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HAVAL 4S20 Repair Manual

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Machine Translated by Google
No.1 SUV brand in China
Engine 4S20
Repair Guide

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Summary of Contents for HAVAL 4S20

  • Page 1 Machine Translated by Google No.1 SUV brand in China Engine 4S20 Repair Guide...
  • Page 2 Machine Translated by Google...
  • Page 3 Machine Translated by Google Maintenance and repair manual 4C20 Petrol engine Editorial staff of the HAVAL Motor Technology Research Center...
  • Page 4 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Introduction This Service and Repair Manual provides general specifications, instructions for troubleshooting, maintenance, assembly, disassembly, adjustment, repair of the 4C20 Turbocharged Gasoline Direct Injection Engine, and other information intended for technical specialists and employees of service centers.
  • Page 5 Foreword The 4C20 gasoline engine is a proprietary design of HAVAL Company Limited. This unit is equipped with a direct fuel injection system and a turbocharger, as well as an electronic control system, thanks to which it adequately competes in modern world markets. The new engine features compact size, light weight, low noise level, excellent dynamics, high power, low fuel consumption, making it an ideal SUV powertrain.
  • Page 6 Machine Translated by Google...

  • Page 7: Table Of Contents

    Machine Translated by Google CONTENT Chapter I. Introduction ........................1 Section I. Terms of Use of this Manual ..............1 Section II. Markings ....................... 3 Chapter II. Technical information about the engine................ 4 Section I Main Specifications ................4 Section II Tightening torques for threaded connections ..........
  • Page 8 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Chapter IX. Lubrication system ....................47 Section I. Oil line ..................47 Section II. Engine oil....................48 Section III. Sump, oil receiver and oil pump ..........51 Section IV. Oil cooler and oil filter ..............56 Chapter X.

  • Page 9: Chapter I. Introduction

    Machine Translated by Google Chapter I. Introduction Chapter I. Introduction Section I. Terms of Use of this Manual 1. Alphabetical index The alphabetical index is intended to make it easier to find information in this manual. For the convenience of finding information, the title of the chapter is indicated in the footer of each odd page. 2.
  • Page 10 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (a) The repair procedure is described in the following sequence: (1) The diagram shows what needs to be done and where. (2) The section required for repair is determined by the title of the work order. (3) It provides information on how to do the job and other technical information.

  • Page 11: Markings

    Machine Translated by Google Chapter I. Introduction 6. Units of measure Name Name Name Symbol Symbol Symbol units units units Watch Megahertz Kilohertz Minutes Milliamp Megaohm Mÿ Second With °C kiloom kOhm Hertz Degree Celsius Liter Milliliter Decibel Volt Newton Kilometer Watt N•m...

  • Page 12: Chapter Ii. Technical Information About The Engine

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Chapter II. Technical information about the engine Section I Main Specifications Name Specifications 4C20 Model Gasoline, four-stroke, liquid-cooled, in-line, direct injection, turbocharged, 16-valve, double overhead camshafts, variable valve timing on intake and exhaust, two balancer Type shafts Number of cylinders Bore...

  • Page 13: Section Ii Tightening Torques For Threaded Connections

    Machine Translated by Google Chapter II. Technical information about the engine Section II Tightening torques for threaded connections Restrictions on Component name Tightening torques 20±1.6 Nm First stage Connecting rod bolt Second Rotate 120°±2° 150±3 Nm stage First Crankshaft pulley bolt 150°±2°...

  • Page 14: Chapter Iv. Engine Attachment

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Chapter III. Frequency of checks and service intervals 1. To ensure proper operation of the 4C20 gasoline engine, the prescribed fic inspections and maintenance/replacement parts. 2. Below is the maintenance schedule for the 4C20 turbocharged gasoline engine: ÿ...

  • Page 15: Section I. Engine Attachment Layout

    Machine Translated by Google Chapter IV. Engine attachments Chapter IV. Engine Attachments Section I. Engine Attachment Layout 1 - V-ribbed belt 2 - Dust cover 7 - Power steering pump 8 - Generator for idler pulley 3 - Attachment drive belt tensioner 4 - Guide pulley II 5 - Starter 6 - Air conditioning compressor...

  • Page 16: Section Iii. Generator

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section II. V-ribbed belt Note: ÿ When removing the V-ribbed belt, mark the direction of rotation with chalk. Installing the belt in the reverse direction may damage the belt. ÿ Do not allow the V-ribbed belt to come into contact with engine oil or coolant.

  • Page 17: Section Iv. Air Conditioning Compressor

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section IV. Air conditioning compressor Disassembly 1. Removing the V-ribbed belt (a) Set the 12.5mm torque wrench to point A, turn the tensioner clockwise to the end position (when viewed from the front of the engine), and remove the V-ribbed belt.

  • Page 18: Section V Idler Pulley And Engine Attachment Drive Belt Tensioner

    Machine Translated by Google Chapter IV. Engine attachments Section V Idler Pulley and Engine Attachment Drive Belt Tensioner Disassembly 1. Removing the V-ribbed belt (a) Set the 12.5mm torque wrench to point A, turn the tensioner clockwise to the end position (when viewed from the front of the engine), and remove the V- ribbed belt.

  • Page 19: Section Vi. Power Steering Pump

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section VI. Power steering pump Disassembly 1. Removing the V-ribbed belt (a) Set the 12.5mm torque wrench to point A, turn the tensioner clockwise to the end position (when viewed from the front of the engine), and remove the V- ribbed belt.

  • Page 20: Section Vii. Starter

    Machine Translated by Google Chapter IV. Engine attachments Section VII. Starter Disassembly 1. Removing the starter (a) Remove the 2 bolts and remove the starter. ÿ Tightening torque: 50±2 Nm. Examination 2. Starter check (a) Check the starter drive gear for wear. If there are signs of wear, the starter must be replaced.

  • Page 21: Section Viii. Bracket For Fastening The Front Support And Branch Pipe Of The Forced Crankcase Ventilation System

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section VIII. Bracket for fastening the front support and branch pipe of the forced crankcase ventilation system Disassembly (b) Remove turbocharger and exhaust manifold 4. Removing the front support bracket (a) Remove the 3 bolts on the cylinder block and remove the left front support bracket.

  • Page 22: Chapter V. Turbocharging System

    Machine Translated by Google Chapter V. Turbocharging System Chapter V. Turbocharging System Section I. Layout of the turbocharging system 1 - Inlet pipe of the turbo cooling system 7 - Section II of the outlet pipeline of the turbocharger cooling system supercharger 2 - Bolt fitting of the inlet / outlet pipe of the turbocharger 8 - Outlet hose of the turbocharger cooling system II...
  • Page 23 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 12 - Turbocharger Oil Inlet Pipe 13 - Turbocharger Oil Inlet Pipe Bolt 14 - Turbocharger Inlet Gasket 15 - Turbocharger Outlet Gasket 16 - Turbocharger Mounting Bracket Adapter Gasket 17 - Turbocharger Mounting Bracket 18 - Turbocharger Wastegate Connecting Hose 19 - Control Hose boost pressure control valve (TCV) 20 - Turbocharger control valve 21 - Turbocharger control valve 22 -...

  • Page 24: Section Ii. Turbocharger

    Machine Translated by Google Chapter V. Turbocharging System Section II. Turbocharger Disassembly Attention: (a) Before disassembling the turbocharger, drain the engine oil and coolant 1. Removing the exhaust manifold heat shield (a) Remove the 3 bolts and remove the heat shield you start manifold.
  • Page 25 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 4. Removing the inlet pipe of the cooling system of the supercharger tour (a) Remove the bolt (A) and the 2 inlet and outlet pipe union bolts (B), and remove the turbocharger. Clue: ÿ...
  • Page 26 Machine Translated by Google Chapter V. Turbocharging System 7. Removing the turbocharger (a) Remove the 3 nuts and remove the turbocharger from the gasket which from the exhaust manifold. Note: (b) After removing the turbocharger inlet gasket body must be replaced. ÿ...
  • Page 27 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 12. Installation of the supply pipe of the cooling system turbocharger (a) Using the nipple bolts (A and B), fix the turbocharger inlet pipe to the cylinder block. ÿ Bolt A. Tightening torque: 10±1 Nm. ÿ...
  • Page 28 Machine Translated by Google Chapter V. Turbocharging System 15. Installation of the exhaust manifold and turbocharger (a) Install the connecting stud to the turbocharger. ÿ Tightening torque: 30±2 Nm. (b) Install the turbocharger inlet gasket and turbocharger to the exhaust manifold and secure with nuts.
  • Page 29 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (b) Install the turbocharger oil outlet pipe with gasket and secure with bolts (shown by arrows). ÿ Tightening torque: 10±1 Nm. Note: (c) After removing the oil outlet pipe gasket, tour blower needs to be replaced.

  • Page 30: Chapter Vi. Inlet And Outlet Systems

    Machine Translated by Google Chapter VI. Intake and exhaust systems Chapter VI. Intake and exhaust systems Section I. Intake system 1 - Intake manifold 2 - Intake manifold gasket 3 - Intake manifold support 4 - Intake manifold mounting bracket...
  • Page 31 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Disassembly 1. Turn out a bolt (it is shown by an arrow) 2. Removing the forced ventilation hose crankcase (a) Loosen the clamp and remove the hose of the forced crankcase ventilation. 3.
  • Page 32 Machine Translated by Google Chapter VI. Intake and exhaust systems 5. Removing the intake manifold (a) Remove 5 screws and 2 nuts, and remove the intake manifold torus Note: ÿ Cover the resulting hole in the engine in the hut zhanie hit foreign objects.
  • Page 33 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Assembly 9. Assembly of the intake manifold (a) Check the condition of the intake manifold gasket. (b) Do not install the intake manifold without masonry. Clue: ÿ The illustration shows the protection against misalignment. novki.

  • Page 34: Section Ii. Exhaust System

    Machine Translated by Google Chapter VI. Intake and exhaust systems Section II. exhaust system 1 - Exhaust manifold 2 - Exhaust manifold pressure block 3 - Threaded stud II for fastening the exhaust manifold 4 - Nut fastening the exhaust manifold 5 - Heat shield for the exhaust manifold 6 - Gasket of the exhaust manifold 7 - Threaded stud I for fastening the exhaust manifold...
  • Page 35 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Disassembly Attention: ÿ Perform disassembly of the system until the components have completely cooled down. Nentov is prohibited! 1. Removing the exhaust manifold heat shield (a) Remove the 3 bolts and remove the heat shield you start manifold.
  • Page 36 Machine Translated by Google Chapter VI. Intake and exhaust systems Examination 5. Surface damage (a) Check the exhaust manifold for cracks or deformation, and scratches on the mating surface. Installation 6. Tightening the threaded stud (if the stud was removed during disassembly) ÿ...
  • Page 37 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 9. Installing the exhaust manifold (a) Install the exhaust manifold to the cylinder head and secure with 5 new nuts. ÿ Pre-tightening torque: 15±2 Nm. ÿ Tightening torque: 22±2 Nm. 10. Installing the exhaust manifold heat shield Torah (a) Install the heat shield to the exhaust manifold mounting lug and secure with 3 bolts.

  • Page 38: Chapter Vii. Supply System

    Machine Translated by Google Chapter VII. Supply system Chapter VII. Supply system Section I. Power System Layout 1 - Fuel rail 2 - Fuel 7 - Gasket support of the fuel pump 8 - Noise- supply pipe 3 - High pressure fuel pump insulating casing of the fuel pump 4 - Fuel pump drive cam 5 - Vacuum pump 6 - high pressure...

  • Page 39: Section Ii. Supply System

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section II. Supply system Disassembly 1. Notes: (a) Before carrying out work, disconnect the wires from the battery to avoid accidental short circuits in circuit, which may cause sparks and ignition fuel vapor injury;...
  • Page 40 Machine Translated by Google Chapter VII. Supply system 5. Removing the high pressure fuel pump. (a) Remove the soundproof cover of the fuel pump juice pressure. (b) Remove the 2 bolts and remove the high pressure fuel pump pressure. 6. Removing the vacuum pump (a) Remove the 2 bolts and remove the vacuum pump.
  • Page 41 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Examination 9. Checking the vacuum pump (a) Check the vacuum pump O-ring for signs of rubber aging, deformation and damage, and replace if necessary. (b) Make sure the O-ring of the vacuum pump is installed correctly.
  • Page 42 Machine Translated by Google Chapter VII. Supply system 11. Installing the high pressure fuel pump (a) Check the O-ring for damage and replace if necessary. (b) Apply a thin layer of engine oil to the surface of the actuator cam (A) and the fuel oil O-ring. high pressure pump.
  • Page 43 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 14. Installing the fuel rail with injectors (a) Check that all fuel injector retainers are installed. (b) Install the fuel rail with injectors to the cylinder head. ÿ Tightening torque: 22±2 Nm. Note: ÿ...

  • Page 44: Chapter Viii. Cooling System

    Machine Translated by Google Chapter VIII. Cooling system Chapter VIII. Cooling system Section I. Coolant Examination 1. Checking the coolant level in the expansion reservoir of the cooling system. (a) When the engine is cold, the coolant level should be between the "MIN"...

  • Page 45: Section Ii. Coolant Pump

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section II. coolant pump 1 — The case of the pump of system of cooling 6 — a casing of a belt of a drive of the pump of system of cooling 2 —...
  • Page 46 Machine Translated by Google Chapter VIII. Cooling system Disassembly 1. Removing the electric coolant pump (a) Loosen the 3 clamps (1, 2 and 3) and remove the electric pump inlet hose. (b) Remove the 3 bolts (A, B and C) and remove the electrical cooling system pump.
  • Page 47 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 6. Removing the balance shaft seal (a) Pry off the balance shaft oil seal with a screwdriver (b) Remove the oil seal. 7. Removing the coolant pump assembly (a) Remove the 5 bolts and remove the coolant pump. 8.
  • Page 48 Machine Translated by Google Chapter VIII. Cooling system Assembly 12. Checking the correct connection of the system pump case cooling. Note: ÿ Disassembly of the coolant pump and pump housing for prohibited. 13. Coolant pump installation (a) Install the water pump housing gasket niya.
  • Page 49 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 15. Installing the coolant pump drive belt (a) Install a new coolant pump drive belt on the pump pulley and pump drive gear. (b) Fix the coolant pump drive pulley to the balance shaft with a bolt. ÿ...

  • Page 50: Section Iii. Thermostat

    Machine Translated by Google Chapter VIII. Cooling system Section III. Thermostat Disassembly 1. Coolant drain 2. Removing the thermostat cover (a) Remove the 2 screws and remove the thermostat cover. 3. Removing the thermostat (a) Remove the thermostat from the coolant pump housing niya.
  • Page 51 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (d) Check thermostat valve travel. (e) Valve travel: 8mm minimum at 101°C coolant temperature. (e) Check if the valve is closed when the coolant temperature is below the opening start temperature (88°C). (g) If the valve does not close at the specified temperature, the thermostat must be replaced.

  • Page 52: Section Iv. Hot Coolant Outlet Pipe

    Machine Translated by Google Chapter VIII. Cooling system Section IV. Hot coolant outlet pipe Disassembly 1. Removing the inlet hose of the electric coolant pump (a) Loosen the 2 clamps and remove the electrical supply hose pump. 2. Removing the hot coolant outlet pipe bones (a) Loosen the 2 bolts and remove the hot coolant outlet pipe giving liquid.
  • Page 53 Machine Translated by Google...

  • Page 54: Chapter Ix. Lubrication System

    Machine Translated by Google Chapter IX. Lubrication system Chapter IX. Lubrication system Section I. Oil line Main oil line of the cylinder block The central oil line of the block of cylinders Oil filter Oil line of a head of the block of cylinders Oil supply channel to the main bearing oil cooler...

  • Page 55: Section Ii. Engine Oil

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section II. Engine oil Examination 1. Checking the correctness of the engine oil (a) Check engine oil specification and viscosity for ambient temperature. Change oil if necessary. 2. Checking the engine oil level (a) 15 to 20 minutes after stopping a warm engine, the engine oil level should be between the maximum and minimum marks.
  • Page 56 Machine Translated by Google Chapter IX. Lubrication system 4. Installing the engine oil pressure sensor (a) Apply Loctite 243 anaerobic thread locker or equivalent to 2-3 threads of the engine oil pressure sensor. (b) Install the engine oil pressure sensor on the qi block lindrow and wrap.
  • Page 57 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 8. Preparation for filling with new engine oil (a) Clean the drain plug, install a new gasket, and screw the plug into the oil pan. ÿ Tightening torque: 25±2 Nm. Note: ÿ...

  • Page 58: Section Iii. Sump, Oil Receiver And Oil Pump

    Machine Translated by Google Chapter IX. Lubrication system Section III. Sump, oil receiver and oil pump 1 - Upper part of the oil pan 2 - 4 - Drain plug 5 - Oil receiver 6 Lower part of the oil pan 3 - - Oil pump Combined drain plug gasket...
  • Page 59 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Disassembly Clue: ÿ Before removing the oil pan, make sure that the engine oil is completely drained from the engine lubrication channels. 1. Removing the drain plug (a) Remove the drain plug and completely drain the engine oil. Clue: ÿ...
  • Page 60 Machine Translated by Google Chapter IX. Lubrication system 4. Removing the oil pump (a) Remove the 3 bolts (A and B) and remove the oil pump. 5. Removing the upper part of the oil pan (a) Remove the 13 bolts in reverse order as shown in the figure, and remove the upper part of the oil pan.
  • Page 61 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (b) Apply sealant to the top flange of the oil pallet (1) Carefully apply sealant to the indicated connection points of the upper oil pan and cylinder block. The thickness of the sealant layer is 2-3 mm. ÿ...
  • Page 62 Machine Translated by Google Chapter IX. Lubrication system 12. Installation of the lower part of the oil pan (a) Remove sealant. (1) Remove old sealant from mating surfaces. (2) Remove the old gasket from threads and hole edges. stiy for bolts. Note: ÿ...

  • Page 63: Section Iv. Oil Cooler And Oil Filter

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section IV. Oil cooler and oil filter 1 - Oil cooler mounting bracket 2 - Oil filter 3 - 7 - Oil cooler mounting bolt 8 - Oil cooler Upper alternator connecting pipe 9 - Lower generator mounting mounting bushing 4 - Oil cooler bracket bushing 10 - Power steering pump mounting...
  • Page 64 Machine Translated by Google Chapter IX. Lubrication system Disassembly Tip: ÿ Depressurize the fuel lines before removing the oil cooler. 1. Removing the oil cooler bracket (a) Remove the bolts in the reverse order to that shown in the figure. (b) Move the oil cooler bracket towards the front engine parts and remove it.
  • Page 65 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Examination 5. Gasket check. (a) Check the condition of the oil cooler gaskets and the oil cooler bracket. If there is damage or deformation, the gasket must be replaced. Assembly 6. Oil cooler installation (a) Install a new gasket (B) of the oil cooler bracket body.
  • Page 66 Machine Translated by Google Chapter IX. Lubrication system (c) Fix the oil cooler bracket (1) Connect the oil cooler bracket to the housing on cooling system pump. (2) Install the screw (4). (3) Install the remaining bolts in 2 stages in the sequence shown in the figure.
  • Page 67 Machine Translated by Google...

  • Page 68: Chapter X. Cylinder Head

    Machine Translated by Google Chapter X. Cylinder head Chapter X. Cylinder head Section I. Cylinder head cover 1 - Cylinder head cover 2 - Ball head 6 - Oil filler cap 7 - Positive crankcase bolt. 3 - Spark plug 4 - Ignition ventilation valve 8 - Cylinder head cover gasket 9 coil 5 - Combination retainer...
  • Page 69 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Disassembly 1. Removal of the pipeline of the forced ventilation system of the crankcase (a) Loosen the 4 clamps and remove the tube and hose of the system when forced crankcase ventilation. 2.
  • Page 70 Machine Translated by Google Chapter X. Cylinder Head (c) Remove the valve of the forced ventilation system of the car tera (1) Release the 4 retainers and remove the system valve forced crankcase ventilation. Clue: ÿ Do not remove valve unless necessary. (d) Remove the cylinder head cover bolts firewood.
  • Page 71 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Installation 5. Installing the cylinder head cover (a) Do not install the cylinder head cover and ignition coils without gaskets (A and B). (b) Inspect the gaskets. In the presence of damage or signs of aging, the gasket must be replaced.

  • Page 72: Section Ii. Cylinder Head

    Machine Translated by Google Chapter X. Cylinder head Section II. cylinder head 1 - Cylinder head 8 - Hot coolant outlet pipe 2 — a cover of bearings of a camshaft 9 - Connecting branch pipe of the outlet oil tube 3 —...
  • Page 73 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Disassembly Note: ÿ Do not allow the piston to be at top dead center while the camshaft is rotating. Risk of damage to valves and/or piston head! ÿ When replacing the cylinder head or cylinder head gasket, the coolant must be replacement.
  • Page 74 Machine Translated by Google Chapter X. Cylinder Head 5. Removing the intake/exhaust camshafts valves Note: ÿ Do not attempt to remove the camshaft with tools or force. This may cause damage to work surfaces. 6. Removing the valve train (a) See Section III. Valve mechanism, page 71. 7.
  • Page 75 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (b) Clean the combustion chamber (1) Remove carbon deposits with a rotating plastic brushes. 10. Checking the plane of the cylinder head (a) Using a straightedge and feeler gauges, check the flatness of the lower and upper flange surfaces of the cylinder head in six directions.
  • Page 76 Machine Translated by Google Chapter X. Cylinder Head (c) Remove any remaining oil from both sides of the cylinder cylinder head cover head gasket. (d) Install the cylinder head. (e) Apply Loctite 5900H to the surface of the cylinder block, cylinder head and cylinder head gasket.
  • Page 77 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (c) Tightening sequence: (1) Bolts 23-1. (2) Bolts 24-29. (d) Tightening torque: ÿ Bolts 1-3: 22±2 N•m ÿ Bolts 4-29: 10±1 N•m 17. Installation of the outlet oil pipe of the cylinder head cover (a) Install the cylinder head cover oil outlet pipe (B) to the appropriate positions on the bearing cap and secure with bolts (A).

  • Page 78: Section Iii. Valve Mechanism

    Machine Translated by Google Chapter X. Cylinder head Section III. valve mechanism 1 - Exhaust valve spring 2 - Valve 6 - Valve actuation lever 7 - clearance hydraulic compensator 3 - Oil Inlet valve spring 8 - Exhaust scraper cap 4 - Valve spring valve 9 - Inlet valve plate 5 - Valve crackers...
  • Page 79 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Disassembly Clue: ÿ Removed parts should be laid out in separate groups mi, so as not to confuse them during assembly. ÿ Apply a small amount of engine oil to the friction surfaces of each part.
  • Page 80 Machine Translated by Google Chapter X. Cylinder head 5. Valve removal (a) Remove the valve from the combustion chamber side. 6. Removing valve stem seals (a) Clamp the metal ring on the bottom of the oil seal. Rotate the ring and pull it out to remove the oil seal.
  • Page 81 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (d) Check valve guide (1) Measure the inside diameter of the guide bush valve with an internal micrometer. ÿ Limit values: 6.000-6.065 mm (2) Replace the valve guide if the actual diameter is out of range. 8.
  • Page 82 Machine Translated by Google Chapter X. Cylinder head 11. Valve spring installation (a) Install valve spring (B) with poppet (A). Clue: ÿ The middle three coils of the exhaust valve spring are blue painted. ÿ Swap the springs of the intake and exhaust valves gentlemen is prohibited.
  • Page 83 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Valve clearance hydraulic compensator repair Note: ÿ Avoid contamination of the valve lifter clearance from dust and other contaminants. ÿ Do not disassemble the hydraulic valve clearance adjuster. ÿ Use to clean the valve lifter gap only clean engine oil.
  • Page 84 Machine Translated by Google Chapter X. Cylinder head 5. Place the valve lash adjuster in container B and use 0.5mm diameter steel wire and slowly push the steel ball 5-10 times to drive the plunger. Continue the above steps until the plunger moves smoothly. This will help clean the high pressure chamber of the hydraulic lifter.
  • Page 85 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 10. Hold the valve clearance adjuster in a vertical position to prevent oil from escaping. Keep dust and other contaminants out of the hydraulic compensator. Fit the hydraulic compensator to the engine as soon as possible.

  • Page 86: Section Iv. Timing Chain

    Machine Translated by Google Chapter X. Cylinder head Section IV. Timing chain 1 - VVT intake valve phase shifter 2 - VVT intake valve 5 - Timing chain tensioner mounting bolt 6 - Timing phase shifter bolt 3 - VVT exhaust valve phase chain tensioner 7 - Timing chain 8 - shifter 4 - Timing Upper timing chain...
  • Page 87 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 1. Alignment marks (a) Check and set the VVT phase shifter marks to the position shown in the figure. This will prevent the pistons from colliding with the valves as the valve rotates. crankshaft after replacing the chain.
  • Page 88 Machine Translated by Google Chapter X. Cylinder head 5. Remove the timing chain (a) Fix the hex part of the camshaft with a wrench, and rotate the camshaft counterclockwise to loosen the tension in the chain between the VVT phase shifters. (b) Remove the timing chain.
  • Page 89 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 8. Timing chain installation (a) Install the timing chain to the VVT exhaust valve camshaft and crankshaft sprocket. shaft, respectively. Alignment mark on the timing chain 9. Installing the drive chain tensioner and damper timing (a) Install the 2 bolts (A) of the drive chain guide Timing.

  • Page 90: Section V. Oil Pump Drive Chain And Drive Chain Balancer Shafts

    Machine Translated by Google Chapter X. Cylinder head Section V. Oil Pump Drive Chain and Balance Shaft Drive Chain 1 - Balancer shaft drive chain guide 2 - Timing chain guide 7 - Bolt for fastening the timing chain tensioner 8 - Balancer mounting bolt 3 - Balancer shaft drive chain 4 - Oil pump drive shaft drive chain tensioner 9 - Upper balancer drive chain chain tensioner 5 - Oil drive chain tensioner...
  • Page 91 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Disassembly 1. Removing the oil pump drive chain (a) Press the plunger of the oil pump drive chain tensioner and secure with the pin (B). (b) Loosen the bolt (A) and remove the tensioner. (c) Remove the oil pump drive chain 2.
  • Page 92 Machine Translated by Google Chapter X. Cylinder head 5. Checking the drive of the tensioner of the drive chain of the balance shafts (a) Check if the plunger rises automatically and the same smoothness of movement and the absence of jamming of the plunger when pressed with a finger.
  • Page 93 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 9. Installing the oil pump drive chain (a) Fit the oil pump drive chain to the gears. crankshaft and oil pump. 10. Installing the oil pump drive chain tensioner (a) Install the oil pump drive chain tensioner and secure with the bolt (C), remove the pin (B), and insert one end of the spring (A) into the groove on the top of the oil pan.

  • Page 94: Chapter Xi. Cylinder Block

    Machine Translated by Google Chapter XI. Cylinder block Chapter XI. Cylinder block Section I. Piston connecting rod 1 - Piston connecting rod 6 - First compression ring 7 - Second assembly 2 - Piston connecting rod compression ring 8 - Oil scraper ring 9 - Piston 10 - Connecting bolt 3 - Connecting rod 4 - Piston pin circlip 5 -...
  • Page 95 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Disassembly 1. Removing the connecting rod bolts and connecting rod caps bearings. (a) Loosen the 4 bolts and remove the connecting rod bearing caps piston nics 1 and 4 cylinders. (b) Rotate the crankshaft 180° and remove the cylinder 2 and 3 piston connecting rod bearing caps.
  • Page 96 Machine Translated by Google Chapter XI. Cylinder block 6. Remove the pistons, number them according to the number cylinder and put separately. Examination 7. Piston pin check (a) Insert the piston pin into the fitting hole of the upper end of the connecting rod.
  • Page 97 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 10. Check piston rings and grooves (a) Measure the clearance between the piston ring and the piston ring groove with a feeler gauge. Piston ring First Rated value (mm): compression 0.040-0.080 mm ring Second compression 0.035-0.080 mm...
  • Page 98 Machine Translated by Google Chapter XI. Cylinder block (c) Grouping of connecting rod bearings: Color/group Reference value (mm) Yellow/3 1.393-1.399 mm Blue/2 1.388-1.394 mm Red/1 1.383-1.389 mm Paint mark depending on the groups (d) Select the connecting rod bearing shell according to the bore diameter of the connecting rod bottom head and crankpin.
  • Page 99 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (c) The oil scraper and compression ring locks are installed at Lock an angle of 120° relative to each other. oil scraper Clue: rings ÿ After assembly, the piston rings must move freely in the groove, without jamming, with clearances as required.
  • Page 100 Machine Translated by Google Chapter XI. Cylinder block (b) Apply a sufficient amount of engine oil to the cylinder wall, piston and crankpin shaft. (c) Install the connecting rod to the appropriate cylinder. (d) Install the piston with the front mark towards the front of the engine with a piston ring compressor.

  • Page 101: Section Ii. Rear Crankshaft Oil Seal

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section II. Rear crankshaft oil seal 1 - Cover of the mounting hole of the torque converter matora 2 - Gearbox mounting guide bushing 3 - Crankshaft rear oil seal 4 - Gearbox adapter plate...
  • Page 102 Machine Translated by Google Chapter XI. Cylinder block Disassembly 1. Remove the flywheel from the back of the crankshaft (a) Fix the flywheel with special tools. bleeding; (b) Loosen and remove the flywheel mounting bolt. Note: ÿ Removed flywheel bolt must be replaced. 2.
  • Page 103 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (c) Apply sealant to the places indicated in the figure. Advice: ÿ The width of the sealant bead must not exceed the specified value. Otherwise, excess sealant will get into the oil pan, which will lead to clogging of the oil receiver screen.

  • Page 104: Section Iii. Timing Mechanism Cover (Grm)

    Machine Translated by Google Chapter XI. Cylinder block Section III. Timing cover (GRM) 1 - timing cover 2 - oil dipstick 3 - oil dipstick pipe 4 - front crankshaft oil seal 5 - soundproof casing of the timing cover...
  • Page 105 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Disassembly 1. Remove the crankshaft pulley (a) Fix the flywheel Note: ÿ Do not apply compressive or tensile force to crankshaft pulley when removing it. (b) Remove the V-ribbed belt; (c) Loosen the crankshaft pulley bolt and remove those pulley.
  • Page 106 Machine Translated by Google Chapter XI. Cylinder block 5. Remove the timing cover (a) Remove all bolts and nuts in succession, starting from the outermost ones and ending with the central ones; (b) Insert a spatula between the timing cover and cylinder head (and cylinder block).
  • Page 107 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 9. Install the timing cover ma (timing) (a) Insert the timing cover, install it on the locating pins (shown by the arrow in the figure); (b) Tighten the cover bolts to the cylinder block and cylinder head; (c) Tighten the bolts in sequence from the center bolts to the outer bolts.

  • Page 108: Crankshaft

    Machine Translated by Google Chapter XI. Cylinder block Section IV. Crankshaft 1 - cylinder block 2 - 15 - flywheel mounting bolt 16 - flywheel 17 - cylinder block horizontal pinch bolt 3 - fifth main bearing crankshaft 18 - cap 4 - fourth main bearing cap 5 - third main crankshaft position sensor drive disk bearing cap 6 - second main bearing cap 7 - first...
  • Page 109 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Disassembly 1. Remove bushing Advice: ÿ The removed bushing O-ring must be replaced change. 2. Remove the main bearing cap (a) Remove the 10 main bearing cap bolts and the 6 cylinder block horizontal pinch bolts securing the main bearing caps;...
  • Page 110 Machine Translated by Google Chapter XI. Cylinder block 5. Remove the sprocket from the crankshaft (a) If the crankshaft sprocket cannot be removed by hand, use two screwdrivers as levers on both sides at the same time. Advice: ÿ Wrap the screwdrivers with protective material to prevent damage to the crankshaft or sprocket.
  • Page 111 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 9. Crankshaft (a) Measure the axial free play of the crankshaft: (1) Fix the dial gauge with bracket to the cylinder block with a bolt so that the dial gauge foot touches the crank web; (2) Press the crankshaft against the indicator and install it at zero;...
  • Page 112 Machine Translated by Google Chapter XI. Cylinder block (b) Crankshaft journal diameter group number Crankpin Group number of knocked out on the crankshaft Diameter Group the diameter of the Number main journal No. 1 No. 2 1 No. 3 No. 5 No.
  • Page 113 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 14. Hub Assembly (a) Replace the O-ring with a new one; (b) Place the seal (A) on the bottom of the bushing end; (c) Install bushing (B) on crankshaft nose. Note: ÿ...
  • Page 114 Machine Translated by Google Chapter XI. Cylinder block 17. Install the crankshaft (a) Crankshaft with date dial installed install the crankshaft position gauge into the holes of the main bearings of the cylinder block (the small toe of the crankshaft must be in front of the cylinder block);...

  • Page 115: Section V. Balance Shaft

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section V. Balance Shaft Disassembly 1. Remove the balance shaft from the exhaust side (a) Loosen one bolt and remove the balance shaft from release sides; (b) Remove the balance shaft bushing from the side you start.
  • Page 116 Machine Translated by Google Chapter XI. Cylinder block 4. Remove the balance shaft from the intake side (a) Loosen the bolt and remove the balance shaft from the side us inlet. Assembly 5. Install the balance shaft bushing (a) Install the balance shaft bushing into the balance shaft hole of the cylinder block on the side release.
  • Page 117 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 8. Install the intermediate gear (a) Mark the tops of the teeth of the middle gear with a marker. (b) After installing the middle gear, the mark on the balance shaft should be between the marked teeth of the gear (c) Install the balance shaft idle gear into the cylinder block;...

  • Page 118: Chapter Xii. Engine Management System

    Machine Translated by Google Chapter XII. Engine management system Chapter XII. Engine management system Section I. Installing System Sensors 1. Installing the crankshaft position sensor (a) Apply a proper amount of lubricant to the O-ring sensor seal; ÿ Tightening torque: 8±2 Nm (b) Insert it by hand and rock it to the right and left.
  • Page 119 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 5. Install the fuel pressure sensor (a) Apply an anaerobic thread locking compound to the threads of the fuel pressure sensor. ÿ Anaerobic thread locking compound Loctite 243 is recommended. (b) Install the fuel pressure sensor to the fuel rail. ÿ...

  • Page 120: Section Ii. General Information About The System

    Machine Translated by Google Chapter XII. Engine management system Section II. General information about the system ÿ.ÿÿÿÿ Characteristics The MT92 engine management system is a system that uses the MT92 engine control unit. This unit is specifically designed to control gasoline direct injection engines and turbocharged engines through a range of sensors and actuators.
  • Page 121 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Description of system functions 1. Determining the position and speed of rotation of the crankshaft (a) The system allows you to determine the position and speed of rotation of the crankshaft through the use of a sensor drive disk 58 lobes, which is necessary to control the ignition and the initial injection moment fuel.
  • Page 122 Machine Translated by Google Chapter XII. Engine management system calculated temperature of the catalytic converter while the vehicle is in motion. The engine control unit calculates the temperature of the three-way catalytic converter based on the current engine parameters. If the design temperature exceeds the allowable temperature of the three-way catalytic converter, it is reduced by the electronic fuel injection system by enriching the fuel mixture, which protects the catalytic converter.

  • Page 123: Section Iii. Basic Control Algorithms

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section III. Basic control algorithms 1. Fuel system control algorithms (a) Fuel pump control algorithms (1) Fuel pump activation algorithm: • When the ignition switch is opened, the pump starts for 1.5 seconds and stops if no power is supplied. signals from the setting disk with 58 protrusions of the crankshaft position sensor.
  • Page 124 Machine Translated by Google Chapter XII. Engine management system 3. Ignition control algorithms (a) Ignition coil magnetization control; (b) The magnetization time of the ignition coil determines the energy of the ignition spark. If the magnetization is continued for too long, the coil may be damaged. If the magnetization is carried out too quickly, it may cause a fire. (c) Launch mode: (1) In start mode, the system sets a fixed ignition timing to ensure ignition of the working mixture in the cylinders to create a positive torque.
  • Page 125 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 4. Idle speed control algorithms (a) Idle air flow control allows the engine management system to maintain the desired engine speed at full throttle, to provide a smooth transition between closing and opening the throttle without stopping the engine, and to maintain speed when the engine load changes. (b) Idle RPM Calculation (1) Basic idle speed (2) Set basic idle speed based on coolant temperature...
  • Page 126 Machine Translated by Google Chapter XII. Engine management system 5. Detonation control algorithms (a) The knock control function is used to prevent possible knocking, optimize the vehicle's dynamic performance and reduce fuel consumption. The system can provide knock control independently in each engine cylinder; (b) Conditions under which the knock control system operates: (1) Engine knock sensors and knock control function are used.
  • Page 127 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 6. Control algorithms associated with the air conditioning system The engine control unit determines the input parameters of the air conditioning system and the readings of the evaporator temperature sensor, and also controls the state of the compressor clutch using the relay of the compressor clutch e / m.
  • Page 128 Machine Translated by Google Chapter XII. Engine management system (a) Operating conditions of the solenoid action of the canister purge valve: (1) To reduce the effect of fuel vapor entering the cylinders during normal engine operation, We must comply with the following conditions to activate the canister purge solenoid valve: •...
  • Page 129 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 11. Turbocharger control algorithms The task of turbocharger control is to regulate the boost pressure by controlling the bypass valve and the relief valve to control the amount of air entering the engine depending on the load. 12.

  • Page 130: Components Of The Electronic Control Unit

    Machine Translated by Google Chapter XII. Engine management system Section IV. Components of the electronic control unit Charge air pressure and temperature sensor 1. Appointment (a) Measurement of pressure and temperature at the inlet after the turbo supercharger. 2. Working parameters 1.
  • Page 131 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 3. Pin arrangement ÿ 1. "Mass" of the signal; ÿ 2. Temperature alarm; ÿ 3. Power supply, 5 V; ÿ 4. Air pressure output. 4. Operation and maintenance (a) When cleaning, be careful not to let the cleaning agent come into contact with means inside the sensor;...
  • Page 132 Machine Translated by Google Chapter XII. Engine management system Air pressure sensor in the intake manifold 1. Appointment (a) Intake manifold air pressure sensor used used to determine the current state of the engine in the pro the course of his work. (b) If the engine management system uses the measurements based on the ratio of speed and density air, the engine control unit calculates the volume...
  • Page 133 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 4. Pin arrangement ÿ 1. Supply voltage +5 V ÿ 2. Signal ground ÿ 3. Voltage signal output 5. Main faults: (a) Freezing, contamination or blockage of the sensitive element; (b) Open or short in transducer circuit inside dates chica.
  • Page 134 Machine Translated by Google Chapter XII. Engine management system Intake air temperature sensor 1. Appointment (a) It is one of the most important gauges of the engine management system. With its help, the current parameters of the engine at the inlet during its operation are determined.
  • Page 135 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 4. Operation and maintenance (a) Keep damp air out of the manifold, as well as condensate on the sensitive element of the sensor. 5. Troubleshooting (a) Remove the intake temperature sensor from the engine and use a standard digital multimeter to measure the resistance of the sensor.
  • Page 136 Machine Translated by Google Chapter XII. Engine management system Knock sensor 1. Appointment (a) The system uses a knock sensor based on frequency response analysis. To measure knocking, this sensor is installed in the part of the cylinder block that is most prone to knocking. Data from the knock sensor is sent to the engine control unit and used to control the ignition timing.
  • Page 137 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Upstream oxygen sensor (OSL model) 1. Appointment Delphi's OSL oxygen sensor uses a multi-layered ceramic element integrated into a flat plate as the main element, and a layer of zirconium dioxide as the active element. The device is a limited diffusion current sensor equipped with a solid measuring cell for measuring the oxygen concentration in exhaust gases over a wide range of parameters.
  • Page 138 Machine Translated by Google Chapter XII. Engine management system 4. Sensor connection diagram Contact color Pin number Pin description Injector signal Brown element "Mass" of the calibrated Yellow resistor "Negative" contact of the White heating element "Positive" contact Violet heating element Total weight"...
  • Page 139 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Downstream oxygen sensor 1. Appointment The oxygen sensor is an important component of a fuel management system operating in a closed loop control loop. It regulates and maintains the optimal composition of the working mixture to ensure optimal efficiency of the catalytic converter.
  • Page 140 Machine Translated by Google Chapter XII. Engine management system (c) Recommended operating conditions: 1. Exhaust gas temperature: 200– 850°C; 2. The level of impurities in the fuel must be below the following values: • Lead – 0.013 g/l • Phosphorus - 0.0012 g/l •...
  • Page 141 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Fuel rail with injectors 1. Appointment The main function of the fuel rail assembly with injectors of a direct injection engine is to distribute the fuel supplied by the injection pump to each cylinder at the required pressure so that the injected fuel mixes with air in the cylinder and combustion is ensured.
  • Page 142 Machine Translated by Google Chapter XII. Engine management system (b) Fuel pressure sensor 1. Working pressure range: 0-25MPa 2. Working temperature range: -40-140°C Input voltage: 5.0±0.25V 4. Output voltage range: 0.5-4.5V (c) Fuel injector specifications: 1. Operating temperature range: -30 to °C 2.
  • Page 143 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 3. Fault detection (a) Check if the fuel rail is subjected to permanent deformation due to incorrect assembly and operation, which may result in fuel leakage. (b) Check whether the injector O-ring is damaged or scratched due to incorrect assembly and operation, which may result in air and oil leakage.
  • Page 144 Machine Translated by Google Chapter XII. Engine management system 2. Features: 1. Working environment temperature range: -30-125°C; 2. System working pressure range: max. 15 MPa; 3. The range of the fuel pump safety valve: 19-22 MPa; 4. Fuel pump inlet pressure: 550 kPa; 5.
  • Page 145 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Electronic Throttle Body 1. Appointment (a) The electronic throttle control unit provides control of the amount of delivery air entering the engine. 2. Features: ÿ Electronic throttle control laziness. 3. Troubleshooting: (1) Throttle valve assembly fails due to excessive carbon deposits.
  • Page 146 Machine Translated by Google Chapter XII. Engine management system Throttle position sensor 1. Appointment (a) Throttle valve control requires a throttle position sensor to detect throttle position and condition. The voltage signal from the non-contact throttle position sensor is sent to the engine control unit, which processes the throttle position data in real time, taking into account operating parameters.
  • Page 147 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Camshaft position sensor 1. Appointment (a) The camshaft position sensor is a Hall effect sensor. It is installed close to the camshaft and acts in conjunction with a target disk mounted on the camshaft in a certain angular position.
  • Page 148 Machine Translated by Google Chapter XII. Engine management system crankshaft position sensor 1. Appointment (a) The crankshaft position sensor is an electromagnetic sensor mounted near the crankshaft and operates in conjunction with a 58-lobed target disk located on the crankshaft. As the crankshaft rotates, the protrusions of the disc move past the sensor.
  • Page 149 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Evaporative emission canister solenoid valve 1. Appointment (a) The engine control unit controls the amount of gasoline vapor that enters the intake manifold from the canister using the solenoid valve. (b) The engine control unit provides linear control of the output square wave duty cycle, valve capacity, and control square wave.

  • Page 150: Diagnosis System Car

    Machine Translated by Google Chapter XII. Engine management system Section V. Vehicle self-diagnosis system 1. Description of the vehicle self-diagnosis system (a) After the system is activated and the engine is started, the engine control unit provides real-time control of all system components to which it is connected.
  • Page 151 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 4. Table of fault codes (a) Table of fault codes for the Delphi MT 92 engine management system Unis code DTC Category Description of the fault code rightness P0533 High voltage in the air conditioning pressure sensor circuit Low voltage or open in the A/C pressure sensor circuit P0532 P0571...
  • Page 152 Machine Translated by Google Chapter XII. Engine management system Unis code DTC Category Description of the fault code rightness P0352 Cylinder #2 Ignition Circuit Malfunction P2138 Inconsistency in the readings of the accelerator pedal position sensors No. 1 and 2 P2123 High voltage in the accelerator pedal position sensor circuit No.
  • Page 153 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Unis code DTC Category Description of the fault code rightness P0507 Excessively high idle P0506 Excessively low idle U0426 Anti-theft system identification failure P0633 No data coming from anti-theft system U0167 No response from anti-theft system P2229 Short circuit in a chain of the sensor of atmospheric pressure on a chain of a high voltage...
  • Page 154 Machine Translated by Google Chapter XII. Engine management system Unis code DTC Category Description of the fault code rightness P2150 Low voltage on the upper contact B of the injector power supply circuit P2149 High voltage on the upper contact B of the injector power supply circuit P0092 Low voltage at the contact of the winding of the injection pump control valve P0091...
  • Page 155 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Unis code DTC Category Description of the fault code rightness Low voltage or open circuit in the winding circuit of the hydraulic variable P0076 valve timing control valve for intake valves Large error in the position of the intake camshaft when changing phases P0012 Long response time when signaling the position of the intake camshaft (with phase...
  • Page 156 Machine Translated by Google Chapter XII. Engine management system DTC P0012: Large intake camshaft position error during phase change (a) Prerequisites: (1) The engine is running. (2) VVT variable valve timing system and camshaft position sensor are OK, system voltage is within the acceptable range. (3) The current phase change rate of the VVT system is below 15°/s.
  • Page 157 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (a) Prerequisites: (1) Engine running for more than 0.5 seconds. (2) System voltage is above 11V but below 16V. (b) Malfunction detection principle: the engine control unit detects the presence of a short between the circuit upper oxygen sensor and power supply circuit (12 V).
  • Page 158 Machine Translated by Google Chapter XII. Engine management system (1) Engine running for more than 0.5 seconds. (2) System voltage is above 11V but below 16V. (b) Malfunction detection principle: the engine control unit detects the presence of low voltage or open circuit in the coil circuit of the hydraulic variable valve timing control valve for intake valves.
  • Page 159 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (c) Emergency operation: (1) The injection session duration change function is suppressed; (2) The value for self-adaptation stops updating; (3) The idle speed correction function is suppressed; (4) Atmospheric pressure value stops updating; (5) Manifold absolute pressure default value.
  • Page 160 Machine Translated by Google Chapter XII. Engine management system (a) Prerequisites: The engine has been running for more than 120 seconds. (b) Malfunction detection principle: The engine control unit detects that the coolant temperature sensor signal value is greater than 97.5%. (c) Emergency operation: (1) The coolant temperature is calculated by the control system using a standard formula based on engine hours and intake air temperature, and the maximum value cannot exceed 90.75°C;...
  • Page 161 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (5) Violation of the tightness of the supply vacuum tube; (6) Violation of the tightness of the exhaust system; (7) Presence of contaminants in the fuel. DTC P0132: Short circuit in the upstream oxygen sensor circuit to high voltage (a) Prerequisites: (1) No faults P0106, P0171, P0172, no faults with the intake air pressure sensor, coolant temperature sensor, throttle position sensor, fuel injectors, crankshaft position sensor, ignition system, idle control system, canister...
  • Page 162 Machine Translated by Google Chapter XII. Engine management system (3) Leaks in the exhaust system; (4) The presence of contaminants in the fuel; (5) Increased engine oil consumption. DTC P0137: Downstream oxygen sensor circuit short to low voltage (a) Prerequisites: (1) No faults related to codes P0106, P0171, no faults for the intake air pressure sensor, coolant temperature sensor, throttle position sensor, fuel injectors, crankshaft position sensor, ignition system, idle control system, purge circuit adsorber, lower oxygen sensor heater, etc.;...
  • Page 163 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (3) The intake air temperature is greater than -7°C; (4) Atmospheric pressure exceeds 72 kPa; (5) System voltage is greater than 11V. (b) Fault detection principle: for more than 5 seconds, the stored self-adaptation value for fuel system that uses a feedback loop is greater than 1.45.
  • Page 164 Machine Translated by Google Chapter XII. Engine management system (1) Short to ground or open circuit between fuel pump relay and engine control module; (2) Relay failure. DTC P0234 Turbocharger Air Consumption Excessive (a) Prerequisites: Engine running. (b) Malfunction detection principle: boost pressure exceeds the set value. (c) Fallback control: limiting turbocharger action and torque.
  • Page 165 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (1) In case of minor ignition affecting only the exhaust system: no emergency operation is provided, a fault code is stored, data freeze frames are logged, the warning lamp comes on; (2) In the event of significant ignition that could cause the catalytic converter to overheat: •...
  • Page 166 Machine Translated by Google Chapter XII. Engine management system (3) Sensor damage. DTC P0336 Crankshaft position sensor signal overlap (a) Prerequisites: (1) Engine running; (2) The number of cylinders detected by the sensor is four. (b) The principle of fault detection: the sensor detects a significant deviation of the signal from the master disk.
  • Page 167 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (c) Emergency operation: (1) No. 2 cylinder fuel injection is suspended; (2) Closed loop fuel control stops. (d) Possible causes of failure: (1) Short to ground or open in the ignition control circuit between the ignition coil and the control unit leniya engine;...
  • Page 168 Machine Translated by Google Chapter XII. Engine management system (b) Malfunction detection principle: the engine control unit determines the presence of a short to ground or an open in the canister purge valve solenoid circuit. (c) Emergency operation: not provided. (d) Possible causes of malfunction: (1) Short to ground in the control circuit between the canister purge solenoid valve and the engine control unit gatela;...
  • Page 169 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (a) Prerequisites: (1) No problems with intake air pressure sensor, coolant temperature sensor, throttle position sensor, cooling system, oxygen sensor, air mixture control system, vehicle speed sensor, fuel injectors, crankshaft position sensor, camshaft position sensor shaft, ignition system, etc.;...
  • Page 170 Machine Translated by Google Chapter XII. Engine management system (4) Internal damage to the engine control unit. DTC P0571: Brake light switch status did not change during deceleration (a) Prerequisites: (1) Vehicle speed exceeds 20 km/h for at least one second;...
  • Page 171 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (1) Engine running for more than 0.5 seconds. (2) System voltage is above 11V but below 16V. (b) Malfunction detection principle: the engine control unit detects the presence of a short to ground or an open in the A/C compressor clutch relay circuit.
  • Page 172 Machine Translated by Google Chapter XII. Engine management system throttle opening exceeds a certain value (5%) while maintaining this state for more than 240 ms. (c) Fail safe operation: Throttle operates in protected mode, engine operates in emergency mode, engine torque is limited. (d) Possible causes of failure: (1) Strong external electromagnetic interference;...
  • Page 173 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (c) Emergency operation: (1) Throttle works in protected mode, engine works in emergency mode, torque motor torque is limited; (2) The maximum engine torque is limited in the absence of other malfunctions, but it is still possible to continue driving in emergency engine operation.
  • Page 174 Machine Translated by Google Chapter XII. Engine management system (2) Unreliable electrical connections (3) Malfunction of the accelerator pedal position sensor. DTC P2127 - Accelerator Pedal Position Sensor Circuit Low Voltage #2 (a) Prerequisite: Engine running. (b) Malfunction detection principle: the engine control unit determines that the signal value of sensor No.
  • Page 175 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (5) BLMCELL value received and stored. (b) Malfunction detection principle: the engine control unit determines that the lambda value received in the process of self-adaptation, exceeds 1.4. (c) Failsafe operation: suppression of the catalytic converter diagnostic function. (d) Possible causes of malfunction: insufficient amount of fuel in the fuel tank and too low pressure in the fuel system.
  • Page 176 Machine Translated by Google Chapter XII. Engine management system (3) CAN Hi circuit short to high voltage. Fault U0167: No response from the anti-theft system (a) Prerequisites: The state of the ignition switch (IGN) changes from OFF to ON, and the engine control unit has performed the anti-theft self-adaptation procedure. (b) Malfunction detection principle: when the ignition is turned on, the response from the anti-theft system is received after the set time after the identification request from the engine control unit.

  • Page 177: Section Vi. Daily And Periodic Maintenance

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section VI. Daily and periodic maintenance 1. Daily and periodic maintenance (a) Fuels and lubricants (1) The content of lead and other heavy metals in unleaded gasoline must comply with national standards, since these metals can cause poisoning of the oxygen sensor and 3-way catalytic converter;...

  • Page 178: Section Vii. Repair Tools

    Machine Translated by Google Chapter XII. Engine management system (4) Evaporative Emission System Adsorber With the help of the canister purge solenoid valve, the engine control unit regulates the volume of fuel vapors entering the engine combustion chambers from the canister. The operation of the valve does not affect the operation of the engine in normal mode during the shutdown of the adsorber.

  • Page 179: Section Viii. Troubleshooting For Common Troubleshooting

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section VIII. Troubleshooting for Common Problems 1. Repair Instructions (a) Preparing for repair: (1) It is forbidden to carry out repairs on the territory of fuel stations; (2) It is forbidden to repair the fuel system when there is a source of fire nearby; (3) Do not smoke while doing repairs.
  • Page 180 Machine Translated by Google Chapter XII. Engine management system (9) Connect the bypass valve harness connector and make sure it is connected correctly. (10) Check the fuel system for leaks. (e) Instructions for removing, installing and inspecting the injection pump (1) It is forbidden to use the injection pump after it has been dropped;...
  • Page 181 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 2. Stationary check of all vehicle systems The condition of all vehicle systems can be checked in the dealer's service shop, equipped with a computer system with diagnostic software from Delphi and a diagnostic scanner. Operating parameters for a serviceable vehicle, as well as possible causes of malfunctions, are listed in Section IX "Typical Data Obtained on the Status of the Delphi Electronic Fuel Injection System".
  • Page 182 Machine Translated by Google Chapter XII. Engine management system 4. Troubleshooting in the absence of a fault code. Fault 01: No communication between the diagnostic scanner and the system Possible causes of malfunction 1. The Solution 1. Connect connector of the diagnostic scanner is not securely the diagnostic scanner again connected 2.
  • Page 183 Machine Translated by Google 4C20 Gasoline Engine Repair Manual 2. Data on the speed of rotation of the crankshaft 2. Missing crank speed data is received that shaft • Make sure that when the pistons in cylinders 1 • Inappropriate distance between set and 4 are at TDC, the 20th protrusion of the disc with 58 lugs and receiving part target disk is opposite the receiving part of the sensor.
  • Page 184 Machine Translated by Google Chapter XII. Engine management system Fault 03: Ignition is on, but the engine does not start Possible causes of malfunction Remedy Fuel system 1. The pressure in the supply pipe of the low pressure fuel line is lower than 550 kPa •...
  • Page 185 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Fault 06: High idle Possible causes of malfunction 1. Remedy Correspond to the specified idle speed move • Incorrect readings of the temperature sensor • Replace coolant temperature sensor coolant • Incorrect readings of the temperature sensor •...
  • Page 186 Machine Translated by Google Chapter XII. Engine management system Fault 11: Reduced engine power Possible causes of malfunction 1. Remedy 1. Clean the Clogged air supply system inlet and replace the filter mesh 2. Throttle does not open fully 2. Using the limit screw, adjust the stroke of the accelerator pedal so that the throttle damper can be fully opened 3.
  • Page 187 Machine Translated by Google 4C20 Gasoline Engine Repair Manual Fault 16: Exceeding harmful emissions according to the results of standard tests Possible causes of malfunction 1. Engine Remedy 1. Overhaul malfunction the engine 2. Leakage in the connection between the cylinder head 2.
  • Page 188 Machine Translated by Google Chapter XII. Engine management system Fault 20: too high fuel consumption Possible causes of malfunction 1. Remedy 1. Use an Wrong measurement method selected appropriate measurement method 2. Unsatisfactory general condition of the car 2. Complete a vehicle overhaul 3.

  • Page 189: Section Ix. Typical Data Received From The Delphi Electronic Fuel Injection System

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section IX. Typical data received from the Delphi electronic fuel injection system 1. Regular check (a) Check for loose connections in the wiring harness connector (b) Check that the fuel lines and vacuum tube are secure; (c) Tighten the oxygen sensor to 3-way catalytic converter bolt, make sure in the reliability of fastening.
  • Page 190 Machine Translated by Google 4C20 Gasoline Engine Repair Manual (f) Step 6: Check while driving (1) While driving, the following checks should be made: • Throttle open more than 10% for more than 15 seconds; • Reduce the fuel supply, shift into direct gear and maintain a speed of 80 km/h for at least less than 5 s.
  • Page 191 Machine Translated by Google Chapter XII. Engine management system • In the absence of the above faults, check the throttle body and make sure that she is correct. (4) Idling test • The control lamp lights up, but the malfunction code is not registered •...

  • Page 192: Section X. Self-Adaptation Of The European-Standard On-Board Self-Diagnosis (Eobd) System In The Event Of A Malfunction Of The Crankshaft Position Sensor

    Machine Translated by Google 4C20 Gasoline Engine Repair Manual Section X. Self-adaptation of the European-standard on-board self-diagnosis (EOBD) system in the event of a malfunction of the crankshaft position sensor 1. System self-adaptation based on crankshaft position sensor signal (a) If the vehicle is equipped with a new processor without a self-adaptation function based on the signal from the position sensor crankshaft, after starting the engine, the control lamp lights up, and using a diagnostic scanner, the presence of a malfunction P1336 is determined;...
  • Page 193 Machine Translated by Google...
  • Page 194 Machine Translated by Google No.1 SUV brand in China Haval Company in Russia: LLC "Haveil Motor Rus" Address: 119530, Russia, Moscow, Aminevskoe shosse, 4A Phone: +7 (499) 272-22-27 www.haval.ru...

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