated water outlet pipe. Warning! When the engine temperature is high, prevent the engine coolant spray, causing burns in the removal procedure. FE02-0098b Remove throttle body retaining nut from the intake manifold.
Page 422 2-340 Engine Mechanical System JL4G18-D Engine 11. Remove the throttle body assembly from the intake manifold and complete the removal procedure. FE02-0102b Installation Procedure: Clean the engine throttle body and the engine intake manifold mating surface and replace the seals. FE02-0103b Install the throttle body to the intake manifold and tighten the retaining nut.
Page 423 Engine Engine Mechanical System JL4G18-D 2-341 Install throttle body bracket and tighten the bolts. FE02-0105b Install the throttle preheated water inlet pipe. Install the throttle preheated water outlet pipe. FE02-0107b EC718/EC718RV EC715/EC715RV 10/2009...
Page 424 2-342 Engine Mechanical System JL4G18-D Engine Install the crankcase ventilation hose. FE02-0109b Connect the throttle position sensor wiring harness connector. FE02-0110b Connect the idle speed control valve wiring harness connector. FE02-0111b EC718/EC718RV EC715/EC715RV 10/2009...
Page 425 Engine Engine Mechanical System JL4G18-D 2-343 Install and tighten the intake manifold clamp. FE02-0113b 10. Install the throttle pull cable. 11. Connect the battery negative cable. FE02-0114b 2.6.8.6 Intake Manifold Assembly Replacement Removal Procedure: Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection.
Page 426 2-344 Engine Mechanical System JL4G18-D Engine Remove the canister solenoid valve vacuum tube. FE02-0116b Remove the vacuum booster vacuum tubes. FE02-0117b Remove the intake manifold retaining bolts and nuts in the sequence shown in the graphic. FE02-0118b EC718/EC718RV EC715/EC715RV 10/2009...
Page 427 Engine Engine Mechanical System JL4G18-D 2-345 Installation Procedure: Clean the cylinder head intake manifold installation surface. FE02-0119b Clean the intake manifold installation surface. Install the intake manifold seals. EC718/EC718RV EC715/EC715RV 10/2009...
Page 428 2-346 Engine Mechanical System JL4G18-D Engine Tighten the intake manifold retaining bolts and nuts in the sequence shown in the graphic. Note The bolts and nuts can not tighten to the specified torque at once, otherwise it will result in the intake manifold leakage.
Page 429 Engine Engine Mechanical System JL4G18-D 2-347 Install the crankcase ventilation tube. Install the throttle body. Install the engine hood. 10. Install the battery negative cable. 2.6.8.7 Engine Mount Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect the battery negative cable.
Page 430 2-348 Engine Mechanical System JL4G18-D Engine Remove the engine mount to engine right retaining bolts and nuts. FE02-0128b Remove the drive belt. Refer to 2.6.8.3 Drive Belt Replacement. Remove the drive belt tensioner. Refer to 2.6.8.4 Drive Belt Tensioner Replacement. Remove the generator bracket bolts.
Page 431 Engine Engine Mechanical System JL4G18-D 2-349 Installation Procedure: Install and tighten the engine mount retaining bolts to the specified torque. Torque: 47 Nm (Metric) 34.8 lb-ft (US English) Install the generator bracket bolts. Torque: 47 Nm (Metric) 34.8 lb-ft (US English) FE02-0132b Install the drive belt tensioner.
Page 432 2-350 Engine Mechanical System JL4G18-D Engine Install and tighten the right engine mount to the body bolts. Torque: 52 Nm (Metric) 38.5 lb-ft (US English) Remove the supporting jack. Install the engine hood. Install the battery negative cable. 2.6.8.8 Timing Chain Tensioner Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning"...
Page 433 Engine Engine Mechanical System JL4G18-D 2-351 As shown in the graphic, mark on the intake and exhaust sprocket timing with a marker and use a special tool GL301-022 to fix the timing chain and special tool GL301-018 to fix the camshaft. FE02-0136b Remove Timing Chain Tensioner Assembly.
Page 434 2-352 Engine Mechanical System JL4G18-D Engine Install the timing chain tensioner and tighten the nuts. Torque: 29 Nm (Metric) 21.5 lb-ft (US English) Rotate the crankshaft pulley counter clockwise to unlock the self-locking device and pop up the handle. Note Rotating process should be even, otherwise it may cause the timing chain teeth skidding.
Page 435 Engine Engine Mechanical System JL4G18-D 2-353 2.6.8.9 Timing Chain Cover Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" and "Cooling System Service Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Discharge the engine coolant. Refer to 2.8.8.1 Engine Coolant Discharge and Filling.
Page 436 2-354 Engine Mechanical System JL4G18-D Engine 12. Rotate the crankshaft, so that the crankshaft pulley timing mark is aligned with calibration line No.0, as shown. FE02-0135b 13. Make sure intake and exhaust VVT sprocket sprocket timing mark location is as shown in order to ensure that the cylinder No.1 is at TDC position.
Page 437 Engine Engine Mechanical System JL4G18-D 2-355 14. Use special tool GL301-020 to remove the crankshaft pulley. GL301-020 FE02-0144b 15. Remove the timing chain tensioner. 16. Remove the timing chain cover M8 tightening bolts. EC718/EC718RV EC715/EC715RV 10/2009...
Page 438 2-356 Engine Mechanical System JL4G18-D Engine 17. Remove the timing chain cover M6 tightening bolts and nuts. 18. Pry groove position with a bar to loosen the timing chain cover. 19. Remove the timing chain cover. EC718/EC718RV EC715/EC715RV 10/2009...
Page 439 Engine Engine Mechanical System JL4G18-D 2-357 Installation Procedure: Clean the residual sealant on the timing chain cover and cylinder. Apply special sealant on the timing chain cover and cylinder block mounting surface evenly and install the timing chain cover. Note Before installing the timing chain cover, pay attention to check the timing chain marks made above are consistent.
Page 440 2-358 Engine Mechanical System JL4G18-D Engine Install M8 timing chain cover tightening bolts and tighten timing chain cover tightening bolts and nuts, total of 12, according to the sequence shown in the graphic. M6 Bolts and Nuts: Torque: 12 Nm (Metric) 8.2 lb-ft (US English) M8 Bolt: Torque: 18 Nm (Metric) 13.4 lb-ft (US English) Install the timing chain tensioner.
Page 441 Engine Engine Mechanical System JL4G18-D 2-359 Use a special tool GL301-020 to install the crankshaft bolt. Torque: 138 Nm (Metric) 102.2 lb-ft (US English) GL301-020 FE02-0144b Install power steering pump. Install the engine mounting. 10. Install the water pump. 11. Install the generator. 12.
Page 442 2-360 Engine Mechanical System JL4G18-D Engine 2.6.8.10 Timing Chain Replacement Removal Procedure: Rotate the crankshaft so that the cylinder No.1 is at TDC position. Remove the timing chain cover. Refer to the2.6.8.9 Timing Chain Cover Replacement. Remove the timing chain tensioner rail components retaining bolts.
Page 443 Engine Engine Mechanical System JL4G18-D 2-361 Remove the crankshaft sprocket Collar. FE02-0161b Remove the timing chain guide rail lower retaining bolts. Remove the timing chain guide rail upper retaining bolt. FE02-0163b EC718/EC718RV EC715/EC715RV 10/2009...
Page 444 2-362 Engine Mechanical System JL4G18-D Engine Remove the timing chain guide rail. Remove the timing chain and crankshaft sprocket. Installation Procedure: Confirm the timing chain three yellow sections. FE02-0166b EC718/EC718RV EC715/EC715RV 10/2009...
Page 445 Engine Engine Mechanical System JL4G18-D 2-363 Install timing chain and crankshaft sprocket and align the first yellow chain section with the crankshaft sprocket timing mark. Note There are total three yellow sections on the timing chain, including two yellow chain section (a difference of 6 links between the sections) and aligned with the intake and exhaust camshaft sprocket timing marks.
Page 446 2-364 Engine Mechanical System JL4G18-D Engine Install the timing chain guide rail components. FE02-0170b Install the timing chain guide rail components retaining bolts. Torque: 10 Nm (Metric) 7.4 lb-ft (US English) FE02-0171b Install the tensioner rail components. EC718/EC718RV EC715/EC715RV 10/2009...
Page 447 Engine Engine Mechanical System JL4G18-D 2-365 Install the tensioner rail components retaining bolts. Torque: 19 Nm (Metric) 14 lb-ft (US English) Install the crankshaft sprocket. 10. Install the timing chain cover and accessories. EC718/EC718RV EC715/EC715RV 10/2009...
Page 448 2-366 Engine Mechanical System JL4G18-D Engine 2.6.8.11 Timing Chain Inspection Remove the timing chain cover. Refer to 2.6.8.9 Timing Chain Cover Replacement. Remove the timing chain. Refer to 2.6.8.10 Timing Chain Replacement. Inspect timing chain guide rail component for cracking, wear and tear.
Page 449 Engine Engine Mechanical System JL4G18-D 2-367 2.6.8.12 Camshaft Replacement Removal Procedure: Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Remove the engine plastic shield. Refer to 2.6.8.1 Plastic Engine Shield Replacement. Remove the cylinder head cover. Refer to 2.6.8.2 Cylinder Head Cover Replacement.
Page 450 2-368 Engine Mechanical System JL4G18-D Engine As shown in the graphic, gradually release the camshaft bearing cap bolts, rotate half a circle to a whole circle each time. Note Be careful when remove the camshaft. Avoid abrasions, scratches or damage to the camshaft surface or bearing surface.
Page 451 Engine Engine Mechanical System JL4G18-D 2-369 Apply a small amount of engine oil to lubricate the journal and camshaft cap. Install the exhaust camshaft. FE02-0181b Install the intake camshaft. Install the intake and exhaust camshaft cover. Note There are letters on the camshaft cover. Avoid installation errors.
Page 452 2-370 Engine Mechanical System JL4G18-D Engine Gradually tighten the camshaft cover bolts according to the sequence as shown in the graphic. Note Tighten the bolts during several stages. Do not tighten at once which may damage the camshaft and the camshaft cover. Torque: M6 Bolts 13 Nm (Metric) 10 lb-ft (US English) M8 Bolts 23 Nm (Metric) 17 lb-ft (US English)
Page 453 Engine Engine Mechanical System JL4G18-D 2-371 2.6.8.13 Engine Replacement Removal Procedure: Remove battery negative cable. Refer 2.11.8.1 Battery Disconnection. Release the fuel pressure. Refer to 2.3.8.1 Fuel Pressure Release Procedure. Discharge the engine coolant. Refer to 2.8.8.1 Engine Coolant Discharge and Filling.
Page 454 2-372 Engine Mechanical System JL4G18-D Engine Disconnect pre-catalytic and post-catalytic oxygen sensor wiring harness connectors. FE02-0463b 10. Remove the engine wiring harness ground cable bolts. FE02-0464b 11. Remove the air-conditioning compressor high and low pressure connecting tubes. FE02-0465b EC718/EC718RV EC715/EC715RV 10/2009...
Page 455 Engine Engine Mechanical System JL4G18-D 2-373 12. Remove the intake manifold assembly. FE02-0466b 13. Removing the radiator inlet and outlet pipes. Warning! Refer to "Cooling System Service Warning" in "Warnings and Notices". FE02-0467b 14. Remove the air filter support. 15. Remove the vacuum booster vacuum tubes. EC718/EC718RV EC715/EC715RV 10/2009...
Page 456 2-374 Engine Mechanical System JL4G18-D Engine 16. Remove the clutch tube. FE02-0469b 17. Disconnect the engine wiring harness to the underhood fuse and relay box cables and connectors. 18. Remove battery negative cable gearbox shell ground cable. FE02-0471b EC718/EC718RV EC715/EC715RV 10/2009...
Page 457 Engine Engine Mechanical System JL4G18-D 2-375 19. Remove the fuel pipe. FE02-0472b 20. Remove the canister vacuum tubes. FE02-0473b 21. Remove shift lever pull cable. FE02-0474b EC718/EC718RV EC715/EC715RV 10/2009...
Page 458 2-376 Engine Mechanical System JL4G18-D Engine 22. Remove the throttle cable. FE02-0475b 23. Remove the heater intake and outlet pipes. FE02-0476b 24. Remove the front wheels. 25. Lift the vehicle. Warning! Refer to "Vehicle Lifting Warning" in "Warnings and Notices". 26.
Page 459 Engine Engine Mechanical System JL4G18-D 2-377 28. Remove the front subframe and related components. Refer to 12.6.4.2 Subframe Replacement. 29. Remove the left and right side drive shafts. Refer to 5.3.4.1 Drive Shaft Replacement". 30. Place a mobile working table under the engine assembly to lower and support the powertrain assembly.
Page 460 2-378 Engine Mechanical System JL4G18-D Engine 33. Slowly lift the vehicle to separate the powertrain from the vehicle body. Note In the lifting process, avoid the powertrain assembly tilt on the working table. Pay attention to the powertrain and vehicle body interference. 34.
Page 461 Engine Engine Mechanical System JL4G18-D 2-379 Lift the vehicle. Install the left and right drive shafts. Install the front subframes. Install the steering cross pin bolts. FE02-0477b 10. Tighten the gearbox oil discharge bolt and fill gearbox oil. Refer to 3.3.8.1 Transmission Fluid Level Inspection.
Page 462 2-380 Engine Mechanical System JL4G18-D Engine 14. Install the throttle pull cable. FE02-0475b 15. Install the gear lever pull cable. FE02-0474b 16. Install canister vacuum tubes. FE02-0473b EC718/EC718RV EC715/EC715RV 10/2009...
Page 463 Engine Engine Mechanical System JL4G18-D 2-381 17. Install the fuel pipe. Note The fuel pipe must be inserted into the fuel distribution tube and then fastened after the second boss. FE02-0472b 18. Connect the battery negative cable gearbox shell ground point.
Page 464 2-382 Engine Mechanical System JL4G18-D Engine 20. Install the clutch pipe and discharge the air. Refer to 3.2.6.3 Hydraulic Clutch Bleeding. FE02-0469b 21. Install the vacuum booster vacuum tubes. 22. Install the air filter support. 23. Install the radiator inlet and outlet pipes. FE02-0467b EC718/EC718RV EC715/EC715RV 10/2009...
Page 465 Engine Engine Mechanical System JL4G18-D 2-383 24. Install the intake manifold assembly. FE02-0466b 25. Install the air-conditioning compressor high and low pressure connecting pipes. FE02-0465b 26. Install the engine wiring harness engine compartment ground cable and tightening bolt. FE02-0464b EC718/EC718RV EC715/EC715RV 10/2009...
Page 466 2-384 Engine Mechanical System JL4G18-D Engine 27. Connect the pre-catalytic and post-catalytic oxygen sensor wiring harness connectors. FE02-0463b 28. Connect ECM harness connector. FE02-0462b 29. Connect the engine wiring harness and floor harness connectors. 30. Install the battery bracket. 31. Fill the engine coolant. 32.
Page 467 Engine Engine Mechanical System JL4G18-D 2-385 2.6.8.14 Cylinder Head Assembly Replacement Removal Procedure: Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Remove the engine plastic shield. Refer to 2.6.8.1 Plastic Engine Shield Replacement. Discharge the engine coolant. Refer to 2.8.8.1 Engine Coolant Discharge and Filling.
Page 468 2-386 Engine Mechanical System JL4G18-D Engine 18. Remove the radiator inlet and outlet pipes. 19. Remove the heater inlet and outlet pipes. FE02-0188b 20. Remove the small cycle pipes cylinder head retaining bolts. FE02-0189b 21. Remove the cylinder head bolts according to the sequence in the graphic.
Page 469 Engine Engine Mechanical System JL4G18-D 2-387 22. Remove the cylinder head bolts. Note Due to confined space, cylinder head bolts and gasket bolts can not be removed together. FE02-0191b 23. Remove the cylinder head bolt gasket with a magnetic stick. FE02-0192b 24.
Page 470 2-388 Engine Mechanical System JL4G18-D Engine Installation Procedure: Clean the surface of the cylinder head and cylinder head. FE02-0194b Install the cylinder head gasket. Note Cylinder head gasket is a single used item and must be replaced with a new part. FE02-0195b Install the cylinder head assembly.
Page 471 Engine Engine Mechanical System JL4G18-D 2-389 Install the cylinder head gasket bolt washers. FE02-0197b Install and tighten the cylinder head bolts, according to the sequence in the graphic. Torque: First Pass: 49 Nm (Metric) 36.3 lb-ft (US English) Second Pass: 80 Nm (Metric) 59.1 lb-ft (US English) Install the small cycle pipes to cylinder head retaining bolts.
Page 472 2-390 Engine Mechanical System JL4G18-D Engine Install the heater inlet and outlet pipes. FE02-0200b Install the radiator inlet and outlet pipes. FE02-0201b Install the camshaft. EC718/EC718RV EC715/EC715RV 10/2009...
Page 473 Engine Engine Mechanical System JL4G18-D 2-391 10. Install the VVT solenoid valve. 11. Install the camshaft position sensor. 12. Install the coolant temperature sensor wiring harness connector. 13. Install the fuel rail assembly. 14. Install the timing chain. 15. Install the timing chain cover. 16.
Page 474 2-392 Engine Mechanical System JL4G18-D Engine Use a universal tool to compress the valve springs. FE02-0205b Remove the valve locking piece with a magnetic stick. Remove the special tools and remove the valve spring seat. FE02-0207b EC718/EC718RV EC715/EC715RV 10/2009...
Page 475 Engine Engine Mechanical System JL4G18-D 2-393 Remove the valve spring. FE02-0208b Remove the valve spring pads with a magnetic stick. FE02-0209b Remove the valve, mark the original position of the valve in order to re-install. FE02-0210b EC718/EC718RV EC715/EC715RV 10/2009...
Page 476 2-394 Engine Mechanical System JL4G18-D Engine Remove the valve seals with the special tool GL301-006. FE02-0211b 10. Remove the valve guide rod with the special tool GL301-009. Cleaning: Clean cylinder head and cylinder head gasket contacting surface. Clean cylinder head and cylinder head cover contacting surface.
Page 477 Engine Engine Mechanical System JL4G18-D 2-395 Inspect and confirm that the sealing surface has no distortion and warping and the cylinder head sealing surface flatness must be 0.05 mm (0.002 in). Inspect and confirm that valve seat ring has no excessive wear and burnt places.
Page 478 2-396 Engine Mechanical System JL4G18-D Engine Install the valves. FE02-0215b Install the valve spring pads. Install the valve springs. EC718/EC718RV EC715/EC715RV 10/2009...
Page 479 Engine Engine Mechanical System JL4G18-D 2-397 Install the valve spring seat. FE02-0218b Use a universal tool to compress the valve springs and install the valve spring locking pieces. FE02-0219b Confirm locking pieces is in place. slowly remove the special tool with a wood hammer gently knock the valve, so that the valve is in place.
Page 480 2-398 Engine Mechanical System JL4G18-D Engine 2.6.8.16 Piston Connecting Rod and Bearing Replacement Removal Procedure: Remove the engine assembly. Refer to 2.6.8.13 Engine Replacement. Remove cylinder head cover. Refer 2.6.8.14 Cylinder Head Assembly Replacement. Remove the oil pan. Refer to 2.9.8.3 Oil Pan Replacement.
Page 481 Engine Engine Mechanical System JL4G18-D 2-399 With a wood handle, remove cylinder No.1 piston rod and mark the location of cylinder No.1. Remove the cylinder No.4 connecting rod bearing cap bolts. Hold the rod bolt, remove the cylinder No.4 connecting rod bearing caps and mark the location cylinder No.4.
Page 482 2-400 Engine Mechanical System JL4G18-D Engine 10. With a wood handle, remove cylinder No.1 piston rod and mark the location of cylinder No.4. 11. Rotate the crankshaft 180 °, so that the cylinder NO.2 and 3 are at BDC positions. Remove the cylinder NO.2 rod bearing cap bolts.
Page 483 Engine Engine Mechanical System JL4G18-D 2-401 13. With a wood handle, remove cylinder No.2 piston rod and mark the location of cylinder No.2. 14. Remove the cylinder No.3 connecting rod bearing cap bolts. 15. Hold the rod bolt, remove the cylinder No.3 connecting rod bearing caps and mark the location of cylinder No.3.
Page 484 2-402 Engine Mechanical System JL4G18-D Engine 16. With a wood handle, remove cylinder No.3 piston rod and mark the location of cylinder No.3. FE02-0233b Inspection Procedures Before Installing The Piston: Check whether the rod is bent or distorted. If the rod is bent or distorted, replace the connecting rod.
Page 485 Engine Engine Mechanical System JL4G18-D 2-403 10. Check whether the engine block cylinder bore is worn, runout and taper. 11. Check whether the engine block cylinder bore is polished, if necessary, slightly polish the cylinder bore. 12. With a ruler and gap regulator, check the engine block top surface flatness.
Page 486 2-404 Engine Mechanical System JL4G18-D Engine With the new engine oil lubricate the cylinder wall. With the new engine oil lubricate the piston, use universal tools and wood handle to install cylinder No.1 piston rod components marked with cylinder No.1 location. Note The dot mark on the piston top surface should face the engine front end.
Page 487 Engine Engine Mechanical System JL4G18-D 2-405 With a small amount of new engine oil lubricate the piston, use universal tools and a wood handle to install cylinder No.4 piston rod components marked with cylinder No.4 location. Note The dot mark on the piston top surface should face the engine front end.
Page 488 2-406 Engine Mechanical System JL4G18-D Engine 10. Rotate the crankshaft 180 °, so that cylinder No.2 and 3 are at BDC positions. With the new engine oil lubricate the piston, use universal tools and a wood handle to install cylinder No.2 piston connecting rod component marked with cylinder No.2 location.
Page 489 Engine Engine Mechanical System JL4G18-D 2-407 13. With the new engine oil lubricate the piston, use universal tools and a wood handle to install cylinder No.3 piston connecting rod component marked with cylinder No.3 location. Note The dot mark on the piston top surface should face the engine front end.
Page 490 2-408 Engine Mechanical System JL4G18-D Engine 16. Install the filters. 17. Install the oil pan. 18. Install the cylinder head. 19. Install the engine assembly. 2.6.8.17 Flywheel Replacement Removal Procedure: Remove gearbox assembly. Refer 3.3.8.3 Transmission Assembly Replacement. Remove the clutch assembly. Refer to 3.2.6.5 Clutch Assembly Replacement.
Page 491 Engine Engine Mechanical System JL4G18-D 2-409 Installation Procedure: Install new bolts to the engine flywheel, but do not tighten at this stage. Note Apply adhesive on the bolts. Adhesive: Thread Locking Sealant. Install a special tool GL301-021 to prevent the crankshaft rotating.
Page 492 2-410 Engine Mechanical System JL4G18-D Engine 10. Remove the crankcase retaining bolts according to the sequence in the graphic. 11. Remove the crankshaft bearing cap bolts according to the sequence in the graphic. Note Do not loose a single bolt completely. Remove the bolt in multiple operations, otherwise it may cause damage to the crankshaft.
Page 493 Engine Engine Mechanical System JL4G18-D 2-411 13. Insert a flat screwdriver into the position shown in the graphic and loosen the crankcase rear end. FE02-0260b 14. Remove the crankcase. 15. Remove the No.3 bearing crankshaft thrust film. Note Rotate the crankshaft, so that thrust film turns to facilitate removal.
Page 494 2-412 Engine Mechanical System JL4G18-D Engine 16. Remove the crankshaft. Crankshaft inspection, the crankshaft bearing clearance matching inspection procedure: Measure the main bearing bore diameter with an inner diameter micrometer and record. Measure the crankshaft axis with an outside diameter micrometer and record.
Page 495 Engine Engine Mechanical System JL4G18-D 2-413 Crank Spindle Main Bearing Thickness Of The Diameter Bore Diameter Main Bearing (mm/ Diameter (mm/ (mm/in) 52.011-52.017 / 47.982-47.988 / 2.0477-2.0479 1.8891-1.8893 2.002 ≤ t ≤ (No.2) (No.3) 2.005/0.0788 ≤ t ≤ 0. 0789 52.017-52.021 / 47.988-47.994 / (No.
Page 496 2-414 Engine Mechanical System JL4G18-D Engine Install the crankcase, install and tighten the crankshaft bearing cap bolts according to the sequence shown in the graphic. Torque First Pass: 44 Nm (Metric) 32.5 lb-ft (US English) Second Pass: 60 Nm (Metric) 44.5 lb-ft (US English) FE02-0269b Remove the crankcase.
Page 497 Engine Engine Mechanical System JL4G18-D 2-415 Install the crankshaft. FE02-0265b Install the crankshaft thrust sheet, with the grooves facing outside. Check the crankshaft axial clearance, to confirm the crankshaft axial clearance is acceptable. Refer to 2.6.1.2 Mechanical System Specification. Standard Value: 0.04-0.24 mm (Metric) 0.0015-0.0094 in (US English) FE02-0266b Install the crankcase bearings.
Page 498 2-416 Engine Mechanical System JL4G18-D Engine After installing the crankshaft in the front and rear crankshaft bearings, check whether the crankshaft journal has acceptable roundness and runout. Note Apply lubricant to the crankshaft journal and slightly lubricate the crankshaft bearings. Apply sealant evenly on the crankshaft and cylinder block mating surface.
Page 499 Engine Engine Mechanical System JL4G18-D 2-417 13. Install the oil filter retaining bolts. Torque 20 Nm (Metric) 14.8 lb-ft (US English) 14. Install pistons, connecting rods and bearings. 15. Install sump. 16. Install the oil pan. 17. Install the cylinder head. 18.
Page 500 2-418 Engine Mechanical System JL4G18-D Engine Remove the second air ring. FE02-0273b Remove the oil ring upper ring combination. FE02-0274b Remove the oil ring lower ring combination. EC718/EC718RV EC715/EC715RV 10/2009...
Page 501 Engine Engine Mechanical System JL4G18-D 2-419 Remove the oil ring. FE02-0276b Remove the piston pin circlip at both ends. FE02-0277b With a special tool GL301-016 remove the piston pin. FE02-0278b EC718/EC718RV EC715/EC715RV 10/2009...
Page 502 2-420 Engine Mechanical System JL4G18-D Engine Disassemble connecting rod, piston pin and piston are shown in the graphic. FE02-0279b Installation Procedure: Install piston pin, connecting rod and piston. Note During installation, connecting rod bearings mark and the piston mark should face the same the direction.
Page 503 Engine Engine Mechanical System JL4G18-D 2-421 Confirm normal movements between the piston and rod without any interference. Check piston pin and connecting rod clearance. Standard Value:0.005-0.011 mm (Metric) 0.0002-0.0004 in (US English) Check the piston and piston pin clearance. Standard Value: 0.005-(-0.001) mm (Metric) 0.0002- (-0.00003) in (US English) Install the oil ring.
Page 504 2-422 Engine Mechanical System JL4G18-D Engine Install the second air ring. Note The side with letters should face the top. FE02-0285b 10. Install first gas ring. Note The chamfered side should face the top. 11. Apply the engine oil to the connecting rod bearings and install the connecting rod journal and the bearing cap.
Page 505 Engine Engine Mechanical System JL4G18-D 2-423 Rotate the crank a circle (360 °), enable the cylinder No. 4 is at TDC position, measure the clearance as arrow pointed in the graphic and record the clearance. FE02-0288b Use a jack to support the engine. Remove the timing chain.
Page 506: Oil Seal
2-424 Engine Mechanical System JL4G18-D Engine 2.6.8.21 Crankshaft Front Seal Replacement Removal Procedure: Remove the crankshaft belt plate. Refer to 2.6.8.9 Timing Chain Cover Replacement. Remove the crankshaft front oil seals. Note Be careful not to damage the crankshaft journal. Installation Procedure: Use a special tool GL301-013 to install the crankshaft front oil seals.
Page 507 Engine Engine Mechanical System JL4G18-D 2-425 2.6.8.22 Crankshaft Rear Seal Replacement Removal Procedure: Remove the flywheel. Refer to 2.6.8.17 Flywheel Replacement. Remove the crankshaft rear oil seals. Note Be careful not to damage the crankshaft journal. FE02-0503b Installation Procedure: Use a special tool GL301-015 to install the crankcase rear oil seals.
Page 508 2-426 Engine Mechanical System JL4G18-D Engine 2.6.9 Special Tools and Equipment 2.6.9.1 Special Tools List Serial Illustration Tool Number Description Number GT301-002 Seal Handle FE01-2014b GT301-006 Valve Oil Seal Removal Tool FE01-2015b GT301-008 Valve Seal Installation Tool FE01-2016b GT301-009 Valve Guide Removal Tool FE01-2017b EC718/EC718RV EC715/EC715RV 10/2009...
Page 509 Engine Engine Mechanical System JL4G18-D 2-427 Serial Illustration Tool Number Description Number Crankshaft Front Oil Seal Installation GT301-013 Tool FE01-2018b Crankshaft Rear Oil Seal Installation GT301-015 Tool FE01-2019b GT301-016 Piston Pin Removal Tool FE01-2020b GT301-018 Camshaft Locking Tool FE01-2022b GT301-020 Crankshaft Drive Belt Locking Tool EC718/EC718RV EC715/EC715RV 10/2009...
Page 510 2-428 Engine Mechanical System JL4G18-D Engine Serial Illustration Tool Number Description Number GT301-021 Flywheel Locking Tool FE01-2023b GT301-022 Timing Chain Locking Tool FE01-2024b EC718/EC718RV EC715/EC715RV 10/2009...
Page 511: Exhaust System Jl4G18-D
Engine Exhaust System JL4G18-D 2-429 2.7 Exhaust System JL4G18-D 2.7.1 Specifications 2.7.1.1 Fastener Tightening Specifications Specifications Applications Model Metric (Nm) US English (lb-ft) Exhaust Manifold Retaining Nut 20-30 14.8-22.2 Exhaust Manifold Bracket Bolts M12 × 1.25 × 28 28-42 20.7-31.1 Heat Insulator Bolts M8 ×...
Page 512: Exhaust Manifold
2-430 Exhaust System JL4G18-D Engine 2.7.2 Description and Operation 2.7.2.1 Exhaust Manifold Exhaust manifold used in this engine is a monolithic four-port manifold, which can be removed from the rear. The function of exhaust manifold is to exhaust gases after combustion with the minimum back-pressure.
Page 513 Engine Exhaust System JL4G18-D 2-431 2.7.3 System Working Principle 2.7.3.1 System Working Principle Inside the three-way catalytic converter, the ceramic substrate exposed to emissions is coated with a catalyst. Catalysts containing platinum, palladium and rhodium, three kinds of precious metals. These catalysts promote chemical reactions. Catalyst is to accelerate the chemical reaction while remain unchanged itself.
Page 514 2-432 Exhaust System JL4G18-D Engine 2.7.4 Component Locator 2.7.4.1 Exhaust FE02-2030b Legend 1. Exhaust Manifold 4. Rear Muffler 2. Three-Way Catalytic Converter Assembly 3. Front Muffler EC718/EC718RV EC715/EC715RV 10/2009...
Page 515 Engine Exhaust System JL4G18-D 2-433 2.7.4.2 Three-Way Catalytic Converter Assembly FE02-2031b Legend 1. Pre-Catalytic Oxygen Sensor Mounting Hole 4. Immunity Section 2. Three-Way Catalytic Converter Assembly 3. Post-Catalytic Oxygen Sensor Mounting Hole EC718/EC718RV EC715/EC715RV 10/2009...
Page 516 2-434 Exhaust System JL4G18-D Engine 2.7.4.3 Front Muffler Assembly FE02-2032b EC718/EC718RV EC715/EC715RV 10/2009...
Page 517 Engine Exhaust System JL4G18-D 2-435 2.7.4.4 Rear Muffler Assembly FE02-2033b EC718/EC718RV EC715/EC715RV 10/2009...
Page 518 2-436 Exhaust System JL4G18-D Engine 2.7.4.5 Front Exhaust Insulation Panel FE02-2078b EC718/EC718RV EC715/EC715RV 10/2009...
Page 519 Engine Exhaust System JL4G18-D 2-437 2.7.4.6 Front Muffler Heat Shield FE02-2034b EC718/EC718RV EC715/EC715RV 10/2009...
Page 520 2-438 Exhaust System JL4G18-D Engine 2.7.5 Diagnostic Information and Procedures 2.7.5.1 Diagnostic Description Refer to "Description and Operation" in the2.7.2.1 Exhaust ManifoldGet familiar with the system functions and operation before start system diagnostics, as this will help with the correct diagnostic steps, more importantly, it will also help to determine whether the customer described situation is normal.
Page 521 Engine Exhaust System JL4G18-D 2-439 Flange Irregular Joints If necessary, repair or replace the associated components. Replace the exhaust manifold. Refer to 2.7.6.1 Exhaust Manifold Exhaust Manifold Cracked or Broken Replacement. Exhaust system components welded joints leakage Replace the leaking parts. 2.7.5.5 Exhaust System Noise When the engine is running, exhaust has noise or unusual sound.
Page 522 2-440 Exhaust System JL4G18-D Engine – Do not start the vehicle when there is engine misfire or the spark plug wire is disconnected. EC718/EC718RV EC715/EC715RV 10/2009...
Page 523 Engine Exhaust System JL4G18-D 2-441 2.7.6 Removal and Installation 2.7.6.1 Exhaust Manifold Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Note Removing the bolt when it is hot is likely to damage the bolt or flange nuts weld on the exhaust manifold. Remove the bolt when the engine is cooled down.
Page 524 2-442 Exhaust System JL4G18-D Engine Remove heat shield to the exhaust manifold retaining bolts. Remove the heat shield on the exhaust manifold. Remove the exhaust manifold bolts and nuts according to the sequence in the graphic. FE02-0294b EC718/EC718RV EC715/EC715RV 10/2009...
Page 525 Engine Exhaust System JL4G18-D 2-443 Remove the exhaust manifold bracket bolts. FE02-0295b Remove the exhaust manifold and exhaust manifold gasket. FE02-0296b Remove the exhaust manifold bracket bolts. FE02-0297b EC718/EC718RV EC715/EC715RV 10/2009...
Page 526 2-444 Exhaust System JL4G18-D Engine 10. Remove the exhaust manifold lower heat shield retaining bolts. FE02-0298b Installation Procedure: Install and tighten the exhaust manifold lower heat shield retaining bolts. Torque: 10 Nm (Metric) 7.4 lb-ft (US English) FE02-0299b Install the exhaust pipe to engine bracket bolts. Torque: 35 Nm (Metric) 25.9 lb-ft (US English) FE02-0300b EC718/EC718RV EC715/EC715RV 10/2009...
Page 527 Engine Exhaust System JL4G18-D 2-445 Clean the cylinder head cover and the exhaust manifold mating face. FE02-0301b Install the exhaust manifold, install and tighten the bolts and nuts according to the sequence in the graphic. Torque: 25 Nm (Metric) 18.5 lb-ft (US English) FE02-0302b Install the exhaust manifold upper heat shield.
Page 528 2-446 Exhaust System JL4G18-D Engine Install and tighten the exhaust manifold bracket retaining bolts. Torque: 35 Nm (Metric) 25.9 lb-ft (US English) FE02-0304b Install the three-way catalytic converter left connecting bolt. Torque: 52 Nm (Metric) 38.5 lb-ft (US English) FE02-0305b Install the three-way catalytic converter right connecting bolt.
Page 529 Engine Exhaust System JL4G18-D 2-447 2.7.6.2 Three-way Catalytic Converter Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Note Removing the bolt when it is hot is likely to damage the bolt or flange nuts weld on the exhaust manifold. Remove the bolt when the engine is cooled down.
Page 530 2-448 Exhaust System JL4G18-D Engine Lift the vehicle. Warning! Refer to "Vehicle Lifting Warning" in "Warnings and Notices". Remove the three-way catalytic converter left connecting bolt. FE02-0290b Remove three-way catalytic converter right connecting bolt. FE02-0291b Remove the three-way catalytic exhaust converter connecting nuts, remove the exhaust pipe gaskets, remove the three-way catalytic converter and remove the exhaust outlet washers.
Page 531 Engine Exhaust System JL4G18-D 2-449 Installation Procedure: Use a rubber hammer and a piece of wood, tapping the exhaust pipe exports to the exhaust manifold gasket, until the surfaces are even, and then install the three-way catalytic converter, tighten the left connecting bolt. Torque: 40 Nm (Metric) 29.6 lb-ft (US English) Note Clean before installing the exhaust outlet gaskets...
Page 532 2-450 Exhaust System JL4G18-D Engine Lower the vehicle. Connect the post-catalytic oxygen sensor wiring harness connector. FE02-0311b Connect the pre-catalytic oxygen sensor wiring harness connector. Connect the battery negative cable. FE02-0312b 2.7.6.3 Front Muffler Replacement Removal Procedure: Warning! Refer to "Vehicle Lifting Warning" in "Warnings and Notices".
Page 533 Engine Exhaust System JL4G18-D 2-451 Remove the front and rear muffler to the rear muffler retaining nuts and the exhaust pipe gasket. FE02-0313b Remove the rubber bearings from the front muffler. Note Do not drop the front muffler during the removal. Remove the front muffler.
Page 534 2-452 Exhaust System JL4G18-D Engine Install the front muffler gasket. Install and tighten the front and rear muffler retaining nuts. Torque: 52 Nm (Metric) 38.4 lb-ft (US English) FE02-0315b Install the rubber bearings on both sides of the front muffler. Lower the vehicle.
Page 535 Engine Exhaust System JL4G18-D 2-453 Lift the vehicle. Remove the rear muffler to front muffler retaining nuts and the exhaust pipe gasket. FE02-0313b Remove the rear rubber bearing (1). FE02-0316b Remove the rear rubber bearing (2). Remove rear muffler Check whether there are holes, damage or cracks. FE02-0317b EC718/EC718RV EC715/EC715RV 10/2009...
Page 536 2-454 Exhaust System JL4G18-D Engine Installation Procedure: Install the rear rubber bearing (2). FE02-0317b Install the rear rubber bearing (1). FE02-0316b Install the exhaust pipe gasket. Install the rear muffler to front muffler retaining nuts. Torque: 52 Nm (Metric) 38.4 lb-ft (US English) Lower the vehicle.
Page 537: Cooling System Jl4G18-D
Engine Cooling System JL4G18-D 2-455 2.8 Cooling System JL4G18-D 2.8.1 Specifications 2.8.1.1 Fastener Tightening Specifications Specifications Applications Model Metric (Nm) US English (lb-ft) Long Water Pump Mounting Bolt M6 × 35 9-13 6.7-9.6 Short Water Pump Mounting Bolt M6 × 25 8-10 6-7.4 Engine Coolant Temperature Sensor...
Page 538 2-456 Cooling System JL4G18-D Engine Applications Specifications Low Speed Cooling Fan Resistor 0.35 Ω EC718/EC718RV EC715/EC715RV 10/2009...
Page 539 Engine Cooling System JL4G18-D 2-457 2.8.2 Description and Operation diameter is 270 mm (10.63 in), both have five blades. Cooling fan assembly is controlled by the engine control module (ECM) 2.8.2.1 Description and Operation using Low-Speed cooling fan relay and high speed cooling fan relay.
Page 540 2-458 Cooling System JL4G18-D Engine 2.8.3 System Working Principle – Thermostat: the thermostat's role is to control engine coolant flow in the cooling system. Thermostat is installed 2.8.3.1 System Working Principle in the front of the engine and sealed by the engine intake pipe joints components, located in the front of the cylinder –...
Page 541 Engine Cooling System JL4G18-D 2-459 – Cooling Fan High-Speed Circuit Description: The engine control module receives the engine coolant temperature sensor and air pressure switch signals. ECM monitors conditions that meet the cooling fan how-speed running conditions, ECM controls the engine wiring harness connector EN01 terminal No.52 internal ground, and the how-speed cooling fan relay pull-in.
Page 542 2-460 Cooling System JL4G18-D Engine 2.8.4 Component Locator 2.8.4.1 Component Locator FE02-2035b Legend 1. Cooling Fan 5. Coolant Recovery Reservoir 2. Radiator Assembly 3. Thermostat 4. Pump EC718/EC718RV EC715/EC715RV 10/2009...
Page 543 Engine Cooling System JL4G18-D 2-461 2.8.5 Disassemble View 2.8.5.1 Disassemble View FE02-2036b Legend 1. Thermostat 12. Radiator Overflow Pipe 2. Engine Coolant Inlet Component 13. Coolant Recovery Reservoir Pressure Cap 3. Cooling Fan Shroud 14. Radiator Outlet Hose 4. Fan Motor 15.
Page 544 2-462 Cooling System JL4G18-D Engine 2.8.6 Schematic 2.8.6.1 Schematic Engine Coolant Temperature Sensor Cooling Fan High Speed Relay A/C Signal Cooling Fan Motor Cooling Fan Low Speed Relay Air Conditioning Pressure Sensor FE02-2037b EC718/EC718RV EC715/EC715RV 10/2009...
Page 545 Engine Cooling System JL4G18-D 2-463 Main Relay Cooling Fan Low Speed Relay Engine Cooling Fan High Control Speed Relay Module Cooling Fan Assembly FE02-7800b EC718/EC718RV EC715/EC715RV 10/2009...
Page 546 2-464 Cooling System JL4G18-D Engine 2.8.7 Diagnostic Information and Procedures 2.8.7.1 Diagnosis Description Refer to 2.8.2.1 Description and OperationGet familiar with the system functions and operation before start system diagnostics, so that it will help to determine the correct diagnostic steps, more importantly, it will also help to determine whether the customer described situation is normal.
Page 547 Engine Cooling System JL4G18-D 2-465 When the engine coolant temperature displays 102°C (215.6 ºF) The cooling fan should be running at high speed. Does the high speed cooling fan run? Refer to 2.8.7.3 High-Speed Cooling Fan Does Not Run Step 4 Turn on the A/C switch, confirm whether the Low-Speed cooling fan runs.
Page 548 2-466 Cooling System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect cooling fan wiring harness connector CA16. Cooling Fan Harness Connector CA16 Measure resistance between cooling fan wiring harness connector CA16 terminal No.3 and a reliable ground. Standard Resistance: Less than 1 Ω Is the resistance specified Value? CA16 terminal No.3 poor connection to ground.
Page 549 Engine Cooling System JL4G18-D 2-467 Turn the ignition switch to "OFF" position. Remove the high-speed cooling fan relay. Cooling Fan Harness Connector CA16 Disconnect the cooling fan wiring harness connector CA16. Test the continuity between the high-speed cooling fan relay A terminal No.30 and the cooling fan wiring harness connector CA16 terminal No.2.
Page 550 2-468 Cooling System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect ECM harness connector EN01. Remove the high-speed cooling fan relay A. EF28 EF27 EF08 Test the continuity between the high-speed cooling fan relay EF01 86 terminal A and EN01 terminal No.52. Measure voltage between high-speed cooling fan relay 86 terminal A and a reliable ground.
Page 551 Engine Cooling System JL4G18-D 2-469 Turn the ignition switch to "OFF" position. Disconnect cooling fan wiring harness connector CA16. Cooling Fan Harness Connector CA16 Turn the ignition switch to "ON" position. Connect scan tool to the datalink connector. Select in sequence: Engine / Action Test / Fan 1. Make low-speed relay work.
Page 552 2-470 Cooling System JL4G18-D Engine Turn the ignition switch to "OFF" position. Remove the low-speed cooling fan relay B. Measure voltage between cooling fan relay B terminal No.87 and a reliable ground. EF28 EF27 EF08 Standard Voltage: 11-14 V EF01 Is the voltage specified value? Relay B terminal No.87 power circuit is faulty.
Page 553 Engine Cooling System JL4G18-D 2-471 Turn the ignition switch to "OFF" position. Remove the low-speed cooling fan relay B. Turn the ignition switch to "ON" position. Measure voltage between relay B terminal No.85 and a EF28 EF27 EF08 reliable ground. EF01 Standard Voltage: 11-14 V Is the voltage specified value?
Page 554 2-472 Cooling System JL4G18-D Engine Replace ECM. Step 11 Next Diagnostic completed. Step 12 2.8.7.5 Cooling Fan Always Runs At Low Speed Note When the cooling fan always runs at low speed, it is recommended to carry out diagnostic when the engine is completely cooled down.
Page 555 Engine Cooling System JL4G18-D 2-473 Turn the ignition switch to "OFF" position. Remove of low-speed cooling fan relay. Cooling Fan Harness Connector CA16 Disconnect cooling fan wiring harness connector CA16. Check and repair circuit between relay and connector short to power supply. EF28 EF27 EF08...
Page 556 2-474 Cooling System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect ECM harness connector EN01. Remove low-speed cooling fan relay B. EF28 EF27 EF08 Test the continuity between cooling fan low speed relay B terminal No.86 and ECM harness connector EN01 terminal EF01 No.62.
Page 557 Engine Cooling System JL4G18-D 2-475 Turn the ignition switch to "OFF" position. Connect scan tool to the datalink connector. Turn off the A/C switch. Turn the ignition switch to "ON" position. Select in sequence: Engine / Data List / Engine Coolant Temperature.
Page 558 2-476 Cooling System JL4G18-D Engine Measure resistance between relay terminal No.87 and terminal No.30. Standard Resistance: 10 kΩ or higher Confirm whether the measured resistance is normal. Replace the relay. Step 6 Check high-speed relay A control circuit. Turn the ignition switch to "OFF" position. Disconnect ECM harness connector EN01.
Page 559 Engine Cooling System JL4G18-D 2-477 2.8.7.7 Thermostat Diagnostic Remove the thermostat. Refer to 2.8.8.4 Thermostat Replacement. Step 1 Next Soak the thermostat in water and heat the water. Step 2 Check the thermostat switch on temperature. Standard Value: 82°C (179.6 ºF) Is the thermostat switch on temperature normal? Replace the thermostat.
Page 560: Engine Overheating
Is there engine coolant loss? Add engine coolant. Is the engine coolant concentration inadequate? Step 2 Use "Geely Genuine ultra-long-acting engine coolant" or the same level of high-quality ethylene glycol base engine coolant, model or standard number: comply with SH0521.
Page 561 Engine Cooling System JL4G18-D 2-479 Check whether the cooling fan is working properly. Step 7 Check the cooling fan circuit. Refer to 2.8.7.2 Cooling Fan Circuit Diagnosis Step 8 Check whether there is water pump fault. Replace the water pump. Refer to 2.8.8.6 Water Pump Replacement Check whether radiator cap is faulty.
Page 562 2-480 Cooling System JL4G18-D Engine Instrument cluster is faulty. Refer to11.7.6 Diagnostic Information and Procedures Step 3 Check whether the cooling fan rotates normally? Refer to 2.8.7.5 Cooling Fan Always Runs At Low Speed Check whether the thermostat is working as per normal? Step 4 Check whether the installed thermostat type is correct.
Page 563 Engine Cooling System JL4G18-D 2-481 Check whether the water pump seal is leaking. Step 4 Replace the Pump Seal. Check whether the cylinder head cover torque is appropriate. Step 5 Tighten the cylinder head gasket bolts to the specified torque. If necessary, replace the cylinder head gasket Check for leaking at the follows locations: Step 6...
Page 564 2-482 Cooling System JL4G18-D Engine 2.8.8 Removal and Installation 2.8.8.1 Engine Coolant Discharge and Filling Warning! Refer to "Cooling System Service Warning" in "Warnings and Notices". Place a recycling container under the vehicle to contain the discharged engine coolant. Remove the radiator cap. FE02-0318b Remove the engine coolant drainage valve.
Page 565 Engine Cooling System JL4G18-D 2-483 Slowly fill the engine coolant into the Coolant Recovery Reservoir to the standard scale, so that the air will be discharged from the cooling outlet pipe. Start the engine until the thermostat switches on. When the radiator inlet and outlet pipes are hot, it can be identified that the thermostat is switched on.
Page 566 2-484 Cooling System JL4G18-D Engine Remove the engine coolant overflow pipe. FE02-0322b Remove the coolant recovery reservoir lower retaining bolt. FE02-0323b Installation Procedure: Install the coolant recovery reservoir upper retaining bolt. Torque: 25 Nm (Metric) 18.5 lb-ft (US English) FE02-0324b EC718/EC718RV EC715/EC715RV 10/2009...
Page 567 Engine Cooling System JL4G18-D 2-485 Install the coolant recovery reservoir lower retaining bolt. Torque: 25 Nm (Metric) 18.5 lb-ft (US English) FE02-0325b Fill the engine coolant to the level between the MIN and MAX. FE02-0326b Install the coolant recovery reservoir cap and the engine coolant overflow pipe.
Page 568 2-486 Cooling System JL4G18-D Engine Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Remove the radiator air baffle and deflector. Disconnect the fan motor wiring harness connector. FE02-0329b Remove the right side of the fan cover retaining bolt. EC718/EC718RV EC715/EC715RV 10/2009...
Page 569 Engine Cooling System JL4G18-D 2-487 Remove the left side of the fan cover retaining bolt. FE02-0331b Remove the fan assembly from the vehicle. FE02-0332b Installation Procedure: Install the fan assembly to the vehicle. FE02-0333b EC718/EC718RV EC715/EC715RV 10/2009...
Page 570 2-488 Cooling System JL4G18-D Engine Install the right side of the fan cover retaining bolt. Torque: 9 Nm (Metric) 6.7 lb-ft (US English) FE02-0334b Install the left side of the fan cover retaining bolt. Torque: 9 Nm (Metric) 6.7 lb-ft (US English) FE02-0335b Connect the cooling fan motor wiring harness connector.
Page 571 Engine Cooling System JL4G18-D 2-489 Install the radiator air baffle and deflector. Connect the battery negative cable. FE02-0337b 2.8.8.4 Thermostat Replacement Removal Procedure: Warning! Refer to "Cooling System Service Warning" in "Warnings and Notices". Discharge the engine coolant. Refer to 2.8.8.1 Engine Coolant Discharge and Filling.
Page 572 2-490 Cooling System JL4G18-D Engine Remove the engine coolant inlet pipe to the cylinder block retaining nuts. FE02-0340b Remove the engine coolant inlet pipe component from the cylinder block. FE02-0341b Remove the thermostat from the cylinder block. Note The thermostat and seals are integrated. Clean the engine coolant inlet pipe and cylinder block mating surface.
Page 573 Engine Cooling System JL4G18-D 2-491 Installation Procedure: Install the thermostat to the cylinder block. Install the engine coolant inlet pipe component to the cylinder block. FE02-0343b Install the engine coolant inlet pipe component to the cylinder block retaining nuts. Torque: 11 Nm (Metric) 8.2 lb-ft (US English) FE02-0344b Install radiator outlet pipe to the engine coolant inlet pipe component.
Page 574 2-492 Cooling System JL4G18-D Engine Tighten the radiator outlet pipe clamp. Fill the engine coolant. FE02-0338b 2.8.8.5 Radiator Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection.
Page 575 Engine Cooling System JL4G18-D 2-493 Remove the left side of radiator retaining bolts. FE02-0348b Remove the right side of radiator retaining bolts and remove the radiator. FE02-0349b Installation Procedure: Install the radiator and tighten the left side of radiator retaining bolts. Torque: 10.5 Nm (Metric) 7.8 lb-ft (US English) FE02-0350b EC718/EC718RV EC715/EC715RV 10/2009...
Page 576 2-494 Cooling System JL4G18-D Engine Install and tighten the right side of radiator retaining bolts. Torque: 10.5 Nm (Metric) 7.8 lb-ft (US English) FE02-0351b Install the radiator outlet pipe and tighten the clamp. FE02-0352b Install the radiator inlet pipe and tighten the clamp. Install the cooling fan.
Page 577 Engine Cooling System JL4G18-D 2-495 Discharge the engine coolant. Refer to 2.8.8.1 Engine Coolant Discharge and Filling. Remove the drive belt. Refer to 2.6.8.3 Drive Belt Replacement. Remove the two short water pump retaining bolts. Remove the four long water pump retaining bolts. FE02-0355b Remove the water pump.
Page 578 2-496 Cooling System JL4G18-D Engine Remove the water pump seals. Water Pump Inspection: Warning! Refer to "Protective Goggles and Glove Warning" in "Warnings and Notices". Check whether the pump body is cracking and leaking. Check whether the water pump bearing has a gap or abnormal sound.
Page 579 Engine Cooling System JL4G18-D 2-497 Install new water pump seals. Note The pump seal is a single used part and must be replaced with new parts. after removal. FE02-0359b Install the four long bolts, but do not tighten at this stage. FE02-0355b Install the two short bolts, but do not tighten at this stage.
Page 580 2-498 Cooling System JL4G18-D Engine Tighten the water pump retaining bolts according to the sequence in the graphic. Torque Short Water Pump Retaining Bolts: 9 Nm (Metric) 6.7 lb- ft (US English) Long Water Pump Retaining Bolts: 11 Nm (Metric) 8.2 lb- ft (US English) Install the drive belt.
Page 581: Lubricating System Jl4G18-D
Engine Lubricating System JL4G18-D 2-499 2.9 Lubricating System JL4G18-D 2.9.1 Specifications 2.9.1.1 Fastener Tightening Specifications Specifications Applications Model Metric (Nm) US English (lb-ft) Oil Pan and Cylinder Block 8-10 6-7.4 Connecting Bolts Oil Filters and Cylinder Block 8-10 6-7.4 Connecting Bolts Oil Sensor Plug and Cylinder R1 / 8 11.5-19.5...
Page 582: Oil Pan
2-500 Lubricating System JL4G18-D Engine 2.9.2 Description and Operation actuator. Engine Control Module (ECM) controls the VVT solenoid valve. When the engine control module provides 2.9.2.1 Description and Operation power to the VVT solenoid valve, the solenoid valve guides the Oil Pan engine oil to flow through the cylinder head cover camshaft front bearing caps.
Page 583 Engine Lubricating System JL4G18-D 2-501 2.9.3 System Working Principle 2.9.3.1 Lubrication Schematic FE02-2042b Legend 1. Intake Camshaft 7. Oil Collection Filters 2. Exhaust Camshaft 8. Oil Pan 3. Oil Filter 9. VVT Actuator 4. Oil Pressure Sensor Plug 10. VVT Solenoid Valve 5.
Page 584 2-502 Lubricating System JL4G18-D Engine 2.9.3.2 Engine Oil Pressure Sensor Plug Control Principle Engine oil pressure sensor plug is a pressure switch and is set on the oil filter. When the engine oil pressure is below the specified value, this switch is switched off and the engine oil pressure warning lamp will be on.
Page 585 Engine Lubricating System JL4G18-D 2-503 2.9.4 Component Locator 2.9.4.1 Component Locator FE02-2043b Legend 1. Oil Filter 3. Oil Pump 2. Oil Pan EC718/EC718RV EC715/EC715RV 10/2009...
Page 586 2-504 Lubricating System JL4G18-D Engine 2.9.5 Disassemble View 2.9.5.1 Disassemble View Legend 1. Engine Block 4. Oil Pump Bolts 2. Oil Pump Gasket 3. Oil Pump Assembly EC718/EC718RV EC715/EC715RV 10/2009...
Page 587 Engine Lubricating System JL4G18-D 2-505 2.9.6 Schematic 2.9.6.1 Schematic Battery Voltage +B Oil Pressure Sensing Plug Instrument Cluster FE02-2045b EC718/EC718RV EC715/EC715RV 10/2009...
Page 588 2-506 Lubricating System JL4G18-D Engine 2.9.7 Diagnostic Information and Procedures 2.9.7.1 Diagnosis Description Refer to 2.9.2.1 Description and OperationGet familiar with the system functions and operation before start system diagnostics, so that it will help to determine the correct diagnostic steps, more importantly, it will also help to determine whether the customer described situation is normal.
Page 589 Engine Lubricating System JL4G18-D 2-507 Check whether the piston and piston rings in the cylinder are improperly installed. Step 6 Repair the faulty part. Check whether there is correct piston ring seal, whether there are broken or worn piston rings. If necessary, Step 7 repair the faulty part.
Page 590 2-508 Lubricating System JL4G18-D Engine Refer to the user manual, according to local temperatures, use the Geely Automobile recommended grade and viscosity engine oil Step 7 Turn the ignition switch to "OFF" position, remove the oil pressure sensor plug. Next Install the engine oil pressure test tool to the oil pressure sensor plug on the oil filter.
Page 591 Engine Lubricating System JL4G18-D 2-509 Check whether the engine oil pressure is too high. Step 2 Check whether the pressure oil filter or the bypass valve is blocked or malfunction. Step 3 Check whether the engine ventilation system is blocked or malfunction. Repair the faulty part.
Page 592 2-510 Lubricating System JL4G18-D Engine 2.9.8 Removal and Installation 2.9.8.1 Oil Pump Replacement Removal Procedure: Warning! After a new oil pump is installed, the oil collection filters, must be inspected. Refer to engine oil pan replacement and oil collection filters replacement. Disconnect the battery negative cable.
Page 593 Engine Lubricating System JL4G18-D 2-511 Remove the oil pump gasket from the engine block. Installation Procedure: Before installation, clean the engine oil pan oil collection filters. Refer to 2.9.8.3 Oil Pan Replacement. Clean engine block oil pump installation surface. FE02-0364b Install the oil pump gasket.
Page 594 2-512 Lubricating System JL4G18-D Engine Install and tighten the oil pump retaining bolts. Torque: 9 Nm (Metric) 6.7 lb-ft (US English) Install the timing chain. Install the timing chain cover. Connect the battery negative cable. FE02-0366b 2.9.8.2 Oil Pump Cleaning and Inspection Cleaning Procedures: Oil Pump Valve Inspection: a.
Page 595 Engine Lubricating System JL4G18-D 2-513 Remove the oil pump cover. Clean oil pump housing and internal parts. FE02-0369b Inspection Procedure: Check all oil pump parts for worn and torn. Apply clean engine oil to all oil pump parts. Note A: Apply grease to the oil pump gear chamber in order to ensure initial oil pump lubrication.
Page 596 2-514 Lubricating System JL4G18-D Engine 2.9.8.3 Oil Pan Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Refer to "Vehicle Lifting Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Lift the vehicle.
Page 597 Engine Lubricating System JL4G18-D 2-515 Remove the oil pan retaining bolts and nuts. Remove the oil pan from the cylinder block. FE02-0375b Installation Procedure: Inspect and clean set of filters before installing the oil pan. FE02-0376b EC718/EC718RV EC715/EC715RV 10/2009...
Page 598 2-516 Lubricating System JL4G18-D Engine Clean oil pan and cylinder block mating surface. Apply sealant on the new engine oil pan evenly. Install the oil pan and tighten the bolts and nuts according to the sequence in the graphic. Torque: 9 Nm (Metric) 6.7 lb-ft (US English) Install the flywheel shield.
Page 599: Ignition System Jl4G18-D
Engine Ignition System JL4G18-D 2-517 2.10 Ignition System JL4G18-D 2.10.1 Specifications 2.10.1.1 Fastener Tightening Specifications Specifications Applications Model Metric (Nm) US English (lb-ft) Crankshaft Position Sensor M6 × 12 8-10 6-7.4 Mounting Bolt Camshaft Position Sensor M6 × 14 8-10 6-7.4 Mounting Bolt Ignition Coil Retaining Bolts...
Page 600 2-518 Ignition System JL4G18-D Engine 2.10.2 Description and Operation 2.10.2.1 Description and Operation This vehicle uses DLI ignition system igniting two cylinders at the same time. The ignition voltage is sent directly from the ignition coil to the Spark Plug. Main system components are ECM, two ignition coils, high voltage damping line, Spark Plug, crankshaft position sensor, camshaft position sensor, knock sensor etc..
Page 601 Engine Ignition System JL4G18-D 2-519 2.10.3 System Working Principle 2.10.3.1 System Working Principle When the ignition switch is at "ON" or "ST" position, the ignition switch wiring harness connector IP23 terminal No.1 and terminal No.2 are connected, so that IG1 relay coil forms a complete circuit.Battery voltage passes through the fuses EF01, EF22, IG1 Relay, fuse IF30 to reach the ignition coil, supplies power to the ignition coil.
Page 602 2-520 Ignition System JL4G18-D Engine 2.10.4 Component Locator 2.10.4.1 Component Locator FE02-2046b Legend 1. Ignition Coil and High-Voltage Damping Line 5. Spark Plug 2. Knock Sensor 3. Camshaft Position Sensor 4. Crankshaft Position Sensor EC718/EC718RV EC715/EC715RV 10/2009...
Page 603 Engine Ignition System JL4G18-D 2-521 2.10.5 Disassemble View 2.10.5.1 Ignition Cylinder Assembly Disassemble View Legend 1. Ignition Switch Retaining Bolts 5. Ignition Cylinder 2. Ignition Switch Assembly 6. EAS Coil 3. Ignition Cylinder Bracket 4. Ignition Key Reminder Switch EC718/EC718RV EC715/EC715RV 10/2009...
Page 604 2-522 Ignition System JL4G18-D Engine 2.10.6 Schematic 2.10.6.1 Schematic Crankshaft Position Sensor 1,4 Cylinder Ignition Coil Engine Control Module Camshaft Position Sensor 2,3 Cylinder Ignition Coil Knock Sensor FE02-2048b EC718/EC718RV EC715/EC715RV 10/2009...
Page 605 Engine Ignition System JL4G18-D 2-523 IG1 Relay To Ignition Switch 1,4 Cylinder Ignition Coil MAIN Engine 2,3 Cylinder Ignition Coil Control Module Battery FE02-9000b EC718/EC718RV EC715/EC715RV 10/2009...
Page 606 2-524 Ignition System JL4G18-D Engine 2.10.7 Diagnostic Information and Procedures 2.10.7.1 Diagnosis Description Refer to 2.10.2.1 Description and OperationGet familiar with the system functions and operation before start system diagnostics, so that it will help to determine the correct troubleshooting steps, more importantly, it will also help to determine whether the customer described situation is normal.
Page 607 Engine Ignition System JL4G18-D 2-525 Location Related Terminal Standard Conducted 1-2-3 Conducted Conducted 4-5-6 If you detect there is one item that is not complying with standards, replace the ignition switch. 2.10.7.4 Ignition Relay IG1 No Power Output Check IG1 relay coil control power supply. Step 1 Turn the ignition switch to "OFF"...
Page 608 2-526 Ignition System JL4G18-D Engine Turn the ignition switch to "OFF" position. IF12 Remove ignition relay. IF26 IF15 Measure voltage between ignition relay IG1 terminal No.87 IF28 IF16 IF21 IF30 and a reliable ground. IF10 Standard Voltage: 11-14 V Is the voltage specified value? The circuit between the relay terminal No.87 and fuse EF22 is open.
Page 609 Engine Ignition System JL4G18-D 2-527 It is prohibited directly contact the ignition wire with the ground, as this may damage the ignition coil or the engine control module. the correct approach is to use a good spark plug with one end to connect the ignition wire, the other to a reliable ground.
Page 610 2-528 Ignition System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect the ignition coil harness connector EN19 (EN20). Measure resistance between the ignition coil secondary terminals. Standard Resistance Value: 9.68-12.32 kΩ Is the resistance specified value? Replace the ignition coil. Refer to 2.10.8.3 Ignition Coil Replacement Resistance FE02-9008b...
Page 611 Engine Ignition System JL4G18-D 2-529 Note: Each time the ignition switch can not stay at the "ST" location more than 5s, otherwise it will damage the starter motor. Note: The scan tool can also be to diagnose. Turn the ignition switch to the "ST"...
Page 612 2-530 Ignition System JL4G18-D Engine 2.10.7.6 Spark Plug Diagnostic FE02-2050b Step 1 Remove the spark plug. Refer to 2.10.8.4 Spark Plug Replacement. Next Step 2 Check whether the terminal terminal A is bent or broken, pull the terminal to test whether the terminal A is loose.
Page 613 Engine Ignition System JL4G18-D 2-531 Next Check center electrode C for signs of abnormal discharge, measure the gap between the center electrodes. Step 5 Check whether the spark plug torque is correct, the spark plug tightening torqueis the 20-30Nm (14.8-22.2lb-ft). If the torque is not adequate, the spark plug will not work correctly.
Page 614 2-532 Ignition System JL4G18-D Engine With normal spark plug, center electrode is gray or yellow. FE02-2051b EC718/EC718RV EC715/EC715RV 10/2009...
Page 615 Engine Ignition System JL4G18-D 2-533 With excessive fuel combustion, spark plug center electrode has serious corrosion. FE02-2052b EC718/EC718RV EC715/EC715RV 10/2009...
Page 616 2-534 Ignition System JL4G18-D Engine With incorrect spark plug heat value or fuel system malfunction, the spark plug center electrode has excessive carbon residue. FE02-2053b EC718/EC718RV EC715/EC715RV 10/2009...
Page 617 Engine Ignition System JL4G18-D 2-535 2.10.8 Removal and Installation 2.10.8.1 Camshaft Position Sensor Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Disconnect the camshaft position sensor wiring harness connector.
Page 618 2-536 Ignition System JL4G18-D Engine Remove the camshaft position sensor. Installation Procedure: Check to confirm whether the camshaft position sensor seals are intact. FE02-0381b Install camshaft position sensor and tighten the retaining bolt. Torque: 9 Nm (Metric) 6.7 lb-ft (US English) EC718/EC718RV EC715/EC715RV 10/2009...
Page 619 Engine Ignition System JL4G18-D 2-537 Connect the camshaft position sensor wiring harness connector. Connect the battery negative cable. FE02-0383b 2.10.8.2 Crankshaft Position Sensor Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection.
Page 620 2-538 Ignition System JL4G18-D Engine Disconnect the crankshaft position sensor wiring harness connector. FE02-0385b Remove the sensor retaining bolts. Note After removing the sensor, plug the sensor mounting hole to prevent debris falling into it. FE02-0386b Installation Procedure: Install the sensor and tighten the retaining bolts. Torque: 9 Nm (Metric) 6.7 lb-ft (US English) Connect the crankshaft position sensor wiring harness connector.
Page 621 Engine Ignition System JL4G18-D 2-539 2.10.8.3 Ignition Coil Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Remove the hood. Refer to 2.6.8.1 Plastic Engine Shield Replacement.
Page 622 2-540 Ignition System JL4G18-D Engine Disconnect the cylinder No.1 high pressure damping line. FE02-0391b Remove cylinder No.2 and No.3 ignition coil retaining bolts. FE02-0392b Remove cylinder No.2 and No.3 ignition coils. FE02-0393b EC718/EC718RV EC715/EC715RV 10/2009...
Page 623 Engine Ignition System JL4G18-D 2-541 Remove cylinder No.1 and No.4 ignition coil retaining bolts. FE02-0394b 10. Remove cylinder No.1 and No.4 ignition coils. FE02-0395b Installation Procedure: Install cylinder No.1 and No.4 ignition coils, and tighten the retaining bolts. Torque: 9 Nm (Metric) 6.7 lb-ft (US English) FE02-0396b EC718/EC718RV EC715/EC715RV 10/2009...
Page 624 2-542 Ignition System JL4G18-D Engine Install cylinder No.2 and No.3 ignition coils, and tighten the retaining bolts. Torque: 9 Nm (Metric) 6.7 lb-ft (US English) FE02-0397b Connect the cylinder No.1 high pressure damping line. Note Confirm the high-pressure damping line is installed in place, otherwise it will cause a secondary arch and engine malfunction.
Page 625: Spark Plug Replacement
Engine Ignition System JL4G18-D 2-543 Connect cylinder No.1 and No.4 ignition coil harness connectors. FE02-0398b Connect cylinder No.2 and No.3 ignition coil harness connectors. Install the engine hood. Connect the battery negative cable. FE02-0399b 2.10.8.4 Spark Plug Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning"...
Page 626 2-544 Ignition System JL4G18-D Engine Use spark plug socket to rotate the spark plug counterclockwise to remove the spark plug. FE02-0401b Remove the Spark Plug from the cylinder head . FE02-0402b Installation Procedure: Clean the Spark Plug and check the spark plug electrode gap.
Page 627 Engine Ignition System JL4G18-D 2-545 Install the high-voltage damping line and the spark plug. Install the engine hood. Connect the battery negative cable. FE02-0403b 2.10.8.5 Knock Sensor Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect the battery negative cable.
Page 628 2-546 Ignition System JL4G18-D Engine Installation Procedure: Install the knock sensor retaining bolts. Torque: 18 Nm (Metric) 13.3 lb-ft (US English) Connect the knock sensor wiring harness connector. Install the starter. Connect the battery negative cable. FE02-0405b EC718/EC718RV EC715/EC715RV 10/2009...
Page 629: Starting / Charging System Jl4G18-D
Engine Starting / Charging System JL4G18-D 2-547 2.11 Starting Charging System JL4G18-D 2.11.1 Specifications 2.11.1.1 Fastener Tightening Specifications Specifications Applications Model Metric (Nm) US English (lb-ft) Battery Cable Nut 8.5-12 6.3-8.9 Battery Bracket To Battery 7.5-10.5 5.6-7.8 Stud Nut Battery Terminal Bolt M6 ×...
Page 630 2-548 Starting / Charging System JL4G18-D Engine Applications Specifications Drive Gear Speed 2,600-4,800 rpm Solenoid Coil (12.2V) 35 A Suction Coil (12.2V) 35 A Generator Specifications Applications Specifications Current 90 A Model JFZ1906 EC718/EC718RV EC715/EC715RV 10/2009...
Page 631 Engine Starting / Charging System JL4G18-D 2-549 2.11.2 Description and Operation – Vehicle electrical load exceeds the generator output, especially if the vehicle is equipped with aftermarket 2.11.2.1 Battery Description and Operation equipments. Warning! – Charging system fault, such as electrical short circuit, generators belt slipping, generator malfunction or voltage Refer to "Battery Acid Fluid"...
Page 632 2-550 Starting / Charging System JL4G18-D Engine Charge a fully discharged battery (off the vehicle): Strictly abide by the following procedure, otherwise a good battery might be mistakenly replaced . Follow the following procedures, charge a fully discharged battery: 1. Measure the battery terminal voltage with a precision voltage meter.
Page 633 Engine Starting / Charging System JL4G18-D 2-551 2.11.3 System Working Principle 2.11.3.2 Charging System Working Principle 2.11.3.1 Starting System Working Principle Generator provides DC voltage to the vehicle electrical system and maintains the battery charged. The voltage output is When the ignition switch in at "ST" position: controlled by the regulator integrated inside the generator: –...
Page 634 2-552 Starting / Charging System JL4G18-D Engine – Because the generator wiring harness connector EN07 terminal No.3 and the battery is connected, when the battery is fully charged, the regulator will reduce the magnetic field excitation current, thereby reducing the generator output voltage to prevent overcharging.
Page 635 Engine Starting / Charging System JL4G18-D 2-553 2.11.4 Component Locator 2.11.4.1 Generator and Starter Legend 1. Generator 2. Starter EC718/EC718RV EC715/EC715RV 10/2009...
Page 636 2-554 Starting / Charging System JL4G18-D Engine 2.11.5 Disassemble View 2.11.5.1 Starter Disassemble View Legend 1. Planetary Gear Reducer Assembly 7. Fork 2. Drive Gear Assembly 8. Motor Rear Cover 3. Brush Holder Assembly 9. Motor Shell 4. Magnetic Frame Assembly 5.
Page 637 Engine Starting / Charging System JL4G18-D 2-555 2.11.5.2 Generator Disassemble View Legend 1. Drive Belt 7. Generator Output Terminal 2. Generator Front Cover 8. Voltage Regulator 3. Cooling Fan 9. Rectifier 4. Rotor 10. Stator 5. Generator Rear Cover 6. Generator Rear Shield EC718/EC718RV EC715/EC715RV 10/2009...
Page 638 2-556 Starting / Charging System JL4G18-D Engine 2.11.6 Schematic 2.11.6.1 Schematic Ignition Starter Starter Battery Switch Relay Motor IGN Relay Generator Instrument Cluster FE02-2057b EC718/EC718RV EC715/EC715RV 10/2009...
Page 639 Engine Starting / Charging System JL4G18-D 2-557 Starting System Diagram Starter Relay Starter Motor FE02-9400b EC718/EC718RV EC715/EC715RV 10/2009...
Page 640 2-558 Starting / Charging System JL4G18-D Engine Charging System Diagram IG1 Relay To Ignition Switch Instrument Cluster Battery Generator FE02-9401b EC718/EC718RV EC715/EC715RV 10/2009...
Page 641 Engine Starting / Charging System JL4G18-D 2-559 2.11.7 Diagnostic Information and Procedures 2.11.7.1 Diagnosis Description Refer to 2.11.2.2 Starting System Description and Operationget familiar with the system functions and operation before start system diagnostics, so that it will help to determine the correct diagnostic steps, more importantly, it will also help to determine whether the customer described situation is normal.
Page 642 2-560 Starting / Charging System JL4G18-D Engine Step 5 Ignition switch is at "ON" position, does relay 85 terminal have 12V voltage? Replace the starter. Confirm whether the fault has been fixed. Step 6 Check starter relay terminal No.85 voltage Turn the ignition switch to "OFF"...
Page 643 Engine Starting / Charging System JL4G18-D 2-561 Check the battery terminal connections for existence of loose and corrosion. Check the engine mechanical system for existence of unusual noise. Check whether the cylinder compression pressure is normal. All normal? Repair the faulty part. Step 6 Replace the starter motor.
Page 644 2-562 Starting / Charging System JL4G18-D Engine Check and repair the cable, if necessary, replace the cable. Replace the starter motor. Step 13 Step 14 Check the starter motor control power supply. Turn the ignition switch to "OFF" position. Disconnect starter harness connector EN18. Turn the ignition switch to "ON"...
Page 645 Engine Starting / Charging System JL4G18-D 2-563 Turn the ignition switch to the "ST" position, Does the starter relay pull-in? Step 16 Go to step 19 Measure starter relay terminal No.87 power supply. Step 17 Remove the starter relay. Measure the starter relay terminal No.87 voltage. Standard Voltage: 11-14 V EF28 EF27...
Page 646 2-564 Starting / Charging System JL4G18-D Engine Turn the ignition switch to "OFF" position. Remove the starter relay. Measure resistance between starter relay terminal No.86 and EF28 EF27 EF08 a reliable ground. Standard Resistance:<1 Ω EF01 Is the voltage specified value? Replace the starter relay.
Page 647 Engine Starting / Charging System JL4G18-D 2-565 Turn the ignition switch to "OFF" position. Disconnect the ignition switch wiring harness connector IP23. Ignition Switch Harness Connector IP23 Measure voltage between IP23 terminal No.5 and a reliable ground. Standard Voltage: 11-14 V Is the voltage specified value? Replace the ignition switch.
Page 648 2-566 Starting / Charging System JL4G18-D Engine Remove the starter motor. Step 4 Check starter motor sleeve and clutch gear for clutch gear cracks,worn or sleeve worn? Replace the starter motor. Refer to 2.11.8.4 Starter Replacement Step 5 Replace the flywheel. Next Step 6 Diagnostic completed.
Page 649 Engine Starting / Charging System JL4G18-D 2-567 Turn the ignition switch to "OFF" position. Disconnect generator harness connector EN07. Remove the instrument cluster, Disconnect the instrument cluster wiring harness connector IP03. Generator Harness Connector EN07 Check the continuity between instrument cluster wiring harness connector IP03 and generator harness connector EN07 terminal No.1.
Page 650 2-568 Starting / Charging System JL4G18-D Engine Turn the ignition switch to "OFF" position. Disconnect generator harness connector EN07. Measure voltage between generator harness connector Generator Harness Connector EN07 EN07 terminal No.2 and a reliable ground. Standard Voltage: 11-14 V Connect generator harness connector EN07.
Page 651 Engine Starting / Charging System JL4G18-D 2-569 The generator regulator power circuit is open. Repair the faulty part. Confirm the fault has been fixed. Step 4 Check the generator regulator excitation power supply. Refer to 2.11.7.6 Charging Indicator Always OnStep 5. Confirm the fault has been fixed.
Page 652 2-570 Starting / Charging System JL4G18-D Engine Check the generator shaft. Step 2 Shut down the engine. Remove the drive belt. Rotate the generator pulley by hand. Does the generator rotate smoothly without catching and grinding noise? Go to step 6 Reinstall the generator.
Page 653 Engine Starting / Charging System JL4G18-D 2-571 Next Diagnostic completed. Step 8 2.11.7.9 Battery Discharging Current Parasitic Load Test If the battery continues to loss power, perform the following test to check whether there are parasitic battery current. Note Before carry out this procedure, please check whether there are installed after market equipments such as DVD, audio power amplifier, subwoofer speaker box back and other non-original accessories.
Page 654 2-572 Starting / Charging System JL4G18-D Engine Note When the system parasitic current can not be confirmed, compare the vehicle with a known good vehicle to helping with diagnostic. 2.11.7.10 Jump Start Procedure Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Park the vehicle that will provide jump starting power properly to make sure the jumper cable can connect Step 1 two vehicles batteries.
Page 655 Engine Starting / Charging System JL4G18-D 2-573 Next Finally, connect the other end of the black cable to the flat battery engine ground, and at least 500mm away Step 9 form the flat battery (19.7 in). Next Start the vehicle, which has a battery with sufficient power, and run the engine speed at intermediate speed Step 10 for more than 3min.
Page 656 2-574 Starting / Charging System JL4G18-D Engine 2.11.8 Removal and Installation 2.11.8.1 Battery Disconnection Disconnecting Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Turn off all electrical equipments, and turn the ignition switch to "OFF" position. FE02-0406b Disconnect the battery negative cable.
Page 657 Engine Starting / Charging System JL4G18-D 2-575 Disconnect battery positive cable. FE02-0408b Connecting Procedure: Connect battery positive cable, and tighten the retaining nut. Torque: 10.3 Nm (Metric) 7.6 lb-ft (US English) FE02-0409b Make sure the ignition switch is turned to "OFF" position. FE02-0410b EC718/EC718RV EC715/EC715RV 10/2009...
Page 658: Battery Replacement
2-576 Starting / Charging System JL4G18-D Engine Connect the battery negative cable. Torque: 10.3 Nm (Metric) 7.6 lb-ft (US English) 2.11.8.2 Battery Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect battery positive and negative cables. Refer to 2.11.8.1 Battery Disconnection.
Page 659 Engine Starting / Charging System JL4G18-D 2-577 Remove the battery. Remove the battery bracket. FE02-0415b Installation Procedure: Install the battery bracket. Note The battery bracket is retained by two convex sets, pay attention during installation align the convex with the bracket holes. FE02-0416b EC718/EC718RV EC715/EC715RV 10/2009...
Page 660 2-578 Starting / Charging System JL4G18-D Engine Install the battery. Install the battery bracket and tighten the nuts and bolts. Torque: 13 Nm (Metric) 9.6 lb-ft (US English) Install the radiator upper grille. Connect the battery positive and negative cables. 2.11.8.3 Generator Replacement Removal Procedure: Warning!
Page 661 Engine Starting / Charging System JL4G18-D 2-579 Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Disconnect the generator harness connector. FE02-0419b Remove the generator charging wiring harness retaining nut. FE02-0420b Remove the drive belt. Refer to 2.6.8.3 Drive Belt Replacement.
Page 662 2-580 Starting / Charging System JL4G18-D Engine Remove the generator upper retaining bolt. Remove the generator from the generator bracket. FE02-0422b Installation Procedure: Install and tighten the generator upper retaining bolt. Torque: 25 Nm (Metric) 18.5 lb-ft (US English) FE02-0423b Install and tighten the generator lower retaining bolt.
Page 663: Starter Replacement
Engine Starting / Charging System JL4G18-D 2-581 Install the drive belt. Install the generator charging wiring harness and tighten the harness retaining nut. Torque: 10 Nm (Metric) 7.4 lb-ft (US English) FE02-0425b Connect the generator harness connector. Connect the battery negative cable. FE02-0426b 2.11.8.4 Starter Replacement Removal Procedure:...
Page 664 2-582 Starting / Charging System JL4G18-D Engine Remove the starter power supply wiring harness retaining nut. FE02-0428b Remove the starter power supply wiring harness. FE02-0429b Remove the starter upper retaining bolt. FE02-0430b EC718/EC718RV EC715/EC715RV 10/2009...
Page 665 Engine Starting / Charging System JL4G18-D 2-583 Remove the starter lower retaining bolt. FE02-0431b Installation Procedure: Install the starter upper retaining bolt. Torque: 37 Nm (Metric) 27.4 lb-ft (US English) FE02-0432b Install the starter lower retaining bolt. Torque: 37 Nm (Metric) 27.4 lb-ft (US English) FE02-0433b EC718/EC718RV EC715/EC715RV 10/2009...
Page 666 2-584 Starting / Charging System JL4G18-D Engine Install the starter power supply wiring harness and tighten the retaining nut. FE02-0434b Connect the starter motor control wiring harness connector. Connect the battery negative cable. FE02-0435b EC718/EC718RV EC715/EC715RV 10/2009...
Page 667: Control System Jl4G15-D
Engine Control System JL4G15-D 2-585 2.12 Control System JL4G15-D 2.12.1 Specifications 2.12.1.1 Fastener Tightening Specifications Specifications Applications Models Metric (Nm) US English (lb-ft) Camshaft Position Sensor Retaining Bolts M6X14 8-10 6.0-7.4 Crankshaft Position Sensor Retaining Bolts M6X12 8-10 6.0-7.4 Ignition Coil Retaining Bolts M6X35 7-11 5.2-7.8...
Page 668 2-586 Control System JL4G15-D Engine Temperatur (℃ / ℉) Temperature (℃ / ℉) Resistance (Ω) Resistance (Ω) 0 / 32 9,399 100/212 10/50 5,658 110/230 20/68 3,511 120/248 30/86 2,240 130/266 40/104 1,465 140/284 50/122 150/302 2.12.1.3 Intake Air Pressure Sensor Output Voltage and Pressure Relationship Pressure (kPa) Output Voltage (V)
Page 669 Engine Control System JL4G15-D 2-587 2.12.2 Description and Operation 9. Knock Control: When the knock sensor detects a knock occurring, the system will calculate the ignition advance 2.12.2.1 Overview angle delay based on the current conditions, knock intensity and other necessary information, and defers the ignition 4G15D uses Delphi MT80 Engine Control System.
Page 670 2-588 Control System JL4G15-D Engine 3. Intake Manifold Pressure / Temperature Sensor Engine control module is a core microprocessor with a a micro chip controller. Its function is to process data from various (MAP / IAT) vehicle sensors to determine the engine's working condition, and through the various actuators controls engine actuators.
Page 671 Engine Control System JL4G15-D 2-589 4. Camshaft Position Sensor (CMP) negative temperature coefficient thermistor as the sensing element, when the coolant temperature rises, the resistance decreases. At -30 ° C (-22 ° F) the resistance is 26000 Ω; at 130 ° C (266 ° F), the resistance is 90 Ω. The sensors is installed in the main coolant path.
Page 672 2-590 Control System JL4G15-D Engine 7. Oxygen Sensor (HO2S) 8. Fuel Injectors FE02-5129b FE02-5131b Oxygen sensor is an important sensor in a close-loop fuel The injector structure is an electromagnetic switch valve control system, which adjusts and maintains the ideal Air-Fuel device.
Page 673 Engine Control System JL4G15-D 2-591 9. Oil Pressure Regulator 11. Ignition Coil With a non fuel return system, fuel pressure regulator is installed in the fuel pump assembly. Hydraulic regulator function is to regulate the fuel pressure in the fuel rail to eliminate the fuel supply rate change, fuel pump supply change and engine vacuum changes interfering the fuel injection.
Page 674 2-592 Control System JL4G15-D Engine 14. Variable Valve Timing Solenoid Valve (VVT) The throttle valve assembly opening is determined by ECM according to the driver-controlled throttle pedal control input signals, and other input signals. ECM calculates the vehicle currently needed power to control the fuel supply (spray) amount, and adjusts based on feedback signals to make sure that the engine works in the best controlled status.
Page 675 Engine Control System JL4G15-D 2-593 2.12.3 System Working Principle 2.12.3.1 Electronic Throttle Body (ETC) Working Principle Electronically controlled throttle body assembly must be use then based on this feedback signal adjusts the vehicle control dedicated engine electronic control module (ECM) with ETC parameters.
Page 676 2-594 Control System JL4G15-D Engine 2.12.3.2 ECM Controlled Fuel Supply System Due to the rapid development of modern science and technology, High-Speed ECM can quickly analyze the driver's 1. Fuel Pump Control intention and calculate the basic throttle opening parameter values, based on the throttle pedal signal, the signal variation When the ignition switch is turned on, the fuel pump will run for and signal change rate.
Page 677 Engine Control System JL4G15-D 2-595 A. Air-Fuel Ratio – When the system detects a ignition system malfunction, it stops the fuel supply. Start Air-Fuel ratio, normal start Air-Fuel ratio, clear the flooded cylinder Air-Fuel ratio, engine running Air-Fuel – When the system voltage is greater than 18 V, it will ratio, cooling state Air-Fuel ratio, warm-up state Air-Fuel enter the electronic throttle body function restriction ratio, theoretical Air-Fuel ratio, power-enriched Air-Fuel...
Page 678 2-596 Control System JL4G15-D Engine 3. Ignition Advance Angle Calculation and Control C. Acceleration Adjustment Ignition advance angle acceleration adjustment is used to mitigate the drive system torque shock caused by engine speed fluctuations, and also to eliminate possible Ignition Angle detonation during acceleration, so that the acceleration is smooth.
Page 679: Idle Speed Control
Engine Control System JL4G15-D 2-597 3. Forced Idle Mode 1. Target Idle Speed Calculating When the driver's intention can not be reliably detected, such as when the pedal signal is lost. The vehicle only maintains Base Idle Speed cooling, heating, electricity supply and lighting functions with engine idling.
Page 680 2-598 Control System JL4G15-D Engine advance angle is either normal ignition advance angle or safety Coolant Temperature ignition advance angle. Knock controlled speed is between Target Idle Speed (rpm) (°C/ ºF) thees two. 100/212 – Steady-State Control 110/230 When the engine is running as per normal, ECM collects and analyzes engine combustion signals filters knocking >?20/248 signal through the knock sensor.
Page 681 Engine Control System JL4G15-D 2-599 – Full-throttle Air-Conditioning Off Mode: Ensure the vehicle • Idle Speed Too High / Too Low dynamic. • Intake Air Pressure Sensor Malfunction Engine speed is less than 3,600 rpm • Engine Misfire No TPS fault TPS is greater than 105%, and since the last time full- •...
Page 682 2-600 Control System JL4G15-D Engine 2.12.4 Component Locator 2.12.4.1 Component Locator Legend 1. Acceleration Pedal Position Sensor 4. Electronic Control Module (ECM) 2. Electronic Throttle Body (ETC) Assembly 3. Intake Air Pressure / Temperature Sensor EC718/EC718RV EC715/EC715RV 10/2009...
Page 683 Engine Control System JL4G15-D 2-601 2.12.5 Disassemble View 2.12.5.1 Disassemble View FE02-8042b Legend 1. Throttle Valve Retaining Bolts 7. Throttle Body 2. Throttle Valve 8. Throttle Drive Motor 3. Throttle Drive Motor Retaining Bolts 9. Throttle Position Sensor 4. Throttle Drive Gear 10.
Page 684 2-602 Control System JL4G15-D Engine 2.12.6 Schematic 2.12.6.1 Schematic 1. 12V Battery Voltage 2. 12V Ignition Power Supply 1. 5V Reference Voltage 3. 12V Power Ground 2. Ignition Coil Control 4. 5V Sensor Power Ground 3. Fuel Injector Control 5. Ignition Module Driver Ground 4.
Page 685 Engine Control System JL4G15-D 2-603 Engine Control Module EF04 Fuel Pump Relay VBAT EO35 Main Relay EO35 EF12 EO35 VBATPROT To Instrument Cluster EO35 VBATPROT EO35 Evaporative Canister Solenoid EO01 VVT Solenoid Fuel Pump Assembly VVT1 EO01 EF22 CAN LO EO35 CAN LO To Ignition Coil...
Page 686 2-604 Control System JL4G15-D Engine Ignition Relay Engine Control Module To Air Conditioning COILA EO01 EO35 EO01 COILB ACRQST+ EO35 Ignition Coil Pressure Switch Cooling Fan Low Speed Relay EO35 To Brake Light Switch BRAKELP EO35 FANLO Engine Coolant Temperature Sensor Cooling Fan High Speed Relay EO01...
Page 687 Engine Control System JL4G15-D 2-605 Engine Control Module Pre-catalytic Oxygen Sensor Crankshaft CPS LH EO01 Position 02A HTR EO01 CPS LO EO01 Sensor 02AHI EO01 EO01 02ALO Post-catalytic Oxygen Sensor EO01 02B HTR EO01 02BHI EO01 02BLO V5REF1 EO35 V5RTN2 EO01 PPS1 EO35...
Page 688 2-606 Control System JL4G15-D Engine 2.12.7 Diagnostic Information and Procedures 2.12.7.1 Diagnosis Description Before carry out the control system diagnostic. Refer to2.12.2 Description and Operationand2.12.3 System Working Principle. Understand and get familiar with control system working principle, and then start systematic diagnostic, so that it will help to determine the correct diagnostic steps, more importantly, it also help to determine whether the customer described situation is normal.
Page 689 Engine Control System JL4G15-D 2-607 Symptoms Suspected Faulty Items Relevant Sections Fault Definition: When Air-Conditioning 2. Electronic Throttle Body Refer to 2.12.7.54 DTC P2135 is working, the engine speed is instable Refer to 2.2.8.8 Engine Control Module or engine stalls. 3.ECM Replacement 1.
Page 690 2-608 Control System JL4G15-D Engine Symptoms Suspected Faulty Items Relevant Sections 20. Vacuum Hose Cracking or Kink, The Connection Is Unreliable Refer to2.7 Exhaust System JL4G18- 21. Exhaust Blocked: Three-Way Catalytic Din2.7.5 Diagnostic Information and Converter Blocked, Muffler Internal Damage Procedures Refer Brake...
Page 691 Engine Control System JL4G15-D 2-609 Symptoms Suspected Faulty Items Relevant Sections 16. Camshaft Convex Corner Wear 17. Valve Timing Incorrect 18. Valve Spring Broken 19. Too Much Carbon Residue In Combustion Chamber Camshaft, Cylinder Head, Piston, Connecting Rod and Bearing Abnormal Refer to2.7 Exhaust System JL4G18- 21.
Page 692 2-610 Control System JL4G15-D Engine Symptoms Suspected Faulty Items Relevant Sections 20. Electromagnetic interference (EMI) on voltage circuit may lead to misfire. Use a scan tool to monitor the engine speed to detect electromagnetic interference. Engine speed parameter suddenly increase while the actual engine speed is almost not changed, then there is electromagnetic interference.
Page 693 Engine Control System JL4G15-D 2-611 Symptoms Suspected Faulty Items Relevant Sections Refer to2.20 Ignition System JL4G15- 6. Ignition System: Ignition Wires, Spark Plug, Din2.20.4 Diagnostic Information and Ignition Coil Procedures 7. ECM Power Supply Circuit Refer to 2.12.7.43 DTC P0562 P0563 8.
Page 694 2-612 Control System JL4G15-D Engine Symptoms Suspected Faulty Items Relevant Sections 9. Intelligent Variable Valve Timing System Refer to2.6 Engine Mechanical System JL4G18-Din2.6.7 Diagnostic 10. Vacuum Hose Cracking or Kink, The Information and Procedures Connection Unreliable 11. Spark Plug: Thermal value is incorrect, damp, crack, gap is incorrect, excessive Refer to2.20 Ignition System JL4G15-...
Page 695 Engine Control System JL4G15-D 2-613 Symptoms Suspected Faulty Items Relevant Sections 2. Starter 3. Start Relay Can Not Start. Fault Definition: When the ignition 4. Ignition Switch switch is at "ST" position, the engine 5. BCM crankshaft does not rotate. Refer to2.5 Engine Anti-theft System 6.
Page 696 2-614 Control System JL4G15-D Engine 2.12.7.5 ECM Terminal List EO01 ECM Harness Connector EO01 FE02-5217b Note: 1. UB is the battery voltage. 2. If there is no instruction, GND is 0 V or close to 0 V. Terminal Name Wiring Terminal Instructions Status Specified Conditions...
Page 697 Engine Control System JL4G15-D 2-615 Terminal Name Wiring Terminal Instructions Status Specified Conditions Pre-Catalytic Oxygen O2AHi 0.5 P Ignition Switch "ON" 0-5 V Sensor B-Side KNOCK_Hi 0.5 L Knock Sensor A-Side Engine Running PWM Wave Heated Pre-Catalytic O2A_HTR 0.75 B/G Heating PWM Wave Oxygen Sensor...
Page 698 2-616 Control System JL4G15-D Engine Terminal Name Wiring Terminal Instructions Status Specified Conditions Electronically Controlled MTR- 0.75 O Ignition Switch "ON" Throttle Body H-Side IMMORQST 0.5 Gr/W Immobilisier A-Side Ignition Switch "ON" INJD 0.5 Y/B Cylinder No.2 Injector Engine Running GND-UB PWM Wave INJB 0.5 Y/V...
Page 699 Engine Control System JL4G15-D 2-617 Terminal Name Wiring Terminal Instructions Status Specified Conditions VBATT 0.75 R Battery Voltage 0.5 W/Y Ignition Switch Ignition Switch "ON" Main Relay Controlled VBATPROT 0.5 G / Y Ignition Switch "ON" Power Supply Air-Conditioning Medium 0.5 B/O On or Off UB or GND...
Page 700 2-618 Control System JL4G15-D Engine Terminal Name Wiring Terminal Instructions Status Specified Conditions 42-45 Post-Catalytic Oxygen O2B_HTR 0.75 B/O Heating PWM Wave Sensor Heating 47-50 Air-Conditioning A/C Relay 0.5 B/Y Air-Conditioning Switch UB or GND Compressor Relay 52-54 Post-Catalytic Oxygen O2BLO 0.5 L/R Ignition Switch "ON"...
Page 701 Engine Control System JL4G15-D 2-619 Z-type Record the DTC code when the fault occurs, but does not light any lamp In three consecutive trips, if the system does not detect any faults, and no other faults are detected, the MIL lamp will be off. If a fault no longer occurs in more than 40 warm-up cycles, vehicle diagnostic system will request to clear the DTC code and the driving distance and the fixed grid data associated with the fault.
Page 702 2-620 Control System JL4G15-D Engine DTC Code Description Fault Type P0222 Electronic Throttle Position Sensor 2 Circuit Low Voltage P0223 Electronic Throttle Position Sensor 2 Circuit High Voltage P0230 Oil Pump Relay Malfunction P0261 Nozzle 1 Circuit Low Voltage Fault P0262 Nozzle 1 Circuit High Voltage Fault P0264...
Page 703 Engine Control System JL4G15-D 2-621 DTC Code Description Fault Type P0602 ECM Processor Malfunction P0604 RAM Error P0606 ECM Processor Malfunction P060A ECM Programming Error P0641 ETC Reference Voltage A Amplitude Malfunction P0646 Air-Conditioning Clutch Relay Short To Low Voltage or Open Circuit P0647 Air-Conditioning Clutch Relay Short To High Voltage P0650...
Page 704 2-622 Control System JL4G15-D Engine DTC Code Description Fault Type U0426 Anti-theft Device Authentication Failure 2.12.7.8 DTC Fail-Safe List DTC Code Diagnostic Restore Conditions DTC Code Fail-Safe Mode Information Electronic Throttle Position Sensor Electronic Throttle Position Sensor P0068 Electronic Throttle Air Flow Error 1 Circuit Low Voltage 1 Circuit Low Voltage Electronic Throttle Position Sensor...
Page 705 Engine Control System JL4G15-D 2-623 DTC Code Diagnostic Restore Conditions DTC Code Fail-Safe Mode Information System enters "Engine Power ETC-Driver Second-Order Management" mode, while Next key cycle, no malfunction P2101 Diagnostic Error reporting P2106, P2110 fault; VCP condition detected. inoperative P2104 Engine Controlled idle P2105...
Page 706 2-624 Control System JL4G15-D Engine DTC Code Diagnostic Restore Conditions DTC Code Fail-Safe Mode Information Intake VCP Hydraulic Control Valve Next key cycle, no malfunction P0077 VCP Inoperative Coil High Voltage condition detected. Intake VCP Camshaft Position P0340 VCP Inoperative, Ignition Angle No malfunction condition detected.
Page 707 Engine Control System JL4G15-D 2-625 DTC Code Diagnostic Restore Conditions DTC Code Fail-Safe Mode Information Pre-Catalytic Oxygen Sensor Open Loop Control; Pre-Catalytic Next key cycle, no malfunction P0135 Heater Malfunction Oxygen Sensor Heater Inoperative condition detected. Pre-Catalytic Oxygen Sensor P1167 Indicating Mixture Too Rich During No malfunction condition detected.
Page 708 2-626 Control System JL4G15-D Engine DTC Code Diagnostic Restore Conditions DTC Code Fail-Safe Mode Information Catalytic converter damaged, the system enters open loop control. in P0300 One or More Cylinder Misfire No malfunction condition detected. certain operating conditions, fault lamp flashes. Next key cycle, no malfunction P0324 Knock Control System Malfunction Ignition Back Angle...
Page 709 Engine Control System JL4G15-D 2-627 DTC Code Diagnostic Restore Conditions DTC Code Fail-Safe Mode Information Next key cycle, no malfunction P0601 ROM Error Vehicle can not start. condition detected. Next key cycle, no malfunction P0602 ECM Processor Malfunction Vehicle can not start. condition detected.
Page 710 2-628 Control System JL4G15-D Engine 6. Refer to the table and check all the data. Data Stream Name Ignition Switch "ON" Idle Speed 2,500 rpm When Engine Speed 0 rpm 795 rpm 2,500 rpm Vehicle Speed Current Computing Load 0.0% 100% 100% Coolant Temperature...
Page 711 Engine Control System JL4G15-D 2-629 Data Stream Name Ignition Switch "ON" Idle Speed 2,500 rpm When EVAP Valve Duty Cycle 6.25% Fuel Adjustment Cell 19 cell 18 cell 2 cell Target Idle Speed 935 rpm 737 rpm 887 rpm Injection 8.67 ms 2.56 ms 1.82 ms...
Page 712 2-630 Control System JL4G15-D Engine 2.12.7.10 Action Test Table By reading the "Action Test Table" on the scan tool, you can check switches, sensors, actuators working state without removing any parts. Before the control system diagnosis, carrying out action test is a prerequisite, so that the diagnose time could be shortened. Note Data under normal conditions is listed in the following table for reference only.
Page 713 Engine Control System JL4G15-D 2-631 Scan Tool Display Test Component Control Range Diagnosis Description Item Note Carry out this test only when the engine coolant temperature is below 100°C Enable the High-Speed cooling (212 ºF) and Air-Conditioning is not switched High-Speed Fan ON/OFF This function controls the High-Speed cooling fan...
Page 714 2-632 Control System JL4G15-D Engine Scan Tool Display Test Component Control Range Diagnosis Description Item 0,700 rpm, 800 Expected idle Control the idle speed rpm, 900 rpm, 1,000 rpm 2.12.7.11 Crankshaft Position Sensor (CKP) Learn Note After crankshaft position sensor replacement, ECM replacement or engine replacement, the crankshaft position sensor adaptive learn must be carried out.
Page 715 Engine Control System JL4G15-D 2-633 Next Complete the learn, clear the DTC code. Step 7 2.12.7.12 Electronic Throttle Body (ETC) Check Electronic throttle body consists of two throttle position sensors and a throttle body drive motor. 1. Electronic Throttle Body Connector View and Functions: FE02-5232b Terminal ID ECM Related Terminal No.
Page 716 2-634 Control System JL4G15-D Engine TPS1 Output Signal Idle: 6%-14% Fully Open: 81%-93% Throttle Body Opening Angle TPS2 Output Signal Idle: 86%-94% Fully Open: 7%-19% Throttle Body Opening Angle FE02-5234b Note When test the above TPS sensor output signals, use an oscilloscope. the output waveform of the circuit should be smooth and without other waveforms.
Page 717 Engine Control System JL4G15-D 2-635 1. Acceleration Pedal Position Sensor Connector End View and Function FE02-5233b Terminal ID ECM Related Terminal No. Function EO36 (38) Sensor No.2 Reference Voltage EO36 (36) Sensor No.1 Reference Voltage EO36 (37) Sensor No.1 Low Reference Voltage EO36 (12) Sensor No.1 Output Signal EO36 (39)
Page 718 2-636 Control System JL4G15-D Engine 2. Acceleration Pedal Position Sensor Technical Specifications 4.59V Output Voltage 2.30V 0.75V 0.38V Accelerator Pedal Turning Angle (°) FE02-5235b Note When test the above APP sensor output signals, use an oscilloscope. the output waveform of the circuit should be smooth and without other waveforms.
Page 719 Engine Control System JL4G15-D 2-637 DTC code Description Diagnostic Procedures Intake Air Pressure Sensor Circuit Low Voltage or Open P0107 Refer to 2.12.7.18 DTC P0107 P0108 Circuit P0108 Intake Air Temperature Sensor Circuit High Voltage Refer to 2.12.7.18 DTC P0107 P0108 P0112 Intake Air Temperature Sensor Circuit Low Voltage Refer to...
Page 720 2-638 Control System JL4G15-D Engine DTC code Description Diagnostic Procedures P0268 Fuel Injector 3 High Voltage Fault P0270 Fuel Injector 4 Low Voltage Fault Refer to 2.12.7.32 DTC P0270 P0271 P0271 Fuel Injector 4 High Voltage Fault P0300 One or More Cylinder Misfire Refer to 2.12.7.33 DTC P0300 P0324...
Page 721 Engine Control System JL4G15-D 2-639 DTC code Description Diagnostic Procedures Air-Conditioning Clutch Relay Circuit Short To High P0647 Voltage P0650 Fault Indicator Malfunction Refer to 2.12.7.48 DTC P0650 P0651 ETC Reference Voltage B Amplitude Fault Refer to 2.12.7.46 DTC P0641 P0651 P0685 Main Relay Malfunction Refer to...
Page 722 2-640 Control System JL4G15-D Engine DTC code Description Diagnostic Procedures U0426 Anti-theft Device Authentication Failure 2.12.7.15 DTC P0011 P0012 P0016 P0026 1. DTC Descriptor: P0011 Intake VCP Valve Timing Response Lag P0012 Intake VCP Camshaft Valve Timing Error P0016 Intake VCP Camshaft Gear Learn Bias Out Of Range P0026 Intake VCP Hydraulic Control Valve Intake camshaft position (CMP) actuator is connected to the intake camshaft and operated by the hydraulic pressure, which is...
Page 723 Engine Control System JL4G15-D 2-641 DTC Code DTC Detection Strategy Conditions For Setting The DTC (Control Strategy) Fault Locations 1. VVT actual angle and default angle difference greater than or equal to 20 degrees. 2. Camshaft completed self learn. 1. Valve Timing 3.
Page 724 2-642 Control System JL4G15-D Engine Check whether the oil is changed in a timely manner and whether the engine oil contains additives or viscosity is incorrect. Replace engine oil and oil filter. When necessary, clean the engine lubrication system. Step 3 Check VVT solenoid valve resistance.
Page 725 Engine Control System JL4G15-D 2-643 Remove the VVT solenoid valve filter. Check whether the filter is blocked. Check whether the filter is damaged. Reinstall the VVT solenoid valve filter. Clean VVT solenoid valve filter. If necessary, replace it. Check whether the timing system is normal. Step 6 Remove the cylinder head cover.
Page 726 2-644 Control System JL4G15-D Engine Press the scan tool power button. Select the following menu items: Engine/Read DTC codes. Read DTC codes. Any DTC code? Intermittent Fault. Refer to 2.12.7.4 Symptoms Table System normal, diagnostic completed. Step 9 5. Repair Instructions: Intake VVT Actuator can only be replaced as an assembly.
Page 727 Engine Control System JL4G15-D 2-645 1. Engine Running 2. No intake air pressure sensor, coolant temperature sensor, ETC Atmospheric Pressure Greater throttle position sensor, fuel injector, P0106 Than The Maximum or Less ignition coil and misfire fault,etc. Than The Minimum 3.
Page 728 2-646 Control System JL4G15-D Engine System2.2.1.3 Altitude and Atmospheric Pressure Correlation". Similar? Replace the intake manifold pressure / temperature sensor. Step 4 Check the intake manifold pressure (MAP) sensor value with the engine running. Start the engine. When idling, observe the intake manifold pressure (MAP) sensor values.
Page 729 Engine Control System JL4G15-D 2-647 Step 7 Check whether the intake manifold pressure sensor parameter respond to changes. Engine Running Change the throttle position, hold the throttle position, observe intake manifold pressure sensor parameter value. Whether the value rapidly changes with the throttle position changes.
Page 730 2-648 Control System JL4G15-D Engine Next Use scan tool to confirm whether the DTC code is stored again. Step 12 Connect scan tool to the datalink connector. Turn the ignition switch to "ON" position. Clear DTC code. Start and run the engine at idle speed to warm up the engine for at least 5 min.
Page 731 Engine Control System JL4G15-D 2-649 3. Schematic: Main Relay VVT Solenoid Engine Control Module From Battery FE02-5204b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 732 2-650 Control System JL4G15-D Engine Measure VVT solenoid valve working power supply. Step 2 Turn the ignition switch to "OFF" position. Disconnect VVT solenoid valve wiring harness connector EO10. VVT Solenoid Harness Connector EO10 Turn the ignition switch to "ON" position. Test EO10 connector terminal No.1 with a multimeter.
Page 733 Engine Control System JL4G15-D 2-651 Check ECM power supply circuit. Step 4 Check whether ECM power supply circuit is normal. Check whether ECM ground circuit is normal. Repair the faulty part. Replace ECM. Refer to 2.2.8.8 Engine Control Module Replacement. Step 5 Next Step 6...
Page 734 2-652 Control System JL4G15-D Engine • Low Reference Voltage Circuit • Sensor Signal Circuit ECM provides 5 V reference voltage through ECM harness connector EO01 terminal No.6 to the sensor harness connector EO16 terminal No.3 and a low reference voltage through EO01 terminal No.19 to EO16 terminal No.1. The sensor provides a signal through EO16 terminal No.4 to ECM harness connector EO01 terminal No.27.
Page 735 Engine Control System JL4G15-D 2-653 3. Schematic: Engine Control Module Intake Air Pressure Temperature Sensor FE02-5207b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 736 2-654 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect intake manifold absolute pressure sensor wiring harness connector EO16. Intake Air Temperature/Pressure Sensor Harness Turn the ignition switch to "ON" position. Connector EO16 Measure voltage between intake manifold absolute pressure sensor wiring harness connector EO16 terminal No.3 and a reliable ground.
Page 737 Engine Control System JL4G15-D 2-655 Replace intake manifold absolute pressure sensor. Step 5 Go to step 10 Next Check sensor 5 V reference voltage circuit. Step 6 Turn the ignition switch to "OFF" position. Disconnect intake manifold absolute pressure sensor wiring harness connector EO16.
Page 738 2-656 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect intake manifold absolute pressure sensor wiring harness connector EO16. Intake Air Temperature/Pressure Sensor Harness Disconnect ECM harness connector EO01. Connector EO16 Measure resistance between intake manifold absolute pressure sensor harness connector EO16 terminal No.4 and ECM harness connector terminal No.27.
Page 739 Engine Control System JL4G15-D 2-657 Turn the ignition switch to "OFF" position. Disconnect intake manifold absolute pressure sensor wiring harness connector EN16. Intake Air Temperature/Pressure Sensor Harness Disconnect ECM harness connector EN01. Connector EO16 Measure resistance between intake manifold absolute pressure sensor harness connector EO16 terminal No.1 and ECM harness connector terminal No.19.
Page 740 2-658 Control System JL4G15-D Engine Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 12 5. Repair Instructions: Replace MAP sensor. Refer to 2.2.8.7 Intake Air Pressure and Temperature Sensor Replacement. Refer to 2.2.8.8 Engine Control Module ReplacementReplace ECM. 2.12.7.19 DTC P0112 P0113 1.
Page 741 Engine Control System JL4G15-D 2-659 Check the existence of the following conditions: Sensor housing is damaged. Sensor loose or improperly installed. Sensor wiring harness connector loose. Next Note It is prohibited Connect intake manifold absolute pressure sensor 5 V reference voltage circuit and other components, otherwise it will damage the sensor and ECM.
Page 742 2-660 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect intake air pressure and temperature sensor wiring harness connector EO16. Intake Air Temperature/Pressure Sensor Harness Turn the ignition switch to "ON" position. Connector EO16 Measure resistance between intake air pressure and temperature sensor wiring harness connector EO16 terminal No.1 and a reliable ground.
Page 743 Engine Control System JL4G15-D 2-661 Turn the ignition switch to "OFF" position. Disconnect intake air pressure and temperature sensor wiring harness connector EO16. Intake Air Temperature/Pressure Sensor Harness Disconnect ECM harness connector EO01. Connector EO16 Measure resistance between intake air pressure and temperature sensor wiring harness connector EO16 terminal No.1 and ECM harness connector terminal No.19.
Page 744 2-662 Control System JL4G15-D Engine Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 10 5. Repair Instructions: Replace intake air pressure and temperature sensors. Refer to 2.2.8.7 Intake Air Pressure and Temperature Sensor Replacement. 2.12.7.20 DTC P0117 P0118 1.
Page 745 Engine Control System JL4G15-D 2-663 3. Schematic: Engine Control Module Engine Coolant Temperature Sensor FE02-5208b 4. Diagnostic Steps: Warning! Refer to "Cooling System Service Warning" in "Warnings and Notices". Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 746 2-664 Control System JL4G15-D Engine Disconnect the engine coolant temperature sensor wiring harness connector EO23. Measure engine coolant temperature sensor resistance. Standard Resistance: (Refer to the specific parameters2.2.1.2 Temperature Sensor Temperature and Resistance Correlation): 2,400 Ω/20°C (68 ºF) Connect the engine coolant temperature sensor wiring harness connector EO23.
Page 747 Engine Control System JL4G15-D 2-665 Step 5 check the engine coolant temperature sensor signal circuit. Turn the ignition switch to "OFF" position. Disconnect the engine coolant temperature sensor wiring harness connector EO23. Engine Coolant Temperature Sensor Harness Disconnect ECM harness connector EO01. Connector EO23 Measure resistance between engine coolant temperature sensor wiring harness connector EO23 terminal No.1 and...
Page 748 2-666 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect the engine coolant temperature sensor wiring harness connector EO23. Engine Coolant Temperature Sensor Harness Disconnect ECM harness connector EO01. Connector EO23 Measure resistance between engine coolant temperature sensor wiring harness connector EO23 terminal No.3 and ECM harness connector terminal No.29.
Page 749 Engine Control System JL4G15-D 2-667 Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 10 5. Repair Instructions: Replace the engine coolant temperature sensor. Refer to 2.2.8.6 Engine Coolant Temperature Sensor Replacement. 2.12.7.21 DTC P0122 P0123 1. DTC Descriptor: P0122 Electronic Throttle Position Sensor 1 Circuit Low Voltage P0123...
Page 750 2-668 Control System JL4G15-D Engine 3. Schematic: Electronic Throttle Body Engine Control Module FE02-5209b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis. check for DTC code P0641, P0651, P0222, P0223.
Page 751 Engine Control System JL4G15-D 2-669 Check EO27 terminal B. Step 2 Turn the ignition switch to "OFF" position. Disconnect ETC harness connector EO27. Disconnect ECM harness connector EO01. Electronic Throttle Body Harness Connector EO27 Measure resistance between EO27 terminal B and a reliable ground.
Page 752 2-670 Control System JL4G15-D Engine Replace ECM. Step 5 Replace ECM. Refer to 2.2.8.8 Engine Control Module Replacement. Carry out crankshaft position sensor self learn. Refer to 2.12.7.11 Crankshaft Position Sensor (CKP) Learn. Next Step 6 Use scan tool to confirm whether the DTC code is stored again. Connect scan tool to the datalink connector.
Page 753 Engine Control System JL4G15-D 2-671 After the vehicle started, ECM works in open-loop mode, in which ECM ignores the Pre-Catalytic oxygen sensor signal voltage when calculating the Air-Fuel ratio. ECM provides an approximate 450mV reference voltage to the Pre-Catalytic oxygen sensor. When the engine is running, Pre-Catalytic oxygen sensors start heating and begin to generate a 0-0.1 V voltage, which fluctuates.
Page 754 2-672 Control System JL4G15-D Engine 3. Schematic: Main Relay Pre-catalytic Oxygen Sensor Engine Control Module From Battery FE02-5205b 4. Diagnostic Steps: Connect scan tool. Step 1 Next Step 2 Start engine and turn on the scan tool. Next Step 3 Maintain the engine speed at 2,500 rpm for more than 2 min to warm up the engine, until the engine coolant temperature reaches 0°C (176 ºF).
Page 755 Engine Control System JL4G15-D 2-673 Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Carry out the oxygen sensor signal test. Step 6 If the voltage is consistently below 0.45 V (mixture too lean), carry out the following steps: • Spray proper amount propane gas into intake. •...
Page 756 2-674 Control System JL4G15-D Engine Measure pre-catalytic oxygen sensor signal circuit. Step 8 Turn the ignition switch to "OFF" position. Disconnect oxygen sensor wiring harness connector EO02. Pre-catalytic Oxygen Sensor Harness Turn the ignition switch to "ON" position. Connector EO02 Measure pre-catalytic oxygen sensor wiring harness connector terminal No.
Page 757 Engine Control System JL4G15-D 2-675 Turn the ignition switch to "OFF" position. Disconnect oxygen sensor wiring harness connector EO02. Pre-catalytic Oxygen Sensor Harness Disconnect ECM harness connector EO01. Connector EO02 Measure resistance between pre-catalytic oxygen sensor wiring harness connector EO02 terminal B and ECM harness connector terminal No.10.
Page 758 2-676 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect oxygen sensor wiring harness connector EO02. Pre-catalytic Oxygen Sensor Harness Disconnect ECM harness connector EO01. Connector EO02 Measure resistance between pre-catalytic oxygen sensor wiring harness connector EO02 terminal A and ECM harness connector terminal No.2.
Page 759 Engine Control System JL4G15-D 2-677 Read control system DTC code again to confirm that the system has no DTC code. Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 16 5. Repair Instructions: Replace the pre-catalytic oxygen sensor. Refer to 2.4.7.2 Pre-Catalytic Oxygen Sensor Replacement.
Page 760 2-678 Control System JL4G15-D Engine Check the existence of following factors that will affect the oxygen sensor working status: Exhaust system leakage or blockage. Water entering the heated oxygen sensor connector. Engine working at high temperatures, exhaust pipes too hot. Next Check pre-catalytic oxygen sensor heater resistance.
Page 761 Engine Control System JL4G15-D 2-679 Turn the ignition switch to "OFF" position. Disconnect oxygen sensor wiring harness connector EO02. Pre-catalytic Oxygen Sensor Harness Disconnect ECM harness connector EO01. Connector EO02 Test Continuity between pre-catalytic oxygen sensor wiring harness connector EO02 terminal C and ECM harness connector EO01 terminal No.14.
Page 762 2-680 Control System JL4G15-D Engine Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 8 5. Repair Instructions: Replace the pre-catalytic oxygen sensor. Refer to 2.4.7.2 Pre-Catalytic Oxygen Sensor Replacement. 2.12.7.24 DTC P0137 P0138 P0140 1. DTC Descriptor: P0137 Post-Catalytic Oxygen Sensor Circuit Short To Low Voltage P0138...
Page 763 Engine Control System JL4G15-D 2-681 DTC Code DTC Detection Strategy Conditions For Setting The DTC (Control Strategy) Fault Locations 1. Engine running longer than 60 s. 1. Oxygen sensor signal circuit open 2. Coolant temperature is less than 70 °C (158 ºF). P0140 2.
Page 764 2-682 Control System JL4G15-D Engine Next Observe oxygen sensor output voltage, which should be within 0.6-0.7 V. Step 4 Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Step 5 Carry out the oxygen sensor signal test. If the data is consistently below 0.45 V (mixture too lean), carry out the following steps: •...
Page 765 Engine Control System JL4G15-D 2-683 Refer to 2.12.7.14 DTC Code Index Step 7 Inspect the exhaust system seal. Check whether the three-way catalytic converter looks good (signs of excessive heat and gasket missing, etc.). Check whether the exhaust pipe is intact, whether the gasket is intact.
Page 766 2-684 Control System JL4G15-D Engine Go to step 15 Next check Post-Catalytic oxygen sensor signal circuit. Step 11 Turn the ignition switch to "OFF" position. Disconnect the oxygen sensor wiring harness connector Post-catalytic Oxygen Sensor Harness EO03. Connector EO03 Disconnect ECM harness connector EO01. Measure resistance between oxygen sensor wiring harness connector EO03 terminal B and ECM harness connector terminal No.30.
Page 767 Engine Control System JL4G15-D 2-685 Turn the ignition switch to "OFF" position. Disconnect the oxygen sensor wiring harness connector Post-catalytic Oxygen Sensor Harness EO03. Connector EO03 Disconnect ECM harness connector EO01. Measure resistance between oxygen sensor wiring harness connector EO03 terminal A and ECM harness connector terminal No.55.
Page 768 2-686 Control System JL4G15-D Engine Road test the vehicle for at least 10 min. Read control system DTC code again to confirm that the system has no DTC code. Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 16 5.
Page 769 Engine Control System JL4G15-D 2-687 Step 1 Initial Inspection Check the existence of following factors that will affect the oxygen sensor working status: Exhaust system leakage or blockage. Water entering the oxygen sensor connector. Engine working at high temperatures, exhaust pipes too hot. Next check oxygen sensor heater resistance.
Page 770 2-688 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect the oxygen sensor wiring harness connector Post-catalytic Oxygen Sensor Harness EO03. Connector EO03 Disconnect ECM harness connector EO01. Test Continuity between oxygen sensor wiring harness connector EO03 terminal C and ECM harness connector EO01 terminal No.46.
Page 771 Engine Control System JL4G15-D 2-689 Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 8 5. Repair Instructions: Replace post-catalytic oxygen sensor. Refer to 2.4.7.1 Post-Catalytic Oxygen Sensor Replacement. 2.12.7.26 DTC P0171 P0172 P1167 P1171 P2187 P2188 1. DTC Descriptor: P0171 Mixture Too Lean P0172...
Page 772 2-690 Control System JL4G15-D Engine 2. Conditions For Setting DTC and The Fault Location: Conditions For Setting The DTC DTC Code DTC Detection Strategy Fault Locations (Control Strategy) 1. Fuel Adjustment Value Higher 1. Engine slows down and enters Than Maximum Limit (DFCO) working condition.
Page 773 Engine Control System JL4G15-D 2-691 Read the throttle position sensor data. Step 3 Start the vehicle. Warm up the engine with normal idle speed and throttle opening is less than 10%. Use scan tool to read throttle position sensor data. Is throttle position sensor data normal? Refer to 2.12.7.27 DTC P0222 P0223...
Page 774 2-692 Control System JL4G15-D Engine (m) Check other fault lights in I/P working condition. Is engine System normal? System normal Step 7 Repair engine and its components. Next Step 8 System normal. 5. Repair Instructions: Replace fuel injectors. Refer to 2.2.8.2 Fuel Injector Replacement.
Page 775 Engine Control System JL4G15-D 2-693 Read DTC codes. Results: DTC Codes Shown To Step only P0222, P0223 P0122, P0123, P0641, P0651 Refer to 2.12.7.46 DTC P0641 P0651 Check EO27 terminal C. Step 2 Turn the ignition switch to "OFF" position. Disconnect ETC harness connector EO27.
Page 776 2-694 Control System JL4G15-D Engine Check ECM power supply circuit and ground circuit. Step 4 Check ECM Power Supply Circuit and ground circuit. Refer to 2.12.7.43 DTC P0562 P0563. ECM power and ground circuits normal? Repair power and ground fault circuits. Replace ECM.
Page 777 Engine Control System JL4G15-D 2-695 2. Conditions For Setting DTC and The Fault Location: Conditions For Setting The DTC (Control DTC Code DTC Detection Strategy Fault Locations Strategy) The ignition switch is turned on, turning on 1. Relay Circuit time longer than the system preset 2.
Page 778 2-696 Control System JL4G15-D Engine Fuel injectors operating voltage is provided by The Main Relay controlled by ECM. battery voltage passes through the main relay terminal No.3 to all fuel injector wiring harness connectors terminal No.1. ECM controls Cylinder No.1 fuel injector internal ground circuit through ECM harness connector EO01 terminal No.65.
Page 779 Engine Control System JL4G15-D 2-697 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis. Initial Inspection Step 1 Check for fuel injector wiring harness connector damage, poor connection, aging and signs of loosening.
Page 780 2-698 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect cylinder No.1 fuel injector wiring harness connector EO11. Cylinder No.1 Fuel Injector Harness Connect a light-emitting diodes test lamp to the fuel injector Connector EO11 wiring harness connector EO11 terminal No.1 and 2. Start the engine.
Page 781 Engine Control System JL4G15-D 2-699 Turn the ignition switch to "OFF" position. Disconnect cylinder No.1 fuel injector wiring harness Cylinder No.1 Fuel Injector Harness connector EO11. Connector EO11 Disconnect ECM harness connector EO01. Measure resistance between cylinder No.1 fuel injector wiring harness connector EO11 terminal No.1 and ECM harness connector terminal No.65.
Page 782 2-700 Control System JL4G15-D Engine Read control system DTC code again to confirm that the system has no DTC code. Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check. Diagnostic completed. Step 10 2.12.7.30 DTC P0264 P0265 1. DTC Descriptor: P0264 Cylinder No.2 Fuel Injector Circuit Low Voltage Fault P0265 Cylinder No.2 Fuel Injector Circuit High Voltage Fault...
Page 783 Engine Control System JL4G15-D 2-701 3. Schematic: EF12 Main Relay Cylinder No.2 Fuel Injector Engine Control Module MAIN EO01 INJD From Battery EO35 FE02-5256b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 784 2-702 Control System JL4G15-D Engine Disconnect the fuel injector wiring harness connector EO12. Measure resistance between the two fuel injector terminals. Standard Resistance: 11.6-12.4 Ω at 20°C(68 ºF) Cylinder No.2 Fuel Injector Connect the fuel injector wiring harness connector EO12. Replace fuel injector.
Page 785 Engine Control System JL4G15-D 2-703 Step 5 Check and repair cylinder No.2 fuel injector power circuit. Turn the ignition switch to "OFF" position. Disconnect the fuel injector wiring harness connector EO12. Remove the engine main relay. Cylinder No.2 Fuel Injector Harness Connector EO12 Measure resistance between cylinder No.1 fuel injector wiring harness connector EO12 terminal No.2 and engine...
Page 786 2-704 Control System JL4G15-D Engine Resistance Between EO12 (1) and A Reliable 10 kΩ or higher Ground Voltage Between EO12 (1) and A Reliable Ground Execute next step as per normal. Next Step 7 Check ECM power supply circuit. Check whether ECM power supply circuit is normal. Check whether ECM ground circuit is normal.
Page 787 Engine Control System JL4G15-D 2-705 Fuel injectors operating voltage is provided by The Main Relay controlled by ECM. battery voltage passes through the main relay terminal No.3 to all fuel injector wiring harness connectors terminal No.1. ECM controls Cylinder No.3 fuel injector internal ground circuit through ECM harness connector EO01 terminal No.64.
Page 788 2-706 Control System JL4G15-D Engine 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis. Initial Inspection Step 1 Check for fuel injector wiring harness connector damage, poor connection, aging and signs of loosening.
Page 789 Engine Control System JL4G15-D 2-707 Turn the ignition switch to "OFF" position. Disconnect cylinder No.3 fuel injector wiring harness connector EO13. Cylinder No.3 Fuel Injector Harness Connect a light-emitting diodes test lamp to the fuel injector Connector EO13 wiring harness connector EO13 terminal No.1 and 2. Start the engine.
Page 790 2-708 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect cylinder No.3 fuel injector wiring harness Cylinder No.3 Fuel Injector Harness connector EO13. Connector EO13 Disconnect ECM harness connector EO01. Measure resistance between cylinder No.3 fuel injector wiring harness connector EO13 terminal No.1 and ECM harness connector terminal No.64.
Page 791 Engine Control System JL4G15-D 2-709 Read control system DTC code again to confirm that the system has no DTC code. Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check. Diagnostic completed. Step 10 5. Repair Instructions: Replace the fuel injector. Refer to 2.2.8.2 Fuel Injector Replacement.
Page 792 2-710 Control System JL4G15-D Engine 3. Schematic: EF12 Main Relay Cylinder No.4 Fuel Injector Engine Control Module MAIN EO01 INJC From Battery EO35 FE02-5266b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 793 Engine Control System JL4G15-D 2-711 Disconnect the fuel injector wiring harness connector EO14. Measure resistance between the two fuel injector terminals. Standard Resistance: 11.6-12.4 Ω at 20°C(68 ºF) Cylinder No.4 Fuel Injector Connect the fuel injector wiring harness connector EO14. replace fuel injector.
Page 794 2-712 Control System JL4G15-D Engine Step 5 Check and repair cylinder No.4 fuel injector power circuit. Turn the ignition switch to "OFF" position. Disconnect the fuel injector wiring harness connector EO14. Cylinder No.4 Fuel Injector Harness Remove the engine main relay. Connector EO14 Measure resistance between cylinder No.4 fuel injector wiring harness connector EO14 terminal No.2 and engine...
Page 795 Engine Control System JL4G15-D 2-713 Resistance Between EO14 (1) and a reliable 10 kΩ or higher ground voltage between EO14 (1) and A Reliable Ground Execute next step as per normal. Next Step 7 Check ECM power supply circuit. Check whether ECM power supply circuit is normal. Check whether ECM ground circuit is normal.
Page 796 2-714 Control System JL4G15-D Engine The engine control module (ECM) uses information from the crankshaft position (CKP) sensor and the camshaft position (CMP) sensors to determine when an engine misre is occurring. By monitoring variations in the crankshaft rotation speed for each cylinder ECM is able to detect individual misre events.
Page 797 Engine Control System JL4G15-D 2-715 3. Schematic: Ignition System Main Relay EF22 IF30 EF01 Ignition Coil A Ignition Switch Engine EO01 COILA Control Module MAIN COILB EO01 Ignition Coil B From Battery FE02-5271b EC718/EC718RV EC715/EC715RV 10/2009...
Page 798 2-716 Control System JL4G15-D Engine Fuel Injector EF12 Main Relay Cylinder No.1 Fuel Injector INJA EO01 Cylinder No.2 Fuel Injector INJD EO01 Engine Cylinder No.3 Fuel Injector Control EO01 INJB Module MAIN Cylinder No.4 Fuel Injector INJC EO01 From Battery EO35 FE02-5272b 4.
Page 799 Engine Control System JL4G15-D 2-717 Check the vacuum tube for damaged, loose, leakage and so Next Check for other DTC codes. Step 2 Connect scan tool to the datalink connector. Turn the ignition switch to "ON" position. Press the scan tool power button. Select the following menu items: Engine/Read DTC codes.
Page 800 2-718 Control System JL4G15-D Engine Replace the spark plug. Refer to 2.10.8.4 Spark Plug Replacement. Go to step Note Prior to the implementation of this program, the following conditions must be met: 1. Disconnect all fuel injector connectors. 2. Engine running time must not be longer than 5 s. Check whether the spark plug arcing is normal.
Page 801 Engine Control System JL4G15-D 2-719 2. Run the engine for no longer than 5 s. Step 9 Use a properly working spark plug and check whether there is misfire cylinder arcing. Replace the installed spark plug with a spark plug that works properly.
Page 802 2-720 Control System JL4G15-D Engine Check valve timing system. Step 12 Refer to the "Engine Mechanical System" in the2.6.8.9 Timing Chain Cover Replacement, Is valve timing normal? Adjust the valve timing. Go to step 17 Check the fuel pressure. Step 13 Refer to "Fuel System"...
Page 803 Engine Control System JL4G15-D 2-721 Read control system DTC code again to confirm that the system has no DTC code. Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check. Diagnostic completed. Step 18 5. Repair Instructions: Replace the spark plug. Refer to 2.10.8.4 Spark Plug Replacement.
Page 804 2-722 Control System JL4G15-D Engine 3. Schematic: Engine Control Module Knock Sensor KNOCK HI EO01 KNOCK LO EO01 FE02-5274b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 805 Engine Control System JL4G15-D 2-723 Turn the ignition switch to "ON" position. Select "Engine"/"Read Data"/"Knock Sensor Signal 1". Start and run the engine at normal working temperature. Road test the vehicle and read the engine speed data on the scan tool. Is data normal? Standard Value: Normal data.
Page 806 2-724 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect Knock Sensor harness connector EN08. Disconnect ECM harness connector EO01. Knock Sensor Harness Connector EO08 Measure resistance between knock sensor harness connector EN08 terminal No.1 and ECM harness connector EN01 terminal No.12.
Page 807 Engine Control System JL4G15-D 2-725 Turn the ignition switch to "OFF" position. Disconnect Knock Sensor harness connector EO08. Disconnect ECM harness connector EO01. Knock Sensor Harness Connector EO08 Measure resistance between knock sensor harness connector EN08 terminal No.2 and ECM harness connector EN01 terminal No.28.
Page 808 2-726 Control System JL4G15-D Engine Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check. Diagnostic completed. Step 10 5. Repair Instructions: Replace the knock sensor. Refer to 2.10.8.5 Knock Sensor Replacement. 2.12.7.35 DTC P0335 P0336 1. DTC Descriptor: P0335 Crankshaft Position Sensor Circuit No Signal P0336 Crankshaft Position Sensor Circuit Signal Interference CKP sensor signals ECM current crankshaft speed and position.
Page 809 Engine Control System JL4G15-D 2-727 3. Schematic: Crankshaft Position Sensor EO01 CPS HI EO01 CPS LO Engine Control Camshaft Position Sensor Module V5RTN2 EO01 CAM1 EO01 EO01 V5REF2 FE02-5297b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 810 2-728 Control System JL4G15-D Engine Standard Value: Normal data. Refer to 2.12.7.9 Data Stream List. If the engine does not start, check the data with the engine running. If the engine speed is shown as "0", it indicates the circuit between the crankshaft position sensor and ECM wiring harness open or short.
Page 811 Engine Control System JL4G15-D 2-729 Turn the ignition switch to "OFF" position. Disconnect the crankshaft position sensor wiring harness Crankshaft Position Sensor Harness connector EO26. Connector EO26 Disconnect ECM harness connector EO01. Measure resistance between crankshaft position sensor wiring harness connector EN26 terminal A and ECM harness connector EN01 terminal No.21.
Page 812 2-730 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect the crankshaft position sensor wiring harness Crankshaft Position Sensor Harness connector EO26. Connector EO26 Disconnect ECM harness connector EO01. Measure resistance between crankshaft position sensor wiring harness connector EN26 terminal B and ECM harness connector EN01 terminal No.20.
Page 813 Engine Control System JL4G15-D 2-731 Next Use scan tool to confirm whether the DTC code is stored again. Step 10 Connect scan tool to the datalink connector. Turn the ignition switch to "ON" position. Clear DTC code. Start and run the engine at idle speed to warm up the engine for at least 5 min.
Page 814 2-732 Control System JL4G15-D Engine 1. ECM detects the engine running. 2. ECM detects the crankshaft ECM detects the engine running position sensor signal. P0340 but does not receive the camshaft position sensor signal 3. Camshaft position sensor signal is 1.
Page 815 Engine Control System JL4G15-D 2-733 Step 1 Initial Inspection Check the sensor wiring harness connector EN15 whether there is loose or poor connection and so on. Check whether the sensor is installed correctly. Check whether the sensor gap is normal. Are above mentioned parts normal? Repair the faulty part.
Page 816 2-734 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect camshaft position sensor wiring harness connector EO15. Camshaft Position Sensor Harness Turn the ignition switch to "ON" position. Connector EO15 Measure voltage between camshaft position sensor wiring harness connector EN15 terminal B and a reliable ground.
Page 817 Engine Control System JL4G15-D 2-735 Step 7 Check sensor signal circuit. Turn the ignition switch to "OFF" position. Disconnect camshaft position sensor wiring harness Camshaft Position Sensor Harness connector EO15. Connector EO15 Disconnect ECM harness connector EO01. Measure resistance between camshaft position sensor harness connector EN015 terminal A and ECM harness connector EN01 terminal No.56.
Page 818 2-736 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect camshaft position sensor wiring harness Camshaft Position Sensor Harness connector EO15. Connector EO15 Disconnect ECM harness connector EO01. Measure resistance between camshaft position sensor wiring harness connector EN15 terminal B and ECM harness connector EN01 terminal No.18.
Page 819 Engine Control System JL4G15-D 2-737 Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check Diagnostic completed. Step 13 5. Repair Instructions: Replace CMP sensor. Refer to 2.10.8.1 Camshaft Position Sensor Replacement. 2.12.7.37 DTC P0351 P0352 1. DTC Descriptor: P0351 Ignition Coil 1 Malfunction P0352 Ignition Coil 2 Malfunction Ignition coil 1 provides ignition for cylinders No.1 and 4.
Page 820 2-738 Control System JL4G15-D Engine 3. Schematic: Main Relay EF22 EF01 Ignition Coil A Ignition Switch Engine EO01 COILA Control Module MAIN COILB EO01 Ignition Coil B From Battery FE02-5281b 4. Diagnostic Steps: Check ignition coil. Refer to2.20 Ignition System JL4G15-Din2.20.4 Diagnostic Information and Procedures.
Page 821 Engine Control System JL4G15-D 2-739 2. Conditions For Setting DTC and The Fault Location: Conditions For Setting The DTC DTC Code DTC Detection Strategy Fault Locations (Control Strategy) Coolant temperature is higher than 70°C (158 ºF), and the fuel system is in close-loop mode.
Page 822 2-740 Control System JL4G15-D Engine Next Select on the scan tool: Engine/Read data/Group 1 oxygen sensor voltage 1 (Pre-Catalytic oxygen sensor), Step 4 Group 1 oxygen sensor voltage 2 (Post-Catalytic oxygen sensor) Next Normal TWC Deteriorated TWC Pre-catalytic Oxygen Sensor Post-catalytic Oxygen Sensor FE02-5092b...
Page 823 Engine Control System JL4G15-D 2-741 • Inspect whether the sensor voltage data is changed significantly, as the signal voltage will increase rapidly. Pre-Catalytic Post-Catalytic Oxygen Oxygen Sensor To Step Sensor Signal Voltage Signal Voltage Obvious Change No Change No Change Obvious Change Obvious Change No Change...
Page 824 2-742 Control System JL4G15-D Engine Read control system DTC code again to confirm that the system has no DTC code. Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check. Diagnostic completed. Step 12 2.12.7.39 DTC P0458 P0459 1. DTC Descriptor: P0458 Canister Control Valve Control Circuit Short To Ground or Open P0459 Canister Control Valve Control Circuit Short To Power Supply...
Page 825 Engine Control System JL4G15-D 2-743 3. Schematic: Main Relay Engine Control Module EO01 Evaporative Canister Solenoid From Battery EO35 FE02-5282b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 826 2-744 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect Canister solenoid valve harness connector Evaporative Canister Solenoid EO24. Measure resistance between the Canister solenoid valve two terminals. Standard Resistance: 19-22 Ω at 20°C(68 ºF) Connect canister solenoid valve harness connector EN24. Is the value specified value? Replace the canister solenoid valve.
Page 827 Engine Control System JL4G15-D 2-745 Turn the ignition switch to "OFF" position. Disconnect Canister solenoid valve harness connector EO24. Evaporative Canister Solenoid Harness Disconnect ECM harness connector EO01. Connector EO24 Measure resistance between Canister solenoid valve wiring harness connector EN24 terminal B and ECM harness connector EN01 terminal No.57.
Page 828 2-746 Control System JL4G15-D Engine Read control system DTC code again to confirm that the system has no DTC code. Intermittent Fault. Refer to 2.2.7.3 Intermittent Fault Check. Diagnostic completed. Step 8 5. Repair Instructions: Replace EVAP solenoid valve. Refer to 2.4.7.3 Canister Solenoid Valve Replacement.
Page 829 Engine Control System JL4G15-D 2-747 The vehicle speed signal is used to monitor the vehicle speed. The vehicle speed signal is one of the fuel control reference signals during an urgent deceleration. The vehicle speed sensor working voltage is provided by The Main Relay which is controlled by ECM via ECM harness connector EN01 terminal No.57.
Page 830 2-748 Control System JL4G15-D Engine 4. Diagnostic Steps: Road test the vehicle. Is the vehicle speed meter display working properly? Step 1 If the instrument panel displays the vehicle speed as per normal, the vehicle speed sensor is working correctly. If the instrument panel displays the vehicle speed abnormally, the vehicle speed sensor or the circuit may be faulty.
Page 831 Engine Control System JL4G15-D 2-749 Turn the ignition switch to "OFF" position. Disconnect vehicle speed sensor wiring harness connector Vehicle Speed Sensor Harness Connector EO21 EO21. Turn the ignition switch to "ON" position. Measure voltage between vehicle speed sensor harness connector EO21 terminal No.1 and a reliable ground.
Page 832 2-750 Control System JL4G15-D Engine Next Use scan tool to confirm whether the DTC code is stored again. Step 8 Connect scan tool to the datalink connector. Turn the ignition switch to "ON" position. Clear DTC code. Start and run the engine at idle speed to warm up the engine for at least 5 min.
Page 833 Engine Control System JL4G15-D 2-751 1. Engine is at idle. 2. Vehicle speed is equal to 0. Idle speed is higher than the P0507 3. Engine coolant temperature is higher target speed by 200 rpm than 60°C (140 ºF) . 4.
Page 834 2-752 Control System JL4G15-D Engine Check air-conditioning working condition. Step 4 Use scan tool to observe whether the Air-Conditioning working status is consistent with the actual Air-Conditioning working condition. Refer to the "Data Stream List". When the air-conditioning is switched on and the pressure switch voltage is greater than 0 V, does the idle speed increase by about 150 rpm? Go to step 7...
Page 835 Engine Control System JL4G15-D 2-753 Carry out crankshaft position sensor self learn. Refer to the "crankshaft position sensor to learn." Next Use scan tool to confirm whether the DTC code is stored again. Step 9 Connect scan tool to the datalink connector. Turn the ignition switch to "ON"...
Page 836 2-754 Control System JL4G15-D Engine 2. Conditions For Setting DTC and The Fault Location: Conditions For Setting The DTC DTC Code DTC Detection Strategy Fault Locations (Control Strategy) 1. Ignition switch is at "ON". 2. Battery voltage is less than 11 V. P0562 Lower Than the Lower Limit 3.
Page 837 Engine Control System JL4G15-D 2-755 Turn the ignition switch to "OFF" position. Remove fuses EF01 and EF18. Test continuity between the two fuses with a multimeter. Conducted? EF28 EF27 EF08 Check whether there is a short circuit. EF01 Replace the fuse. 1413 12 11 10 FE02-5287b Check ECM fuse IF12 in I/P fuse block.
Page 838 2-756 Control System JL4G15-D Engine Check ECM grounding the circuit. Step 4 Turn the ignition switch to "OFF" position. Disconnect ECM harness connector EO35. Measure resistance between ECM harness connector EO35 ECM Harness Connector EO35 terminal No.73 of and a reliable ground. Standard Resistance: Less than 1 Ω...
Page 839 Engine Control System JL4G15-D 2-757 Turn the ignition switch to "OFF" position. Disconnect ECM harness connector EO35. Test continuity between ECM harness connector EO35 EF28 EF27 EF08 terminal No.1 and fuse EF04. Measure resistance between ECM harness connector EO35 EF01 terminal No.1 and a reliable ground.
Page 840 2-758 Control System JL4G15-D Engine Replace ECM. Step 8 Carry out crankshaft self learn after ECM replacement. Refer 2.12.7.11 Crankshaft Position Sensor (CKP) Learn. Next Use scan tool to confirm whether the DTC code is stored again. Step 9 Connect scan tool to the datalink connector. Turn the ignition switch to "ON"...
Page 841 Engine Control System JL4G15-D 2-759 3. Schematic: Brake Light Switch Engine Control Module To Brake Light FE02-5360b 4. Diagnostic Steps: Note Before carrying out this diagnosis step, observe the data list on scan tool and analyze the accuracy of the data, as these will help with quick diagnosis.
Page 842 2-760 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect ECM harness connector EO35. Press the brake pedal. ECM Harness Connector EO35 Measure ECM harness connector EO35 terminal No.18 voltage. Standard Voltage: 11-14 V Is voltage normal. Replace ECM.
Page 843 Engine Control System JL4G15-D 2-761 Conditions For Setting The DTC DTC Code DTC Detection Strategy Fault Locations (Control Strategy) P0602 ECM Internal Monitoring P0604 ECM Internal Monitoring P0606 ECM Internal Monitoring P060A ECM Internal Monitoring P1516 ECM Internal Monitoring P2101 ECM Internal Monitoring 4.
Page 844 2-762 Control System JL4G15-D Engine 2. Conditions For Setting DTC and The Fault Location: Conditions For Setting The DTC DTC Detection Strategy Fault Locations Code (Control Strategy) P0641 Hardware Circuit Malfunction 1. Electronic Throttle Body 2. Electronic Throttle Circuit P0651 Hardware Circuit Malfunction 3.
Page 845 Engine Control System JL4G15-D 2-763 Read control system DTC code again to confirm that the system has no DTC code. Intermittent Fault. Refer to 2.12.7.3 Intermittent Fault Check Check ECM power supply circuit and ground circuit. Step 4 Check ECM power supply circuit and ground circuit. Refer "2.12.7.43 DTC P0562 P0563.
Page 846 2-764 Control System JL4G15-D Engine Air-Conditioning compressor working voltage is provide by main relay which is controlled by ECM. ECM controls Air-Conditioning compressor relay internal ground through ECM harness connector EO35 terminal No.51 of, relay pull-in. ECM has a drive circuit which controls relay coil ground, and drive circuit is equipped with a feedback circuit to ECM.
Page 847 Engine Control System JL4G15-D 2-765 Repair instrument cluster circuit. Step 2 Instrument Repair Repair instrument cluster power supply circuit. Refer to 11.7.6.7 DTC U129C U129D. Repair instrument cluster ground circuit. Refer to 11.7.6.7 DTC U129C U129D. Is fault resolved? System normal. Check instrument DTC.
Page 848 2-766 Control System JL4G15-D Engine Is fault solved? System normal Repair ECM power supply circuits. Step 7 Repair ECM power supply circuit. Refer to 2.12.7.43 DTC P0562 P0563. Is fault solved? System normal. Replace ECM. Step 8 Connect scan tool. Turn the ignition switch to "ON"...
Page 849 Engine Control System JL4G15-D 2-767 3. Schematic: Main Relay EO35 VBATPROT EO35 EO35 VBATPROT Ignition Switch Engine EO35 Control VBAT EO35 Module EO35 PWR GND FE02-5286b 4. Diagnostic Steps: Visual Inspection. Step 1 Check main relay for signs of damage. Replace the main relay.
Page 850 2-768 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Remove of ECM harness connector EO35. Measure voltage between ECM harness connector EO35 ECM Harness Connector EO35 terminal No.62 and a reliable ground. Measure resistance between ECM harness connector EO35 terminal No.62 and a reliable ground.
Page 851 Engine Control System JL4G15-D 2-769 Turn the ignition switch to "ON" position. Measure voltage between ECM harness connector EO35 terminal No.3 and a reliable ground. ECM Harness Connector EO35 Standard Value: Test Items Specified Value Voltage Between EO35 (3) and A Reliable 11-14 V Ground Turn the ignition switch to "OFF"...
Page 852 2-770 Control System JL4G15-D Engine Install the main relay. Connect ECM harness connector EO35 terminal No.62 to ground. EF17 EF16 EF15 Measure voltage between main relay terminal No.3 and a reliable ground. EF14 Standard voltage: 11-14 V Voltage normal? Replace the main relay. Go to step 10 1413 12 11 10 FE02-5302b Test continuity between main relay and ECM harness connector.
Page 853 Engine Control System JL4G15-D 2-771 Carry out crankshaft self learn after ECM replacement. Refer 2.12.7.11 Crankshaft Position Sensor (CKP) Learn. Next Use scan tool to confirm whether the DTC code is stored again. Step 10 Connect scan tool to the datalink connector. Turn the ignition switch to "ON"...
Page 854 2-772 Control System JL4G15-D Engine 1. Engine At idle. 2. Acceleration pedal position sensor signal 1 and signal 2 circuits all open, there is a sensor related fault. P2106 Fault Protection Limits 3. Sensor DTC codes appears, engine enters into the limited implementation state.
Page 855 Engine Control System JL4G15-D 2-773 Diagnostic Step 3 Check ECM power supply circuit. Check whether ECM power supply circuit is normal. Check whether ECM ground circuit is normal. Repair the faulty parts. Go to step 5 Replace ECM. Step 4 Replace ECM.
Page 856 2-774 Control System JL4G15-D Engine 2. Conditions For Setting DTC and The Fault Location: DTC Detection Strategy Conditions For Setting The DTC (Control Strategy) Fault Locations Code 1. Electronic Throttle Body 1. Ignition Switch "OFF". Dirty Electronic Throttle Return P2119 2.
Page 857 Engine Control System JL4G15-D 2-775 Replace electronic throttle body. Step 4 Replace electronic throttle body. Refer to the "Electronic Throttle Body Replacement". Next Use scan tool to confirm whether the DTC code is stored again. Step 5 Connect scan tool to the datalink connector. Turn the ignition switch to "ON"...
Page 858 2-776 Control System JL4G15-D Engine Diagnostic completed. Step 10 2.12.7.52 DTC P2122 P2123 1. DTC Descriptor: P2122 Electronic Throttle Pedal Position Sensor 1 Circuit Low Voltage P2123 Electronic Throttle Pedal Position Sensor 1 Circuit High Voltage In order to protect the security of the system, acceleration pedal position sensor (APP) uses a dual-sensor setting, sliding resistive. APP sensor 1 output is IP50 terminal No.4, through ECM wiring harness Connect EO35 terminal No.12 to ECM.
Page 859 Engine Control System JL4G15-D 2-777 3. Schematic: V5REF1 EO35 PPS1 EO35 Engine EO35 V5RTN1 Control V5REF2 EO35 Module EO35 PPS2 V5RTN2 EO35 Acceleration Pedal Position Sensor FE02-5229b 4. Diagnostic Steps: Check APP sensor harness connector IP50 terminal No.2 voltage. Step 1 Turn the ignition switch to "OFF"...
Page 860 2-778 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect APP sensor harness connector IP50. Turn the ignition switch to "ON" position. Acceleration Pedal Position Sensor IP50 Measure resistance between IP50 terminal No.3 and a reliable ground. Standard Resistance: Less than 3 Ω...
Page 861 Engine Control System JL4G15-D 2-779 Check APP sensor harness connector IP50 terminal No.4 output voltage. For the Standard Value. Refer to 2.12.7.13 Acceleration Pedal Position Sensor (APP) Check. Acceleration Pedal Position Sensor IP50 Is the output voltage Standard Value? Replace the APP sensor. Refer to the "APP sensor better."...
Page 862 2-780 Control System JL4G15-D Engine Check ECM power supply circuit and ground circuit. Refer to 2.12.7.43 DTC P0562 P0563. ECM power and ground circuits normal? Power and ground circuit fault. Replace ECM. Refer to 2.2.8.8 Engine Control Module Replacement. Step 7 Next Carry out crankshaft position sensor learn.
Page 863 Engine Control System JL4G15-D 2-781 2. Conditions For Setting DTC and The Fault Location: DTC Detection Strategy Conditions For Setting The DTC (Control Strategy) Fault Locations Code P2127 Hardware Circuit Malfunction Voltage is below the minimum limit, or short to ground 1.
Page 864 2-782 Control System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect APP sensor harness connector IP50. Turn the ignition switch to "ON" position. Acceleration Pedal Position Sensor IP50 Measure resistance between IP50 terminal No.5 and a reliable ground. Standard Resistance: Less than 3 Ω...
Page 865 Engine Control System JL4G15-D 2-783 Check APP sensor harness connector IP50 terminal No.6 output voltage. For the Standard Value. Refer to 2.12.7.13 Acceleration Pedal Position Sensor (APP) Check. Acceleration Pedal Position Sensor IP50 Is the output voltage Standard Value? Replace the APP sensor. Refer to the "APP sensor replacement."...
Page 866 2-784 Control System JL4G15-D Engine Check ECM Power Supply Circuit and ground circuit. Refer to 2.12.7.43 DTC P0562 P0563. ECM power and ground circuits normal? Power and ground circuits fault. Replace ECM. Refer to 2.2.8.8 Engine Control Module Replacement. Step 7 Next Carry out crankshaft position sensor learn.
Page 867 Engine Control System JL4G15-D 2-785 2. Conditions For Setting DTC and The Fault Location: DTC Detection Strategy Conditions For Setting The DTC (Control Strategy) Fault Locations Code 1. ETC 2. TPS Sensor Voltage is lower than the minimum limit, or circuit short to P2135 Hardware Circuit Malfunction Circuit...
Page 868 2-786 Control System JL4G15-D Engine Replace ECM. Refer to 2.2.8.8 Engine Control Module Replacement. Step 4 Next Carry out crankshaft position sensor learn. Refer to 2.12.7.11 Crankshaft Position Sensor (CKP) Learn. Step 5 Next Step 6 Use scan tool to confirm whether the DTC code is stored again. Connect scan tool to the datalink connector.
Page 869 Engine Control System JL4G15-D 2-787 4. Diagnostic Steps: Check whether there is other APP sensor related DTC code? Step 1 Connect scan tool to the datalink connector. Turn the ignition switch to "ON" position. Press the scan tool power button. Select the following menu items: Engine/Read DTC codes.
Page 870 2-788 Control System JL4G15-D Engine Start and run the engine at idle speed to warm up the engine for at least 5 min. Road test the vehicle for at least 10 min. Read control system DTC code again to confirm that the system has no DTC code.
Page 871 Engine Control System JL4G15-D 2-789 Conditions For Setting The DTC Code DTC Detection Strategy Fault Locations DTC (Control Strategy) 1. Ignition key 2. Ignition Key Incentive Coil 3. ECM Anti-theft Device Authentication U0426 Ignition Switch "ON". Malfunction 4. Chip Security Module 5.
Page 872 2-790 Control System JL4G15-D Engine 2.12.7.58 Crankshaft Rotation Normal, But The Engine Can Not Start Note Before carry out this diagnostic step, make sure the engine oil meets manufacturers requirements and make sure the fuel tank has sufficient fuel, battery capacity meets the requirements for engine starting. Observe the scan tool data list, analyze the accuracy of the data, as it will help with quick Diagnostic.
Page 873 Engine Control System JL4G15-D 2-791 Repair fuel pump relay. Step 4 Refer to "Fuel System" in the2.3.7.3 Fuel Pump Inoperative. Replace the pump relay. Repair pump relay circuit. Repair circuit faults. Start the engine, fault solved? System normal. Check the fuel pump circuit. Step 5 Turn the ignition switch to "OFF"...
Page 874 2-792 Control System JL4G15-D Engine Turn the ignition switch to "ON" position. Connect scan tool, select the "Function Test" then "fuel pump relay" to drive the fuel pump relay. Standard fuel pressure: 400 kPa Is fuel pressure normal? Go to step 9 Replace the fuel pump.
Page 875 Engine Control System JL4G15-D 2-793 System normal. Step 12 Check crankshaft position sensor and circuit. Check crankshaft position sensor. Refer to 2.12.7.35 DTC P0335 P0336. Measure crankshaft position sensor resistance with a multimeter. Standard Resistance: 504-616 Ω Inspect sensor circuit, repair the faulty part. If necessary, replace the crankshaft position sensor.
Page 876 2-794 Control System JL4G15-D Engine Check engine mechanical parts. Step 16 Remove the engine. Check engine mechanical parts. If necessary, repair the damaged engine parts. identify the engine damaged parts repair has been completed. Next Diagnostic completed. Step 17 2.12.7.59 Electronic Throttle Body (ETC) Adaptive Learn Program Note After the throttle body for cleaning and serving, carry out ETC self-adaptive learn.
Page 877 Engine Control System JL4G15-D 2-795 2.12.8 Removal and Installation 2.12.8.1 Acceleration Pedal Replacement Removal Procedure: Warning! Warning: Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Disconnect the acceleration pedal harness connector. Remove the acceleration pedal bolts and remove the acceleration pedal.
Page 878 2-796 Control System JL4G15-D Engine Installation Procedure: Install the acceleration pedal and tighten the retaining nuts. Torque: 15 Nm (Metric) 11 lb-ft (US English) FE02-8029b Connect the acceleration pedal harness connector. Connect the battery negative cable. EC718/EC718RV EC715/EC715RV 10/2009...
Page 879: Fuel System Jl4G15-D
Engine Fuel System JL4G15-D 2-797 2.13 Fuel System JL4G15-D 2.13.1 4G15-D Fuel System Overview Compared with 4G18-D, 4G15-D engine fuel system has the same content in Specification, Description and Operation, the System Working Principle, Component Locator, Schematic, Removal and Installation. For specific information, please refer to2.3 Fuel System JL4G18-D.
Page 880 2-798 Fuel System JL4G15-D Engine 2.13.1 Diagnostic Information and Procedures 2.13.1.1 Fuel Pump Inoperative Schematic Engine Fuel Pump Relay Control Module Fuel Pump From Battery FE02-5224b Diagnostic Steps: Check fuel pump fuse EF05. Step 1 Is the fuel pump fuse EF05 blown? Go to step 3 1413 12 11 10 FE02-5403b...
Page 881 Engine Fuel System JL4G15-D 2-799 Repair fuel pump fuse EF05 circuit. Step 2 Check fuel pump fuse EF05 circuit. Repair fuel pump power circuit short to ground. Replace the fuse EF05. Fuse Rating: 15 A Is fuel pump working properly? System normal Check fuel pump relay terminal No.3 voltage.
Page 882 2-800 Fuel System JL4G15-D Engine Use scan tool to drive pump relay. Check fuel pump relay terminal No.1 voltage with a multimeter. Standard Voltage: 11-14 V Is the voltage Standard Value? EF28 EF27 EF08 Go to step 8 EF01 FE02-5501b Repair ECM harness connector EO35 terminal No.71 and pump relay connector No.1 circuit open fault.
Page 883 Engine Fuel System JL4G15-D 2-801 Step 10 Check pump relay terminal No.5 voltage. Turn on the ignition switch. Standard Voltage: 11-14 V Confirm whether the voltage is standard value. Go to step 12 EF28 EF27 EF08 EF01 FE02-5407b Step 11 Replace the fuel pump relay.
Page 884 2-802 Fuel System JL4G15-D Engine Check the circuit between fuel pump wiring harness connector SO29 terminal No.3 and the fuel pump relay terminals No.5. Fuel Pump Harness Connector SO29 Repair the circuit between fuel pump wiring harness connector SO29 terminal No.3 and the fuel pump relay terminals No.5 open fault.
Page 885 Engine Fuel System JL4G15-D 2-803 Replace the fuel pump. Step 16 Replace the fuel pump. Refer to 2.3.8.3 Fuel Pump Assembly Replacement. Confirm repair completed. Next Step 17 System normal. 2.13.1.2 All Fuel Injectors Inoperative Schematic: To Ignition Switch Main Relay Fuel Injector 1 Fuel Injector 2 Engine...
Page 886 2-804 Fuel System JL4G15-D Engine Repair the engine anti-theft system malfunction. Step 2 Repair the engine anti-theft system malfunction. Refer to 2.5.7.12 Engine Anti-theft Warning Lamp Flashing, Vehicle Can Not Start. Is fuel injector working properly? System normal Check ECM fuse. Step 3 Check whether ECM fuse IF12 is blown? Go to step 6...
Page 887 Engine Fuel System JL4G15-D 2-805 Check ECM ground circuit. Repair open circuit ECM connector EO35 terminal No.73 and the body. ECM Harness Connector EO35 Is fuel injector working properly? System normal FE02-5504b Check fuel injector wiring harness connector terminal No.2 voltage. Step 6 Turn on the switch.
Page 888 2-806 Fuel System JL4G15-D Engine Turn on the ignition switch and try to Start the engine. At the same time, check the fuel injector wiring harness connector terminal No.1 periodical low voltage waveform. Fuel Injector 1 Harness Connector EO11 Is there a periodical low voltage waveform? Go to step 10 FE02-5506b Replace ECM.
Page 889 Engine Fuel System JL4G15-D 2-807 2.13.2 Removal and Installation 2.13.2.1 Fuel Injector Replacement Removal Procedure: Warning! Warning: Refer to "Battery Disconnection Warning" in "Warnings and Notices" Release fuel system pressure. Refer to 2.3.8.1 Fuel Pressure Release Procedure. Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection.
Page 890 2-808 Fuel System JL4G15-D Engine Remove the fuel pipe form fuel rail. Remove the fuel rail retaining bolts and remove the fuel rail. Remove fuel injectors spring and unplug the fuel injectors. EC718/EC718RV EC715/EC715RV 10/2009...
Page 891 Engine Fuel System JL4G15-D 2-809 Installation Procedure: Apply a small amount of engine oil to lubricate the fuel injector O-ring. Install the fuel injectors to the fuel rail. Note Fuel injectors terminal should face outward. FE02-0030b Install fuel injectors springs, make sure that the fuel injector wiring harness connector port and the fuel rail mounting hole are in the same direction.
Page 892 2-810 Fuel System JL4G15-D Engine Connect the fuel pipe into fuel rail. Note Fuel pipe must be inserted into the fuel rail after the second boss and then tighten. Connect engine fuel injector wiring harness connector. FE02-8027b Connect crankcase ventilation tube. Connect the battery negative cable.
Page 893 Engine Auxiliary Emission Control JL4G15-D 2-811 2.14 Auxiliary Emission Control JL4G15-D 2.14.1 4G15-D auxiliary emission control devices, an overview Compared with 4G18-D, 4G15-D engine auxiliary emission control devices has the same content in Specification, Description and Operation, the System Working Principle, Component Locator, Schematic, Removal and Installation.
Page 894 2-812 Auxiliary Emission Control JL4G15-D Engine 2.14.1 Component Locator 2.14.1.1 Component Locator Legend 1. Canister Solenoid Valve EC718/EC718RV EC715/EC715RV 10/2009...
Page 895 Engine Auxiliary Emission Control JL4G15-D 2-813 2.14.2 Diagnostic Information and Procedures 2.14.2.1 Canister Solenoid Valve Inoperative Schematic: Main Relay Engine Control Module Evaporative Canister Solenoid From Battery FE02-5221b Diagnostic Steps: Check engine emission warning lamp malfunction. Step 1 Start the engine. Check whether engine emissions malfunction warning lamp is lit? Go to step 3 Step 2...
Page 896: Auxiliary Emission Control Jl4G15-D
2-814 Auxiliary Emission Control JL4G15-D Engine Check Canister solenoid valve power supply circuit. Step 3 Turn on the ignition switch. Measure Canister solenoid valve EO24 terminal A voltage with a multimeter. Evaporative Canister Solenoid Harness Standard Voltage: 11-14 V Connector EO24 Is the voltage Standard Value? Go to step 5 FE02-5227b...
Page 897 Engine Auxiliary Emission Control JL4G15-D 2-815 Turn off the ignition switch. With a multimeter, check resistance between Canister solenoid valve wiring harness connector EO24 terminal B Evaporative Canister Solenoid Harness Connector EO24 and ECM harness connector EO01 terminals No.57 to determine the continuity.
Page 898 2-816 Auxiliary Emission Control JL4G15-D Engine Confirm the repair has been completed. Next System normal. Step 9 EC718/EC718RV EC715/EC715RV 10/2009...
Page 899: Engine Anti-Theft System Jl4G15-D
Engine Engine Anti-theft System JL4G15-D 2-817 2.15 Engine Anti-theft System JL4G15- 2.15.1 4G15-D Engine Anti-theft System Overview Compared with 4G18-D, 4G15-D engine anti-theft system has the same content in Specification, Description and Operation, System Working Principle, Component Locator, Schematic, Removal and Installation. For specific information, please refer to2.3 Fuel System JL4G18-D.
Page 900 2-818 Engine Anti-theft System JL4G15-D Engine 2.15.1 Diagnostic Information and Procedures 2.15.1.1 Engine Anti-theft System Warning Lamp Flashing, The Vehicle Can Not Be Started Schematic: Engine Control Module To Ignition Switch Engine Theft-deterrent System Control To Datalink Connector Module Theft- deterrent Coil From Battery...
Page 901 Engine Engine Anti-theft System JL4G15-D 2-819 Repair fuse IF26 and IF21 circuits. Step 2 Check the fuse IF26 circuit, repair short-circuit fault. Check the fuse IF21 circuit, repair short-circuit fault. Replace the fuses. Can vehicles normally start? System normal Check engine anti-theft system control module ground. Step 3 With a multimeter, measure resistance between continuity between engine anti-theft system control module terminal...
Page 902 2-820 Engine Anti-theft System JL4G15-D Engine Disconnect electronic Anti-theft coil harness connector. Measure coil resistance with a multimeter. Standard Resistance: resistance 5 Ω (68 ºF) at room temperature Engine Anti-Theft Coil 20°C Is EAS coil resistance specified value? Go to step 7 FE02-6609b Replace electronic Anti-theft coil.
Page 903 Engine Engine Anti-theft System JL4G15-D 2-821 Go to step 9 Step 8 Repair circuit between EAS coil harness connector and engine anti-theft system control module harness connector. Check serial communication circuit resistance between engine anti-theft system control module wiring harness connector IP25 terminals No.5 and engine control module wiring harness connector EO01 terminal No.62 to determine circuit continuity.
Page 904 2-822 Engine Anti-theft System JL4G15-D Engine Repair serial communication circuit between engine anti-theft system control module and engine control Step 10 module. Repair serial communication circuit open between engine anti-theft system control module wiring harness connector IP25 terminals No.5 and engine control module wiring harness connector EO01 terminal No.62.
Page 905: Engine Mechanical Systems Jl4G15-D
Engine Engine Mechanical Systems JL4G15-D 2-823 2.16 Engine Mechanical Systems JL4G15-D 2.16.1 4G15-D Engine Mechanical System Overview Compared with 4G18-D, 4G15-D engine mechanical system has the same content in Specification, Description and Operation, the System Working Principle, Component Locator, Schematic, Removal and Installation. For specific information, please refer to2.3 Fuel System JL4G18-D.
Page 906 2-824 Engine Mechanical Systems JL4G15-D Engine 2.16.1 Specifications 2.16.1.1 Fastener Tightening Specifications Specifications Applications Model Metric (Nm) US English (lb-ft) Spark Plug Bolts M14 × 1.25 20-30 14.8-22.2 Cylinder Head Cover (Short Bolts) 7-11 5.2-8.2 Cylinder Head Cover (Long Bolts, 9-13 6.7-9.6 Nuts, Special Bolts)
Page 907 Engine Engine Mechanical Systems JL4G15-D 2-825 Specifications Applications Model Metric (Nm) US English (lb-ft) Water Pump Outlet Components 25 and Above 18.5 and Above Bolt Oil Pump Mounting Bolt 7.2-10.8 5.3-8 Timing Chain Cover Bolt 14.4-21.6 10.7-16 Timing Chain Cover Bolt 8.8-13.2 6.5-9.8 Engine Right Mounting Bolts...
Page 908 2-826 Engine Mechanical Systems JL4G15-D Engine Specifications Applications Model Metric (Nm) US English (lb-ft) Power Steering Pump Mounting 36-54 26.6-39.8 Bolt Compressor Retaining Bolt 20-30 14.8-22.1 VVT Solenoid Valve Components 7-11 5.2-8.1 Retaining Bolt 2.16.1.2 Mechanical System Specifications Items Specifications Bore (mm/in) 77.8/3.07 Stroke (mm/in)
Page 909 Engine Engine Mechanical Systems JL4G15-D 2-827 Items Specifications Valve Timing Intake Valve Opening 16 ° Before TDC Intake Valve Closing 70.5 ° After BDC Exhaust Valve Opening 55.5 ° Before TDC Exhaust Valve Closing 17 ° After BDC Crank Pin Connecting Rod Bearing Clearance (mm/in) 0.020-0.044/0.0007-0.0017 Connecting Rod Bearing Axial Clearance (mm/in)
Page 910 2-828 Engine Mechanical Systems JL4G15-D Engine Items Specifications Second Compression Ring End Gap (mm/in) 0.20-0.40/0.0079-0.0157 First Compression Ring End Gap (mm/in) 0.25-0.35/0.0098-0.0138 Sealants and Adhesives Cylinder Head Cover Mat Sealant Kesaixin 1596 Flat Silicone Rubber Sealants Engine Oily Road Conce Kesaixin 1243-Type Anaerobic Thread Locking Sealant Oil Pan and Crankcase Mating Surface Kesaixin 1596 Flat Silicone Rubber Sealants...
Page 911 Engine Engine Mechanical Systems JL4G15-D 2-829 Packet No. Thickness (mm/in) Packet No. Thickness (mm/in) 5.36(0.2110) 5.72(0.2260) 5.38(0.2118) 5.74(0.2260) 5.40(0.2126) EC718/EC718RV EC715/EC715RV 10/2009...
Page 912 2-830 Engine Mechanical Systems JL4G15-D Engine 2.16.1.4 Intake and Exhaust Valves Lifter Selection Table Intake Valve Selection Table Lifter No. and Thickness EC718/EC718RV EC715/EC715RV 10/2009...
Page 913 Engine Engine Mechanical Systems JL4G15-D 2-831 Exhaust Valve Selection Table Lifter No. and Thickness EC718/EC718RV EC715/EC715RV 10/2009...
Page 914 2-832 Engine Mechanical Systems JL4G15-D Engine 2.16.2 System Working Principle 2.16.2.1 System Working Principle For specific working descriptions, Refer to2.6 Engine Mechanical System JL4G18-Din2.6.3.1 System Working Principle. Legend 1. TDC: Top Dead Center 5. ABDC: After Bottom Dead Center 2. BDC: Bottom Dead Center 6.
Page 915 Engine Engine Mechanical Systems JL4G15-D 2-833 2.16.3 Removal and Installation 2.16.3.1 4G15-D Mechanical Parts Disassemble Instructions Other than using an electronic throttle body instead of the mechanical throttle body, there is no difference between this engine mechanical parts 4G15-D engine. Therefore this section only lists electronic throttle body replacement.
Page 916 2-834 Engine Mechanical Systems JL4G15-D Engine Remove throttle body from the intake manifold. Clean the engine throttle body and intake manifold mating surface and replace with a new gasket. FE02-0103b Installation Procedure: Install and tighten throttle body retaining bolts and nuts. Torque: 15 Nm (Metric) 11 lbf-ft (US English) FE02-8013b Connect throttle control valve wiring harness connector.
Page 917: Exhaust System Jl4G15-D
Engine Exhaust System JL4G15-D 2-835 2.17 Exhaust System JL4G15-D 2.17.1 4G15-D Engine Exhaust System Overview Compared with 4G18-D, 4G15-D engine exhaust system has the same content in Specification, Description and Operation, System Working Principle, Component Locator, Schematic, Removal and Installation. For specific information, please refer to2.3 Fuel System JL4G18-D.
Page 918 2-836 Exhaust System JL4G15-D Engine 2.17.1 Specifications 2.17.1.1 Fastener Tightening Specifications Specifications Applications Model Metric (Nm) US English (lb-ft) Exhaust Manifold Retaining Nut 20-30 14.8-22.2 Exhaust Manifold Bracket Retaining M12 × 1.25 × 28 28-42 20.7-31.1 Bolts Heat Shield Retaining Bolts M8 ×...
Page 919: Engine Cooling System Jl4G15-D
Engine Engine Cooling System JL4G15-D 2-837 2.18 Engine Cooling System JL4G15-D 2.18.1 4G15-D Engine Cooling System Overview Compared with 4G18-D, 4G15-D engine cooling system has the same content in Specification, Description and Operation, System Working Principle, Component Locator, Schematic, Removal and Installation. For specific information, please refer to2.3 Fuel System JL4G18-D.
Page 920 2-838 Engine Cooling System JL4G15-D Engine 2.18.1 Specifications 2.18.1.1 Cooling System Specifications Applications Specifications Cooling Type Coolant Comply With SH0521 (Freezing Point ≤-40°C /-40 ºF) Engine Coolant Specifications / Grades Engine Coolant Capacity (Coolant Recovery Reservoir) 6.0 L (10.6 pt) Thermostat Type Wax-Type Thermostat Pump Type...
Page 921 Engine Engine Cooling System JL4G15-D 2-839 2.18.2 Schematic 2.18.2.1 Schematic Main Relay EO35 Fan Low Speed Relay EO35 FANLO Fan High Speed Relay Engine Control Module FANHI EO35 Fan Assembly FE02-7901b EC718/EC718RV EC715/EC715RV 10/2009...
Page 922 2-840 Engine Cooling System JL4G15-D Engine 2.18.3 Diagnostic Information and Procedures 2.18.3.1 Cooling Fan Circuit Diagnosis Diagnostic Tips: – If there is an overheating complaint, verify whether the it is because the engine coolant boiling or the engine coolant temperature gage indicates the coolant overheating.
Page 923 Engine Engine Cooling System JL4G15-D 2-841 Refer to 2.18.3.2 High Speed Cooling Fan Inoperative Turn on the A/C switch and confirm whether the low speed cooling fan is running. Step 4 Turn the ignition switch to "OFF" position. Connect scan tool to datalink connector. Select in sequence: Engine / Data List / Engine Coolant Temperature.
Page 924 2-842 Engine Cooling System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect cooling fan wiring harness connector CA16. Cooling Fan Harness Connector CA16 Measure resistance between cooling fan wiring harness connector CA16 terminal No.3 and a reliable ground. Standard Resistance: Less than 1 Ω...
Page 925 Engine Engine Cooling System JL4G15-D 2-843 Turn the ignition switch to "OFF" position. Remove the High-Speed cooling fan relay. Cooling Fan Harness Connector CA16 Disconnect cooling fan wiring harness connector CA16. Test continuity between high speed cooling fan relay A terminal No.30 and cooling fan wiring harness connector CA16 terminal No.2.
Page 926 2-844 Engine Cooling System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect ECM harness connector EO35. Remove the High-Speed cooling fan relay A. EF17 EF16 EF15 Test continuity between high speed cooling fan relay A terminal No.86 and EO35 terminal No.66. EF14 Measure voltage between high speed cooling fan relay A terminal No.86 and a reliable ground.
Page 927 Engine Engine Cooling System JL4G15-D 2-845 Turn the ignition switch to "OFF" position. Disconnect cooling fan wiring harness connector CA16. Cooling Fan Harness Connector CA16 Turn the ignition switch to "ON" position. Connect scan tool to the datalink connector. Select in sequence: Engine / Action Test / fan 1. Make low-speed relay work.
Page 928 2-846 Engine Cooling System JL4G15-D Engine Turn the ignition switch to "OFF" position. Remove the low-speed cooling fan relay B. Measure voltage between low speed cooling fan relay B terminal No.87 and a reliable ground. EF28 EF27 EF08 Standard Voltage: 11-14 V EF01 Is the voltage specified Value? Relay B terminal No.87 power supply circuit...
Page 929 Engine Engine Cooling System JL4G15-D 2-847 Turn the ignition switch to "OFF" position. Remove the low speed cooling fan relay B. Turn the ignition switch to "ON" position. Measure voltage between low speed cooling fan relay B EF28 EF27 EF08 terminal No.85 and a reliable ground.
Page 930 2-848 Engine Cooling System JL4G15-D Engine Replace ECM. Step 11 Carry out crankshaft self learn after ECM replacement. Refer 2.12.7.11 Crankshaft Position Sensor (CKP) Learn. Next Diagnostic completed. Step 12 2.18.3.4 Cooling Fan Always Runs At Low-Speed Note When this fault is present, it is recommended to carry out diagnostic when engine is completely cooled down. Verify the fault.
Page 931 Engine Engine Cooling System JL4G15-D 2-849 Turn the ignition switch to "OFF" position. Remove the low-speed cooling fan relay. Cooling Fan Harness Connector CA16 Disconnect cooling fan wiring harness connector CA16. Check and repair circuit between relay and connector short to power supply fault.
Page 932 2-850 Engine Cooling System JL4G15-D Engine Turn the ignition switch to "OFF" position. Disconnect ECM harness connector EN01. Remove the low-speed cooling fan relay B. EF17 EF16 EF15 Test continuity between cooling fan low speed relay B terminal No.86 and ECM harness connector EO35 terminal EF14 No.67.
Page 933 Engine Engine Cooling System JL4G15-D 2-851 Next Check the engine coolant temperature sensor signal. Step 2 Turn the ignition switch to "OFF" position. Connect scan tool to the datalink connector. Turn off A/C switch. Turn the ignition switch to "ON" position. Select in sequence: Engine / Data List / Engine Coolant Temperature.
Page 934 2-852 Engine Cooling System JL4G15-D Engine Turn the ignition switch to "OFF" position. Remove the high-speed cooling fan relay. Cooling Fan Harness Connector CA16 Disconnect cooling fan wiring harness connector CA16. Check and repair circuit between relay and connector short to power supply fault.
Page 935 Engine Engine Cooling System JL4G15-D 2-853 Turn the ignition switch to "OFF" position. Disconnect ECM harness connector EN01. Remove the high-speed cooling fan relay A. EF17 EF16 EF15 Test continuity between cooling fan high speed relay A terminal No.86 and ECM harness connector EO35 terminal EF14 No.66.
Page 936: Lubrication System Jl4G15-D
2-854 Lubrication System JL4G15-D Engine 2.19 Lubrication System JL4G15-D 2.19.1 4G15-D Engine Lubrication System Overview Compared with 4G18-D, 4G15-D engine lubrication system has the same content in Specification, Description and Operation, the System Working Principle, Component Locator, Schematic, Removal and Installation. For specific information, please refer to2.3 Fuel System JL4G18-D.
Page 937 Engine Lubrication System JL4G15-D 2-855 2.19.1 Specifications 2.19.1.1 Oil Pump Specifications Applications Specifications Side Clearance 0.025-0.062 mm (0.0010-0.0024 in) Tooth Gap 0.030-0.099 mm (0.0012-0.0039 in) ≤40 kPa (≤6 psi) Engine Oil Pressure Sensor Plug Pressure Oil Pump Output Pressure 0.6 MPa (87 psi) Oil Pump Relief Valve Opening Pressure 0.42-0.58 MPa (61-85 psi) EC718/EC718RV EC715/EC715RV 10/2009...
Page 938: Ignition System Jl4G15-D
2-856 Ignition System JL4G15-D Engine 2.20 Ignition System JL4G15-D 2.20.1 4G15-D Engine Ignition System Overview Compared with 4G18-D, 4G15-D engine ignition system has the same content in Specification, Description and Operation, System Working Principle, Component Locator, Schematic, Removal and Installation. For specific information, please refer to2.3 Fuel System JL4G18-D.
Page 939 Engine Ignition System JL4G15-D 2-857 2.20.1 Specifications 2.20.1.1 Ignition System Specification Applications Specifications Ignition Sequence 1-3-4-2 Ignition Timing 8 °-14 °before TDC Ignition Type Spark Discharge Spark Plug Gap 0.8-1.0 mm (0.03-0.04 in) Spark Plug Manufacturer Zhuzhou Torch Spark Plug Co., Ltd. Spark Plug Model K6RTC EC718/EC718RV EC715/EC715RV 10/2009...
Page 940 2-858 Ignition System JL4G15-D Engine 2.20.2 Component Locator 2.20.2.1 Component Locator Legend 1. Knock Sensor 4. Camshaft Position Sensor 2. Ignition Coil 3. Crankshaft Position Sensor EC718/EC718RV EC715/EC715RV 10/2009...
Page 941 Engine Ignition System JL4G15-D 2-859 2.20.3 Schematic 2.20.3.1 Schematic Crankshaft Position Sensor Engine Control Module Camshaft Position Sensor Ignition Coil Knock Sensor FE02-9106b EC718/EC718RV EC715/EC715RV 10/2009...
Page 942 2-860 Ignition System JL4G15-D Engine IG1 Relay To Ignition Switch 1,4 Cylinder Ignition Coil COLA MAIN EO01 Engine 2,3 Cylinder Ignition Coil Control Module Battery COLB EO01 FE02-9101b EC718/EC718RV EC715/EC715RV 10/2009...
Page 943 Engine Ignition System JL4G15-D 2-861 2.20.4 Diagnostic Information and Procedures 2.20.4.1 Spark Plug No Arcing Note Before carry out this diagnostic procedure, make sure that the engine Anti-theft locking system is not activated and working properly. Note During this test, it is prohibited to connect the high-voltage damping line to ground, as this may damage the ignition coil or the engine control module.
Page 944 2-862 Ignition System JL4G15-D Engine Measure the ignition coil secondary resistance. Step 4 Turn the ignition switch to "OFF" position. Disconnect the ignition coil harness connector EO19. Measure resistance between ignition coil secondary terminals. Standard Resistance Value: 8.86-10.82 kΩ Is resistance normal? Replace the ignition coil.
Page 945 Engine Ignition System JL4G15-D 2-863 Note Connect scan tool, when the ignition switch is turned to "ST" position, observe the scan tool data: Engine / data list / "engine speed." Turn the ignition switch to the "ST" position, is engine speed showing? Step 6 Showing speed? Go to step 10...
Page 946 2-864 Ignition System JL4G15-D Engine 2.20.5 Removal and Installation 2.20.5.1 Camshaft Position Sensor Replacement Removal Procedure: Warning! Warning: Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Disconnect camshaft position sensor wiring harness connector.
Page 947 Engine Ignition System JL4G15-D 2-865 Installation Procedure: Check whether the camshaft position sensor seal is intact. FE02-8019b Install camshaft position sensor. FE02-8020b Install and tighten camshaft position sensor retaining bolts. Torque: 10 Nm (Metric) 7.4 lb-ft (US English) FE02-8021b EC718/EC718RV EC715/EC715RV 10/2009...
Page 948 2-866 Ignition System JL4G15-D Engine Connect camshaft position sensor wiring harness connector. Connect the battery negative cable. FE02-8022b 2.20.5.2 Ignition Coil Replacement Warning! Warning: Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection.
Page 949 Engine Ignition System JL4G15-D 2-867 Remove the ignition coil bolts and remove the ignition coil. Installation Procedure: Install the ignition coil and tighten retaining bolts. Torque: 10 Nm (Metric) 7.4 lb-ft (US English) Connect the ignition coil harness connector. EC718/EC718RV EC715/EC715RV 10/2009...
Page 950 2-868 Ignition System JL4G15-D Engine Connect high-voltage damping line according to the number of labels on the ignition coil. FE02-8006b Connect high-voltage damping line. Connect the battery negative cable. FE02-8001b 2.20.5.3 High-voltage Damping Line Replacement Removal Procedure: Warning! Warning: Refer to "Battery Disconnection Warning" in "Warnings and Notices".
Page 951 Engine Ignition System JL4G15-D 2-869 Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Disconnect high-voltage damping line from the ignition coil. FE02-8043b Unplug the high-voltage damping line and remove from the high-voltage wire mount. FE02-8008b Installation Procedure: Install the high-voltage damping line to the engine. FE02-8009b EC718/EC718RV EC715/EC715RV 10/2009...
Page 952 2-870 Ignition System JL4G15-D Engine Connect the high-voltage damping line to the ignition coil. FE02-8001b Connect high-voltage damping line according to the number of labels on the ignition coil. FE02-8006b As shown in graphic, fix the high-voltage damping line on the mount in order to avoid high-voltage damping line interference with each other.
Page 953: Starting / Charging System Jl4G15-D
Engine Starting / Charging System JL4G15-D 2-871 2.21 Starting Charging System JL4G15-D 2.21.1 4G15-D Engine Starting / Charging System Overview Compared with 4G18-D, 4G15-D engine starting / charging system has the same content in Specification, Description and Operation, the System Working Principle, Component Locator, Schematic, Removal and Installation.
Page 954 2-872 Starting / Charging System JL4G15-D Engine 2.21.1 Specifications 2.21.1.1 Starter Motor Specifications Starter Motor Specifications Applications Specifications Starter Rated Output 12 V, 1.2 kW Non-Load Performance Voltage 11.0 V, Current 90 A, Speed 2,800 r/min Load Performance Voltage 7.7 V, Current 300 A, Torque 8 Nm, Speed 890 r /min Solenoid Coil Working Voltage 12.2 V, Current 30 A...
Page 955: Transmission / Drive Axle
Transmission / Drive Axle Table of Contents 3 Transmission / Drive Axle 3.1 Warnings and Notices.....3-3 3.3.2 Description and Operation......3-30 3.3.2.1 Transmission System Operation......3-30 3.1.1 Warnings and Notices...........3-3 3.3.3 System Working Principle.......3-31 3.2 Clutch System.........3-4 3.3.3.1 Shifting Working Principle........3-31 3.2.1 Specifications...........3-4 3.3.3.2 Vehicle Speed Sensor Working Principle..3-34 3.2.1.1 Fastener Tightening Specifications....3-4 3.3.3.3 Reverse Switch Working Principle....3-34...
Page 956 Table of Contents Transmission / Drive Axle 3.3.9 Special Tools and Equipment....3-112 3.3.9.1 Special Tools List...........3-112 EC718/EC718RV EC715/EC715RV 10/2009...
Page 957: Warnings And Notices
Transmission / Drive Axle Warnings and Notices 3.1 Warnings and Notices Engine Lifting Notice Note 3.1.1 Warnings and Notices Notice: When raising or supporting the engine for any Battery Disconnect Warning reason, do not use a jack under the oil pan, any sheet Warning! metal, or the crankshaft pulley.
Page 958: Clutch System
Clutch System Transmission / Drive Axle 3.2 Clutch System 3.2.1 Specifications 3.2.1.1 Fastener Tightening Specifications Specifications Applications Model Metric (Nm) US English (lb-ft) Clutch Cylinder Bolts M8 × 1.25 × 25 18-22 13.3-16.2 Clutch Master Cylinder Assembly Retaining 16-26 11.8-19.2 Clutch Cylinder Oil Pipe Bracket Bolts M8 ×...
Page 959 Transmission / Drive Axle Clutch System 3.2.2 Description and Operation 3.2.2.1 Description and Operation The clutch is located between the engine and the transmission. The clutch is retained to the flywheel rear surface by retaining bolts. The clutch spline hub and transmission input shaft form rigid connections.
Page 960 Clutch System Transmission / Drive Axle 3.2.3 System Working Principle 3.2.3.1 System Working Principle 1. Make Sure Vehicle Smooth Start: Before start, the vehicle is stationary. If the engine and transmission has a rigid connection, and once a gear is engaged, vehicle will suddenly move forward because of the suddenly transmitted power.
Page 961 Transmission / Drive Axle Clutch System 3.2.4 Disassemble View 3.2.4.1 Disassemble View Clutch FE03-2021b Legend 1. Master Cylinder Oil Outlet Components 10. Pedal Retaining Nut 2. Clutch Master Cylinder Retaining Nuts 11. Clutch Pedal and Brake Pedal Bracket Mounting Nut 3.
Page 962 Clutch System Transmission / Drive Axle Clutch Body Legend 1. Clutch Driven Plate 8. Separation Fork Jacket 2. Clutch Pressure Plate 9. Clutch Hydraulic Hose 3. Release Bearings 10. Clutch Cylinder Oil Inlet Pipe 4. Transmission Assembly 11. Clutch Hydraulic Hose Retaining Bracket 5.
Page 963 Transmission / Drive Axle Clutch System 3.2.5 Diagnostic Information and Procedures 3.2.5.1 Diagnosis Description Refer to "Description and Operation" and start system diagnostics. When a malfunction occurs. Refer to "Description and Operation " as it will help determine the correct symptom diagnostic procedures, so that it will also help to determine whether the customer described condition is normal.
Page 964 3-10 Clutch System Transmission / Drive Axle Replace the clutch slave cylinder. Refer to 3.2.6.7 Clutch Slave Cylinder Replacement Clutch master cylinder leaking internally? Step 7 Inspect for correct clutch pedal reserve. Release the clutch pedal to the halfway position. Apply the clutch pedal several times.
Page 965 Transmission / Drive Axle Clutch System 3-11 Next Check whether the pipes are broken or damaged, causing the clutch slave cylinder oil pressure can not be Step 2 released in time. Replace the damaged pipe. Check whether the clutch slave cylinder is binding? Step 3 Replace the clutch slave cylinder.
Page 966 3-12 Clutch System Transmission / Drive Axle Next Diagnostic completed. Step 10 3.2.5.4 Clutch Pedal Hard to Push Note If the clutch oil is not correct, replace the clutch master cylinder, clutch working cylinder, bleed the system and fill the correct oil.
Page 967 Transmission / Drive Axle Clutch System 3-13 Check whether the clutch pedal height is correct, otherwise the clutch master cylinder can not be completely Step 3 reset. Measure the clutch pedal free travel. Refer to 3.2.6.4 Clutch Pedal Free Travel Adjustment.
Page 968 3-14 Clutch System Transmission / Drive Axle Next Check whether there is engine oil in Clutch Driven plate block? Step 3 Rule out engine oil leakage and replace the clutch driven plate. Step 4 Check whether the Clutch Driven plate damping spring is damaged. Replace the clutch driven plate. Next Step 5 Diagnostic completed.
Page 969 Transmission / Drive Axle Clutch System 3-15 3.2.6 Removal and Installation 3.2.6.1 Clutch Pedal Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Remove instrument panel. Refer 12.8.3.1 Instrument Panel Replacement.
Page 970 3-16 Clutch System Transmission / Drive Axle Remove clutch / brake pedal assembly bolt and nuts. FE03-0202b Remove the clutch / brake pedal assembly, remove screws and pull retaining nuts out of the pedal. Remove the return spring and clutch pedal. FE03-0203b Installation Procedure: Install the return spring and clutch pedal.
Page 971 Transmission / Drive Axle Clutch System 3-17 Install clutch / brake pedal assembly bolt and nuts. Torque: 23 Nm (Metric) 17.0 lb-ft (US English) Install clutch pedal assembly upper retaining bolts. Torque: 23 Nm (Metric) 17.0 lb-ft (US English) Install the vacuum brake booster rod U-shaped clip and the brake pedal connecting pin.
Page 972 3-18 Clutch System Transmission / Drive Axle Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Remove Instrument panel lower left panel. Refer to 12.8.3.1 Instrument Panel Replacement. Note Before disconnecting the cylinder, release the clutch / brake fluid. Loose thread on the master cylinder drive dual wire hoop, Remove tank to the master cylinder oil inlet hose (1).
Page 973 Transmission / Drive Axle Clutch System 3-19 Installation Procedure: Install clutch master cylinder and tighten clutch master cylinder retaining nuts (1). Torque: 23 Nm (Metric) 17.0 lb-ft (US English) Install piston rod U-shaped clip to the clutch master cylinder piston rod, and tighten the clutch master cylinder piston rod and the piston rod U-shaped locking nut (20.
Page 974 3-20 Clutch System Transmission / Drive Axle During the hydraulic system bleeding, make sure the clutch / brake fluid level is between reservoir minimum (MIN) and maximum (MAX) marker. FE03-0211b Connect one end of the vinyl plastic hose to the bleeder nipple, the other end to a half full brake fluid container.
Page 975 Transmission / Drive Axle Clutch System 3-21 3.2.6.4 Clutch Pedal Free Travel Adjustment Measure clutch pedal travel. Press the clutch pedal to the end. Measure the distance between the start position and the end position. Adjust the clutch pedal travel. Release the locking nut and rotate the bolt.
Page 976 3-22 Clutch System Transmission / Drive Axle 3.2.6.5 Clutch Assembly Replacement Removal Procedure: Warning! Refer to "Battery Disconnection Warning" in "Warnings and Notices". Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection. Lift the vehicle. Remove the engine bottom shield. Refer to 12.10.1.7 Left and Right Engine Bottom Shield Replacement.
Page 977 Transmission / Drive Axle Clutch System 3-23 Disconnect the battery negative cable. Refer to 2.11.8.1 Battery Disconnection Lift the vehicle. Remove the engine bottom shield. Refer to 12.10.1.7 Left and Right Engine Bottom Shield Replacement. Remove transmission assembly. Refer 3.3.8.3 Transmission Assembly Replacement.
Page 978 3-24 Clutch System Transmission / Drive Axle Install the pilot bearing to the transmission input shaft. Install the transmission assembly. Install the engine bottom shield. Lower the vehicle. Connect the battery negative cable. FE13-0220b 3.2.6.7 Clutch Slave Cylinder Replacement Removal Procedure: Remove the bolts and Disconnect the tube from the clutch slave cylinder.
Page 979 Transmission / Drive Axle Clutch System 3-25 Installation Procedure: Connect the clutch slave cylinder to the transmission housing and tighten the bolts. Torque: 20 Nm (Metric) 14.8 lb-ft (US English) FE03-0223b Connect the clutch fluid tube to the clutch slave cylinder and tighten the bolts.
Page 980 3-26 Clutch System Transmission / Drive Axle 3.2.7 Special Tools and Equipment 3.2.7.1 Special Tools List Serial Illustration Tool Number Description Number GT301-017 Clutch Installation Tool FE01-2021b EC718/EC718RV EC715/EC715RV 10/2009...
Page 981: Manual Transmission
Transmission / Drive Axle Manual Transmission 3-27 3.3 Manual Transmission 3.3.1 Specifications 3.3.1.1 Fastener Tightening Specifications Specifications Applications Model Metric (Nm) US English (lb-ft) Manual-Shift Assembly Retaining Bolts M8 × 40 20-26 15-19 Engine and Transmission Connecting Bolts M12 × 50 96-110 71-81 (Upper)
Page 982 3-28 Manual Transmission Transmission / Drive Axle Applications Specifications 3rd Gear 1.25 4th Gear 0.909 5th Gear 0.78 Reverse 3.083 Main Reduction Ratio 4.308 ≥185 km/h (115 mph) Maximum Speed ≤12 s 0-100 km/h Acceleration Time ≤40% Max.Grade Ability Gear Oil Capacity 2.2 L Lubricant Comply with GB13895, API quality grade GL-4, Viscosity: SAE...
Page 983 Transmission / Drive Axle Manual Transmission 3-29 Specifications Size Parameters Metric (mm) US English (in × 10 Gear Cover Oil Seal (Upper) Surface To 0-19.685 0-0.5 The Seal Hole Surface EC718/EC718RV EC715/EC715RV 10/2009...
Page 984 3-30 Manual Transmission Transmission / Drive Axle 3.3.2 Description and Operation gear fork, and between the 5th/reverse gear fork and the 3rd/ 4th gear fork, there are interlock pin to prevent engaging two 3.3.2.1 Transmission System Operation gears at the same time, so as to ensure transmission work properly.
Page 985 Transmission / Drive Axle Manual Transmission 3-31 3.3.3 System Working Principle Reverse Gear Working Status: 3.3.3.1 Shifting Working Principle Because the engine output torque and speed range is relatively narrow, unable to meet the complex requirements of the vehicle under the conditions of a big range of traction and speed changes, the role of transmission is to expand the driving wheel torque and speed range by changing the transmission ratio, therefore to adapt to constantly changing conditions.
Page 986 3-32 Manual Transmission Transmission / Drive Axle 1st Gear Working Status: 2nd Gear Working Status: FE03-2004b FE03-2005b The shift control makes the 1st/2nd shift shaft and fork move The shift control makes the 1st/2nd shift shaft and fork move to the front end of the transmission. The 1st/2nd gear to the rear end of the transmission.
Page 987 Transmission / Drive Axle Manual Transmission 3-33 3rd Gear Working Status: 4th Gear Working Status: FE03-2006b FE03-2007b The shift control makes the 3rd/4th shift shaft and fork move to The shift control makes the 5th/Reverse shift shaft and fork the left side (front end) of the transmission. The 3rd/4th gear move to the left side (rear end) of the transmission.
Page 988 3-34 Manual Transmission Transmission / Drive Axle 5th Gear Working Status: FE03-2008b The shift control makes the 5th/Reverse shift shaft and fork move to the left side (front end) of the transmission. The 5th/ Reverse gear synchronizer and 5th gear are meshing. Main shaft receives the input torque from the 5th gear and outputs torque and speed opposite to the input shaft.
Page 989 Transmission / Drive Axle Manual Transmission 3-35 3.3.4 Component Locator 3.3.4.1 Transmission Assembly Location EC718/EC718RV EC715/EC715RV 10/2009...
Page 990 3-36 Manual Transmission Transmission / Drive Axle 3.3.4.2 Vehicle Speed Sensor, Reverse Switch Location Legend 1. Vehicle Speed Sensor 4. Transmission Fluid Filling Hole 2. Reversing Switch 3. Fluid Drain Hole EC718/EC718RV EC715/EC715RV 10/2009...
Page 991 Transmission / Drive Axle Manual Transmission 3-37 3.3.5 Disassemble View 3.3.5.1 Gear Components and Gear Box Disassemble View Legend 1. Transmission Front End Case 11. 4th Gear Bearing 2. Input Shaft Front Bearing 12. 4th Gear 3. Input Shaft 13. 4th Gear Locking Ring 4.
Page 992 3-38 Manual Transmission Transmission / Drive Axle 21. Main Shaft Front Bearing 31. 2nd Gear 22. Main Shaft 32. 3rd Gear Output Gear 23. 1st Gear Bearing 33. 3rd/4th Output Gear Bush 24. 1st Gear 34. 4th Gear Output Gear 25.
Page 993 Transmission / Drive Axle Manual Transmission 3-39 3. 3rd/4th Gear and 5th/Reverse Installation Sleeve 14. 5th/Reverse Gear Shaft Rear Snap Ring 4. Interlocking Pin 15. 5th Fork 5. 3rd/4th Gear Fork Shaft 16. 1st/2nd Gear Fork 6. 3rd/4th Gear Fork 17.
Page 994 3-40 Manual Transmission Transmission / Drive Axle 3.3.6 Schematic 3.3.6.1 Reverse Switch, Vehicle Speed Sensor Circuit Schematic Main Relay Vehicle Speed EF12 Sensor MAIN Rear Instrument Parking Cluster Radar Module SO40 Rear Parking Switch IF14 IP29 SO41 SO37 Left Right Rear Rear Battery...
Page 995 Transmission / Drive Axle Manual Transmission 3-41 3.3.7 Diagnostic Information and Procedures 3.3.7.1 Diagnosis Description Refer to3.3.2 Description and Operationget familiar with the contents of system functions and operation before start system diagnostic, so that it will help to determine the correct diagnostic steps, more importantly, it will also help to determine whether the customer described the situation is normal.
Page 996 3-42 Manual Transmission Transmission / Drive Axle b. Wheel Bearing Noise When the transmission is in neutral gear and the vehicle is sliding, the wheel bearing issue a continuous roar or friction sound. Since there is no wheel bearing pre-load force, when the wheels leave the ground the wheel bearing noise will be significantly reduced.
Page 997 Transmission / Drive Axle Manual Transmission 3-43 Operate the shift lever. Shifting force is20-30 N (4.5-6.7 LB). Transmission shift control travel should meet the range P Shift Lever Working Status shown in the graphic. Repair or replace worn transmission shift 1st,3rd,5th Gear Position control assembly or the fork.
Page 998 3-44 Manual Transmission Transmission / Drive Axle Check transmission shift control cable movement. Step 4 Disconnect cable between the shift lever and the transmission control cable connection. Check whether the transmission control cable is difficult to stretch or broken. Replace the transmission shift control cable. Replace the shift lever.
Page 999 Transmission / Drive Axle Manual Transmission 3-45 Symptoms Suspected Parts Refer to 3.3.8.4 Shift Control Assembly 4. Shift Control Assembly Replacement,3.3.8.5 Shift Control Assembly Disassemble and Assemble. 5. Shift Fork and Locking Mechanism 3.3.8.6 Shift Shaft Replacement. Diagnostic Steps: Check the transmission and the engine mount. Step 1 When engine is running, is it jittering.
Page 1000 3-46 Manual Transmission Transmission / Drive Axle Is the gear self-locking nut installed correctly? Tighten or replace the gear self-locking nut. FE03-2023b Step 4 Check the shift control assembly. Remove the shift control assembly to check for wear and tear or deformation.
Page 1001 Transmission / Drive Axle Manual Transmission 3-47 2. Transmission Shift Control Cable 3.3.8.9 Shift Lever Replacement. 3.3.8.4 Shift Control Assembly 3. Shift Control Assembly Replacement,3.3.8.5 Shift Control Assembly Disassemble and Assemble. 3.3.8.3 Transmission Assembly Replacement,3.3.8.6 Shift Shaft 4. Shift Fork and The Lock Mechanism Replacement,3.3.8.7 Input Shaft...

This manual is also suitable for:

Ec715rv 2009 Ec718rv 2009 Ec715 2009

Geely EC718 2009 Workshop Manual

5 Main

Preface

Warnings

Vehicle Overview

1.1 Warnings and Notices.....................1-3

1.2 Vehicle Inspection.........................1-11

1.3 Lifting and Jacking the Vehicle......1-14

1.4 Maintenance..................................1-18

1.5 Service Information System..........1-26

............................................................1-66

1-2 Table of Contents

1.10 Noise, Vibration and Abnormal Sound

1.12 Special Tools ...............................1-71

1.11 Water Leaks................................1-69

11-2

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