BAIC Senova X25 2015 Maintenance Manual
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BAIC Senova X25 2015 Maintenance Manual

BAIC Senova X25 2015 Maintenance Manual

Engine
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Maintenance Manual of Senova X25
Engine
BAIC Motor Sales Co., Ltd.

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Summary of Contents for BAIC Senova X25 2015

  • Page 1 Maintenance Manual of Senova X25 Engine BAIC Motor Sales Co., Ltd.
  • Page 2 Maintenance Manual X25 2015 Engine Version：11.2015...

  • Page 5: Table Of Contents

    X25 2015 Engine Contents 6.1 Removal and Installation of Engine Mounting 10 Engine Assembly ............1 Cushion ................ 90 1 System Overview ............1 6. Removal and Installation of Transmission Mounting 2 Check and Diagnosis ..........2 Cushion ................ 92 2.1 Engine Service Precautions ........
  • Page 6 X25 2015 Engine 4.2 Air Intake Manifold ..........148 20 Electronic Control System ........199 4.2.1 Removal and Installation of Intake Manifold ... 148 1 Overview ..............199 4.2.2 Detection of the Intake Manifold ...... 150 1.1 System Overview ..........199 5 Air Intake/Exhaust System ........
  • Page 7 X25 2015 Engine limit P001622 Deviation of relative position between position self-learning fault P156400 System voltage crankshaft and intake camshaft higher than the hardly meets self-learning conditions of electronic maximum limit P001629 Signal of relative position throttle P156500 Initialization self-learning fault of deviation between crankshaft and intake camshaft electronic throttle lower limit position P156800 unreasonable ..............
  • Page 8 X25 2015 Engine 2.23 P020313 Control circuit fault of third cylinder fuel self-learning value higher than the upper limit injector P026711 Control circuit of third cylinder fuel (intermediate load zone) P217800 Air-fuel ratio injector undervoltage P026812 Control circuit of third closed-loop control self-learning value lower than the cylinder fuel injector overvoltage ......
  • Page 9 X25 2015 Engine 4.2.2 Removal and Installation of the Crankshaft 2 Check and Diagnosis ..........406 Position Sensor ............366 2.1 Common Fault Checking and Eliminating ... 406 4.2.3 Check the Crankshaft Position Sensor ....368 2.1.1 Fuel Pressure Is Too Low ........406 4.3 Intake Manifold Absolute Pressure Sensor ..
  • Page 10 X25 2015 Engine -VI-...

  • Page 11: Engine Assembly

    X25 2015 Engine 10 Engine Assembly 1 System Overview The powertrain of this model adopts the A131, A151 engines, which are the 1.3L/1.5L, 4-cylinder, 16 valves and DOHC gasoline engine. 1 Technical Features a. Light and Compact It uses cast aluminum cylinder blocks, resin intake manifold, and a resin cylinder head cover, which remarkably reduce the engine weight and make for a light and compact design.

  • Page 12: Check And Diagnosis

    X25 2015 Engine 2 Check and Diagnosis 2.1 Engine Service Precautions Precondition The precondition for using the Maintenance Manual is able to use the maintenance tools correctly so as to ensure safety and working efficiency of the engine maintainers. Safety Warning Carefully read and follow the cautions and warnings included in this manual, to avoid potential injury.
  • Page 13 X25 2015 Engine − When executing the simulation of thermal working conditions or any other repair work that may increase the temperature, the temperature of the ECU shall not exceed 80℃. − Don't test the input and output electrical signals of the parts by piercing the wire coating. −...

  • Page 14: Common Fault Checking And Eliminating

    X25 2015 Engine 2.2 Common Fault Checking and Eliminating 2.2.1 Engine Starts Abnormally Inspection steps Check results Fault elimination Preliminary Inspection Normal There's a fault Operation methods Check whether the anti-theft Release its anti-theft Proceed to Step 1. Anti-theft system working system is available effect Check the starter...

  • Page 15: Engine Idle Speed Abnormal

    X25 2015 Engine Inspection steps Check results Fault elimination Operate the front electric Find the cause from windows and check whether End of diagnosis Faults still exist other symptoms fault occurs after repairs 2.2.2 Engine Idle Speed Abnormal Inspection steps Check results Preliminary Inspection Normal...

  • Page 16: Poor Engine Acceleration And Power Reduction

    X25 2015 Engine Inspection steps Check results Further check and Excessive compression eliminate abnormal Check compression pressure Proceed to Step 9. pressure difference pressure fault of the of all cylinders among cylinders cylinder => Refer to Page 130 Operate the front electric Find the cause from windows and check whether End of diagnosis...
  • Page 17 X25 2015 Engine Inspection steps Check results Check the ignition timing Normal There's a fault Operation methods Check the ignition advance Ignition advance angle Proceed to Step 8. Replace the ECM angle abnormal Check the cylinder Normal There's a fault Operation methods pressure Low compression...

  • Page 18: Regular Tests

    X25 2015 Engine 2.3 Regular Tests 2.3.1 Oil Pressure Switch Tips Test oil pressure in case of following conditions to judge whether the fault is caused by abnormal oil pressure:  Difficulty in starting the engine, unstable idling, weak acceleration. ...
  • Page 19 X25 2015 Engine 3. Disconnect the connecting plug -Arrow A- of the starter, lift up the guard -Arrow C- of the starter terminal and unscrew the fixing nut -Arrow B- of the starter terminal. Nuts - Arrow B - Specifications：M8× 1.25 Nut -Arrow B- tightening torque: 10 - 12 Nm Nut -Arrow B- tool: 13mm hexagon sleeve 4.
  • Page 20 X25 2015 Engine Note  Before installing the engine oil pressure switch, clean the threads and the threaded hole of the engine oil pressure switch.  When installing the engine oil pressure switch, apply some sealant to the threads of the engine oil pressure switch.

  • Page 21: Cylinder Pressure Test

    X25 2015 Engine Tips  If the oil pressure is lower than the standard value, then: − Check the screen of the engine oil strainer for blockage. − If there is no blockage in the strainer screen or duct for engine oil, it indicates failure in the engine oil pump. Replace the engine oil pump.

  • Page 22: Fuel Pressure Test

    X25 2015 Engine 5. Screw the cylinder pressure gauge into the threaded installation hole of the spark plug in one of the cylinders. Tips Keep the connection sealed. 6. Have one technician set the transmission to N and fully press the accelerator pedal (throttle fully open).
  • Page 23 X25 2015 Engine  Make sure there is adequate fuel.  No blockage exists in the fuel filter or the fuel pump screen. Test procedure 1. Turn off the ignition and all electrical equipment. 2. Remove driver foot space trim panel assembly =>Body and painting: Repair group: 82: Instrument panel;...

  • Page 24: Technical Parameters

    X25 2015 Engine 3 Technical Parameters Torque Name Specification Grade Tools Fixing bolt of battery tray M8× 1.25× 16 14～16 10mm Hexagon Sleeve — Fixing nut of the engine wiring terminal M8× 1.25 6～10 13mm Hexagon Sleeve — Fixing nut of the engine wiring terminal M5×...
  • Page 25 X25 2015 Engine Torque Name Specification Grade Tools Fixing bolts of crankshaft position sensor M6× 1.0× 16 8～12 10mm Hexagon Sleeve Camshaft position sensor fixing bolt M6× 1.0× 16 8～12 10mm Hexagon Sleeve Fixing bolt of the engine lifting lug M8×...

  • Page 26: Powertrain Units

    X25 2015 Engine 4 Powertrain Units 4.1 Removal and Installation of Powertrain Assembly Components Required special tools and service equipment T51131001-Engine balance hanger T51271002-Engine balancing stand cross rod component Removal Note  Before removing and installing the powertrain assembly components, disconnect all power supply harnesses, drain the engine coolant, and disconnect the harnesses, pipes and other connections between the powertrain assembly components and the body.
  • Page 27 X25 2015 Engine 6. Remove the rubber blockage -arrow A- on the battery tray on, and pry up the harness clip - Arrow B-. 7. Unscrew fixing bolts -arrows- for the battery tray and remove the battery tray-1-. Bolt -Arrow- specification: M8× 1.25× 16 Bolt -Arrow - tightening torque: 14 - 16 Nm Bolt -Arrow- tool: 10mm hexagon sleeve 8.
  • Page 28 X25 2015 Engine 10. Press the locking clip -Arrow- and remove the cover -1- of the engine compartment electrical box. 11. Unscrew the fixing nut -Arrow A- of the engine harness terminal, disengage the fixing clip -Arrow B- of the front compartment electrical box and remove the front compartment electrical box -1-.
  • Page 29 X25 2015 Engine 14. Loosen the fixing clamp -Arrow- of the brake vacuum hose and disengage the brake vacuum hose -1-. 15. Unscrew the fixing bolt -Arrow A- of brake pump vacuum hose bracket and put aside the brake pump vacuum hose bracket -1-. Bolt -Arrow A- specification:M8×...
  • Page 30 X25 2015 Engine 18. Disengage the connection of the selector cable -1- and the gearshift rocker arm assembly -2- with the cable bracket -3-. 19. Unscrew the fixing bolt -Arrow- of the manual transmission bond strap and put aside the bond strap -1-. Bolt - Arrow - Specifications：M6×...
  • Page 31 X25 2015 Engine 21. Pry out selector cable and gearshift cable along -Arrow A-,-Arrow B- from cable bracket. Applicable to the automatic transmission 22. Disengage the connection between the shift cable assembly -1- and the shift arm -2-. 23. Press the unlocking part -Arrow-, and disengage the connection between the gearshift cable assembly -1- and the fixing bracket -3-.
  • Page 32 X25 2015 Engine 25. Unscrew the fixing bolt -Arrow- of the engine wiring harness bonding and put aside the engine bond strap -1-. Bolt -Arrow- specification: M8× 1.25× 20 Bolt -Arrow - tightening torque: 14 - 16 Nm Bolt -Arrow- tool: 13mm hexagon sleeve 26.
  • Page 33 X25 2015 Engine 29. Disconnect the connecting plug -Arrow A- and -Arrow B- of the engine control unit and engine wiring harness connector -Arrow-C, and pry up the connector fixing clip -Arrow D- and the wiring harness fixing clip -Arrow E-. 30.
  • Page 34 X25 2015 Engine 32. Lift up the carpet -1-, pry up the fixing clip -Arrow- of the front passenger foot rest and remove the front passenger foot rest -2-. 33. Disengage the clip -Arrow- of the front oxygen sensor connector. 34.
  • Page 35 X25 2015 Engine 37. Disconnect the wiring harness connector -Arrow A- and disengage the wiring harness fixing clip -Arrow B- and -Arrow C-. 38. Disengage the wiring harness rubber cover -1- and pull out the engine wiring harness -2-. Tips While pulling out the wiring harness, take out the wiring harness connector separately for fear that the connector is clamped at the outlet and thus damages the wiring harness.
  • Page 36 X25 2015 Engine 43. Unscrew the fixing bolt -Arrow- of the clutch slave cylinder and put aside the clutch slave cylinder -1-. Bolt -Arrow- specification: M8× 1.25× 25 Bolt -Arrow - tightening torque: 17 - 23 Nm Bolt -Arrow- tool: 10mm hexagon sleeve Tips Don't depress clutch pedal assembly after disengaging.
  • Page 37 X25 2015 Engine 46. Unscrew the fixing bolt -Arrow- on the A/C compressor, and suspend it on the body with a sturdy rope or wire. Bolt -Arrow- specification: M8× 1.25× 100 Bolt -Arrow - tightening torque: 22 - 30 Nm Bolt -Arrow- tool: 10mm hexagon sleeve 47.
  • Page 38 X25 2015 Engine 52. Unscrew the fixing nut - arrow -, and disengage the connection between the front stabilizer bar right link -1- and front stabilizer bar -2-. Nut - Arrow- specification：M12× 1.5 Nut -Arrow - tightening torque: 70 - 90 Nm Nut -Arrow - tool:18mm combination wrench 53.
  • Page 39 X25 2015 Engine 57. Disconnect the connecting plug -Arrow- of the front oxygen sensor -1-. Tightening torque of the front oxygen sensor -1-: 40～60 Nm 58. Pry up the connection between the wiring harness clip -Arrow- and the body and disengage the dustproof rubber cover -1- of the rear oxygen sensor.
  • Page 40 X25 2015 Engine Tips  Apply a small amount of engine oil inside the installation hole of the lug gasket to facilitate its removal or installation.  Please ask another technician to hold the auxiliary silencer assembly for fear that it falls from high. ...
  • Page 41 X25 2015 Engine 63. Disconnect electric power-assist steering assembly connector - arrow A- and - arrow B-. 64. Place front subframe component -1- with the engine and transmission lifting device. 65. Remove the fixing bolt - arrow A - and - arrow B-, and lower the front subframe assembly -1-. Bolt - Arrow A - Specifications：M14×...
  • Page 42 X25 2015 Engine Bolt -Arrow B- tool: 21mm hexagon sleeve Tips It must be carried out with the assistance of another assembly worker. 66. Put the workbench under the power assembly component and gradually lower the vehicle until the lower planes of the engine assembly -1- and the transmission assembly -2- just contact the upper plane of the workbench -3-.
  • Page 43 X25 2015 Engine 70. Unscrew the fixing bolt -Arrow A- of the automatic transmission mounting bracket. Bolt - Arrow A - Specifications：M10× 1.25× 40 Nut -Arrow A- tightening torque: 60 - 70 Nm Bolt -Arrow A- tool: 13mm hexagon sleeve 71.
  • Page 44 X25 2015 Engine Nut -Arrow B- tool: 18mm hexagon sleeve Applicable to all models 76. Remove the engine balance bracket with the tool number -T51131001- and the engine balance bracket crossbar component with the tool number -T51271002-. Fix the power assembly component on the workbench with the strapping tape, gradually lift the body, and push out the workbench and the power assembly component.

  • Page 45: Removal And Installation Of Engine Assembly

    X25 2015 Engine 4.2 Removal and Installation of Engine Assembly Required special tools and service equipment Hoisting device Removal 1. Remove the power assembly component => Refer to Page 2. Disconnect the connecting plug -Arrow A- of the ignition coil and the connecting plug -Arrow B- of the fuel injector.
  • Page 46 X25 2015 Engine 5. Disconnect connecting plug -Arrow A- of V.V.T solenoid valve. 6. Disconnect the connecting plug -Arrow B- of the generator, lift up the generator terminal guard -1- and unscrew the terminal nut -Arrow C-. Nut - Arrow C- specification：M8× 1.25 Nut -Arrow C- tightening torque: 18 - 22 Nm Nut -Arrow C- tool: 13mm hexagon sleeve 7.
  • Page 47 X25 2015 Engine 9. Disconnect the connecting plug -Arrow A- of the knock sensor. 10. Disconnect the connecting plug -Arrow B- of the starter, lift up the starter terminal guard -1- and unscrew the fixing nut -Arrow C- of the starter terminal.
  • Page 48 X25 2015 Engine Applicable to the automatic transmission 14. Disconnect the automatic transmission connector - arrow A-, and disengage the harness fixing clip - arrow B-. 15. Disconnect the automatic transmission connector - arrow A -, - arrow B-, and gear switch connector - arrow C-. 16.
  • Page 49 X25 2015 Engine 18. Unplug the manual transmission plug -Arrow A-. 19. Unscrew the fixing bolt -Arrow B- of the engine wiring harness installation bracket and remove the engine wiring harness assembly -1-. Bolt - Arrow B - Specifications：M8× 1.25× 20 Bolt -Arrow B- tightening torque: 14 - 16 Nm Bolt -Arrow B- tool: 10mm hexagon sleeve Applicable to all models...
  • Page 50 X25 2015 Engine 22. Unscrew the fixing bolt -Arrow- of the bell housing -1- and remove the bell housing -1-. Bolt - Arrow - Specifications：M6× 1.0× 16 Bolt -Arrow - tightening torque: 8 - 10 Nm Bolt -Arrow- tool: 10mm hexagon sleeve Applicable to the automatic transmission 23.
  • Page 51 X25 2015 Engine Applicable to F15 manual transmission 25. Unscrew the connecting bolt -Arrow- of the engine assembly -1- and the transmission assembly -2- and remove the engine assembly -1-. Bolt -Arrow- specification: M8× 1.25× 40 Bolt -Arrow - tightening torque: 20 - 28 Nm Bolt -Arrow- tool: 10mm hexagon sleeve Applicable to the manual transmission MF513A 26.
  • Page 52 X25 2015 Engine 27. Use the clutch disc positioner - T61133001- to position the clutch friction lining -1- for fear that the clutch friction lining -1- falls onto the ground in removal. 28. Unscrew the fixing bolt -Arrow- of the clutch pressure plate. Bolt -Arrow- specification: M8×...

  • Page 53: Engine Assembly: Disassembly

    X25 2015 Engine 4.3 Engine Assembly: Disassembly Disassembly 1. Fasten the flywheel with a flywheel stopper (Tool No.:T61131201). 2. Loosen the fixing bolt -Arrow- of the flywheel but do not unscrew it (remove the flywheel stopper -T61131201-). 3. Unscrew the flywheel bolts -Arrow-, and remove the flywheel -1-. (AT) Bolt -Arrow- Size: M11×...
  • Page 54 X25 2015 Engine 5. Unscrew the drain bolt -1- and collect engine lubricant with proper container. Tightening torque of drain bolt -1-: 38~42 Nm Drain bolt -1- tool: 17mm hexagon sleeve 6. Unscrew the fixing bolt -Arrow- of the ignition coil and remove the ignition coil -1-.
  • Page 55 X25 2015 Engine Note While removing the fuel rail with fuel injector assembly, do not remove one end separately and remove the other later, but remove both ends slowly and uniformly. Press in two ends uniformly while installing to ensure they are installed to due positions.
  • Page 56 X25 2015 Engine 12. Disengage the connection between the PCV venting hose -3- and the cylinder head cover. 13. Unscrew the fixing bolt -Arrow A- of the intake manifold assembly and remove the intake manifold assembly -1-. Bolt -Arrow A- specification:M8× 1.25× 40 Nut -Arrow A- tightening torque: 18 - 22 Nm Bolt -Arrow A- tool: 12mm hexagon sleeve Tips...
  • Page 57 X25 2015 Engine 17. Unscrew the fixing bolt -Arrow A- on the inlet pipe assembly, and remove the inlet pipe assembly -1-. Bolt - Arrow A - Specifications：M6× 1.0× 20 Nut -Arrow A- tightening torque: 8 - 10 Nm Bolt -Arrow A- tool: 10mm hexagon sleeve Tips Sealing gasket of the water inlet pipe component must be replaced.
  • Page 58 X25 2015 Engine 21. Unscrew the fixing bolt -Arrow A- of thermostat shell and remove the thermostat shell -1-. Bolt - Arrow - Specifications：M6× 1.0× 22 Bolt -Arrow - tightening torque: 8 - 10 Nm Bolt -Arrow- tool: 10mm hexagon sleeve 22.
  • Page 59 X25 2015 Engine 25. Unscrew the fixing bolt -Arrow- of the crankshaft position sensor and remove the crankshaft position sensor -1-. Bolt - Arrow - Specifications：M6× 1.0× 16 Bolt -Arrow - tightening torque: 8 - 12 Nm Bolt -Arrow- tool: 10mm hexagon sleeve Note ...
  • Page 60 X25 2015 Engine 27. Use the fixing tool -T41131501- of the water pump pulley to fix the water pump pulley -1-, unscrew the fixing bolt -Arrow- and remove the water pump pulley -1-. Bolt - Arrow - Specifications：M6× 1.0× 10 Bolt -Arrow - tightening torque: 7 - 9 Nm Bolt -Arrow- tool: 10mm hexagon sleeve 28.
  • Page 61 X25 2015 Engine 30. Unscrew the fixing bolt -Arrow- of the exhaust manifold heat shield and remove the exhaust manifold heat shield -1-. Bolt - Arrow - Specifications：M6× 1.0× 16 Bolt -Arrow - tightening torque: 9 - 11 Nm Bolt -Arrow- tool: 10mm hexagon sleeve 31.
  • Page 62 X25 2015 Engine Note  At the -Arrow- as shown, apply a strip of liquid sealant in continuous pearl-drops (diameter: 4 mm).  Cylinder head cover must be installed within 3 minutes after the sealant is applied, otherwise remove the sealant that is already applied and apply a new coat.
  • Page 63 X25 2015 Engine Note  Remove sealant on oil pan and cylinder block surface, clean and apply sealant as per the illustrated requirement.  Apply sealant to the joint between cylinder block and front cover and the joint between cylinder block and rear oil seal to the diameter of 4mm.
  • Page 64 X25 2015 Engine 37. Unscrew the fixing bolts -Arrow A-, -Arrow B-, -Arrow C-, -Arrow D- and -Arrow E- on the timing chain housing, and remove the housing carefully. Bolt - Arrow A - Specifications：M6× 1.0× 25 Nut -Arrow A- tightening torque: 8 - 12 Nm Bolt -Arrow A- tool: 10mm hexagon sleeve Bolt - Arrow B - Specifications：M6×...
  • Page 65 X25 2015 Engine 38. Press the tension adjusting bar assembly -1- along the direction -Arrow B- and fix the chain tensioner with the fixing pin -2- (the fixing pin is self-provided). 39. Unscrew the fixing bolt -Arrow A- on the chain tensioner -3-, and remove the tensioner.
  • Page 66 X25 2015 Engine 43. Use a wrench to tighten the hexagon part of the camshaft, remove bolt -Arrow- on the V.V.T sprocket, and remove the V.V.T sprocket. Bolt -Arrow - tightening torque: 59 - 70 Nm Bolt -Arrow- tool: 14mm hexagon sleeve Tips Before installing the V.V.T sprocket, apply an appropriate amount of engine oil at the following locations.
  • Page 67 X25 2015 Engine Tips  No. 2 and No. 5 bearing caps of intake and exhaust camshafts are the same in shape that shall be installed by relevant identification marks. The directions of marks on the bearing caps shall be the same as the directions before removal.

  • Page 68: Engine Structure

    X25 2015 Engine 5. Engine Structure 5.1 Cylinder Head Component 5.1.1 Overview on Cylinder Head Assembly 1 - Exhaust camshaft cap 2 - Intake camshaft cap   Check, replace as necessary Check, replace as necessary 3 - Valve tappet 4 - Valve lock clamp ...

  • Page 69: Disassembly Of The Cylinder Head Component

    X25 2015 Engine  Check=>Refer to Page 64 11 - Exhaust valve 12 - Cylinder head bolt washer   Check=>Refer to Page 66 Check, replace as necessary 13 - Cylinder head fixing bolt 14 - Intake camshaft   Total: 10 Removal and installation=>Refer to Page 108...
  • Page 70 X25 2015 Engine Valve spring compressor Removal clamp of the oil seal Installation tool for the oil seal of the valve Tips These instructions are for the removal and installation of one valve but may be used as reference for the removal and installation of other valves.
  • Page 71 X25 2015 Engine Tips  No. 2 and No. 5 bearing caps of intake and exhaust camshafts are the same in shape that shall be installed by relevant identification marks. The directions of marks on the bearing caps shall be the same as the directions before removal.
  • Page 72 X25 2015 Engine 10. Pull out the valve oil seal -1- with the oil seal disassembling clamp. Tips  The valve oil seal cannot be reused.Replace it.  To facilitate the re-installation of the valve, place the valve spring and other components in order, and mark them.

  • Page 73: Cylinder Head Cleaning

    X25 2015 Engine 3. Apply engine oil on the valve oil seal lip, and carefully install it onto the valve duct. 4. Compress the valve spring with the valve spring compressor, and install the locking clip -1- of the valve spring. Note After the installation of the camshaft, check the valve clearance=>Refer to Page...

  • Page 74: Cylinder Head Check

    X25 2015 Engine 1. Carefully and gently clean off the residual sealant or dirt on the cylinder head installation surface -1-, air intake manifold installation surface -2- and exhaust manifold installation surface -3- with a draw knife. Note The cylinder head is made of cast aluminum. Don't use excessive force during cleaning, in order to avoid scratching the installation surfaces of the cylinder head.

  • Page 75: Check On Cylinder Head Bolt

    X25 2015 Engine 5.1.5 Check on Cylinder Head Bolt 1. Measure the external diameter at -Arrow A- as shown of the cylinder head blot. 2. Measure the smaller external diameter at -Arrow B- as shown of the cylinder head blot. 3.

  • Page 76: Valve Mechanism

    X25 2015 Engine 5.2 Valve Mechanism 5.2.1 Valve Cleaning 1. Carefully remove all carbon deposit on the valve -1- with a draw knife, and brush off the dirt with a soft brush. 2. Brush off the dirt on the valve seat -2- with a soft brush. Note Don't clean the valve seat -2- with a wire brush or other hard object, as this may lead to improper sealing of the valve.

  • Page 77: Check Valve Clearance

    X25 2015 Engine 2. Measure the valve edge -a-. If the measured value exceeds the limit, replace the valve. Tips During the measurement, the bottom surface of the valve should be in parallel with and contacted to each other; if not, trim with tools. Standard: ...
  • Page 78 X25 2015 Engine 1. Turn the crankshaft clockwise, and align the timing mark - Arrow B- of intake camshaft with the timing mark -Arrow A- of exhaust camshaft, as shown in the picture.The cylinder 1 is at the top dead center position position now.

  • Page 79: Check On Valve Seat

    X25 2015 Engine 4. Check the valve clearance -Arrow- indicated in the picture. a. Intake valve：0.18～0.26 mm b. Exhaust valve：0.26～0.34 mm Tips No.2 is the exhaust valve side. No.3 is the intake valve side. 5.2.4 Check on Valve Seat Measure the dimension of -a- of the protruding part between the valve rod end and spring seat surface;...

  • Page 80: Check On Valve Spring

    X25 2015 Engine 5.2.6 Check on Valve Spring 1. Measure the free height -B- of valve spring, and if the measured value excesses the limit value, replace the spring. − Standard: 43.1 mm − Limit value: 42.1 mm 2. Measure the squareness -A- of the valve spring, and if the measured value exceeds the limit value, replace the spring.

  • Page 81: Check On Valve Tightness

    X25 2015 Engine Tips The thickness of valve tappet is within the range of 2.70 - 3.30mm.There are 31 types of valve tappets, each with a 0.02mm difference.More detailed information is shown in the following table Valve tappet information Identification Identification Identification Thickness mm...
  • Page 82 X25 2015 Engine 2. Install all the spark plugs -1-. 3. Install all the intake valves -3- and exhaust valves -4-. 4. Add alcohol into all cylinder head combustion chambers -2-, and check the intake valves -3- and exhaust valves -4- for leakage. Tips ...

  • Page 83: Check Camshaft Dimensions

    X25 2015 Engine 5.3 Check Camshaft Dimensions Tips Checking method for the intake camshaft and the exhaust camshaft is the same and therefore checking of the intake camshaft is taken as the example below. 1. Completely clean the camshaft -1- with volatile solvent (such as gasoline).

  • Page 84: Cylinder Block Component

    X25 2015 Engine 5.4 Cylinder Block Component 5.4.1 Overview on Cylinder Block Component 1 - Crankshaft rear oil seal fixing bolt 2 - Crankshaft rear oil seal cover   Quantity: Replace 6 Replacement  Specification：M6× 1.0× 20  Tightening torque：8～10 Nm 3 - Cylinder block 4 - Thrust bearing ...

  • Page 85: Cylinder Block Component: Disassembly

    X25 2015 Engine   Tightening torque：33～37 Nm+60° to 64° Tightening torque：13～17 Nm+90° to 94° 11 - Connecting rod bearing cap 12 - Connecting rod lower bearing bush   Check, replace as necessary Check, replace as necessary 13 - Upper bearing bush of the connecting rod 14 - Sensor ring ...
  • Page 86 X25 2015 Engine 3. Push out the piston connecting rod component -1- carefully. Note  While pushing out the piston connecting rod component, do not let the connecting rod scratch the cylinder wall or let sharp object contact the connecting rod bearing bush and its junction surface. Tips ...
  • Page 87 X25 2015 Engine 5. Remove the thrust bearing -Arrow-. 6. Take the crankshaft -1- out of the cylinder block. Tips The thrust bearing is located at the fourth bearing, altogether two pieces, on two back-to-back sides. 7. Remove the master bearing bush -1- of the crankshaft. Note Once crankshaft master bearing bush is removed, store it in the original sequence, to avoid confusion.

  • Page 88: Check On Cylinder Block

    X25 2015 Engine 2. When installing the piston and connecting rod component, pay attention to the installation angle of the piston ring Rotate each piston ring to ensure the opening -2- of the first piston ring is 180° to the opening -5- of the second piston ring and that the two openings are not aligned with the axis -3- of the piston pin.

  • Page 89: Cylinder-Boring

    X25 2015 Engine Note If there is any vertical scratch on the inner wall of the cylinder block, it means scuffing has occurred inside the engine.The deeper the scratch is, the more serious the scuffing is. Replace the cylinder block if necessary. 4.

  • Page 90: Check Oil Clearance Of The Crankshaft Bearing

    X25 2015 Engine Note  To avoid possible deformation caused by temperature rise during the boring process, follow the sequence from No.2 to No.4 first and then from No.1 to No.3.  When boring the cylinder, ensure the four cylinders are bored to the same dimension. Do not bore only one cylinder to a greater dimension.

  • Page 91: Check Thrust Bearing Of The Crankshaft

    X25 2015 Engine 6. Measure the width of the pressed part of the plastic gauge -1- based on the scale printed on the package. Standard valve：0.014～0.052 mm Limit value: 0.1 mm Tips If the oil film clearance of the crankshaft journal doesn't meet the standard, replace the upper and lower crankshaft bearing, and remove the crankshaft if necessary.

  • Page 92: Crankshaft Bearing

    X25 2015 Engine 5. Adopt the gauge printed on the plastic gauge, and measure the width of the widest part of the plastic gauge. Standard valve：0.014～0.052 mm Limit value: 0.1 mm 5.4.8 Crankshaft Bearing 8.1 Assembly of Crankshaft Upper Bearing 1.
  • Page 93 X25 2015 Engine 3. Install the lubricated crankshaft upper bearing on the cylinder block, and ensure the bearing is built-in the kerf on the cylinder block -Arrow-. Repair Group 10 - Engine Assembly 83...

  • Page 94: Assembly Of Crankshaft Lower Bearing

    X25 2015 Engine 8.2 Assembly of Crankshaft Lower Bearing 1. Identify the crankshaft bearing group according to the color in the picture -Arrow-. 2. Select lower bearing for the crankshaft according to the mark on the rear flange of the crankshaft as well as the following table. Date of production Crankshaft Bearing...

  • Page 95: Piston And Connecting Rod Components

    X25 2015 Engine 5.5 Piston and Connecting Rod Components 5.5.1 Overview on Piston and Connecting Rod Components 1 - 1st piston ring 2 - 2nd piston ring   Removal and installation=>Refer to Page 86 Removal and installation=>Refer to Page 86 3 - Oil ring 4 - Piston ...

  • Page 96: Disassembly Of Piston Connecting Rod Components

    X25 2015 Engine 11 - Connecting bolt  Total: 8  Tightening torque：13～17 Nm+90° to 94° 5.5.2 Disassembly of Piston Connecting Rod Components Special Tools and Maintenance Equipment Required: T61131204- Piston guide cylinder Removal 1. Remove the piston connecting rod components=>Refer to Page 137.
  • Page 97 X25 2015 Engine 4 .Fix the piston and connecting rod components on the base, and ensure the piston forward mark -Arrow B- faces upwards. 5. Press the push rod -1- with pressure tooling along -Arrow A-, and remove the piston pin. Tips Place the removed piston, piston pin and connecting rod in sequence.

  • Page 98: Check On Piston Ring

    X25 2015 Engine 5.5.3 Check on Piston Ring Special Tools and Maintenance Equipment Required: Feeler gauge Use a feeler gauge to check the clearance between the piston ring and the ring-shaped slot, and replace the piston ring or replace the piston and the piston ring if the measured value excesses the limit value.

  • Page 99: Check On Side Clearance At Connecting Rod's Bigger End

    X25 2015 Engine 5.5.4 Check on Side Clearance at Connecting Rod's Bigger End Special Tools and Maintenance Equipment Required: Feeler gauge  Use a feeler gauge to measure the side clearance at the bigger end of connecting rod as shown in the picture. Standard valve：0.10～0.35 mm Limit value: 0.4 mm 5.5.5 Check on Connecting Rod Bolt...

  • Page 100: Powertrain Mounting Components

    X25 2015 Engine 6. Powertrain Mounting Components 6.1 Removal and Installation of Engine Mounting Cushion Required special tools and service equipment T51131001-Engine balance hanger T51271002-Engine balancing stand cross rod component Removal 1. Removal of the air chamber cover=>Body and painting; Repair group:83; Exterior equipment;Removal and installation of the air chamber cover.
  • Page 101 X25 2015 Engine 4. Unscrew the fixing bolt -Arrow C- of the engine ground wire. Bolt -Arrow C- specification:M8× 1.25× 20 Bolt -Arrow B- tightening torque: 14 - 16 Nm Bolt -Arrow C- tool: 13mm hexagon sleeve 5. Unscrew the fixing bolt -Arrow A- on the engine mounting bracket. Bolt - Arrow A - Specifications：M10×...

  • Page 102: Removal And Installation Of Transmission Mounting Cushion

    X25 2015 Engine 6. Removal and Installation of Transmission Mounting Cushion Removal 1. Turn off the ignition and all electrical equipment. 2. Remove the battery => Electrical equipment; Repair Group: 60: Power distribution; Battery; Removal and installation of battery. 3. Remove the air filter => Refer to Page 147.
  • Page 103 X25 2015 Engine 8. Install the engine balance bracket with the tool number -T51131001- and the engine balance bracket crossbar component with the tool number -T51271002- and fix the engine assembly -1-. 9. Remove the rear mounting cushion => Refer to Page 96 Applicable to the automatic transmission 10.
  • Page 104 X25 2015 Engine 12. Unscrew fixing bolt -Arrow B- and fixing nut -Arrow C- of the transmission mounting cushion. Bolt - Arrow A - Specifications：M12× 1.25× 40 Nut -Arrow A- tightening torque: 75 - 85 Nm Bolt -Arrow A- tool: 15mm hexagon sleeve Nuts - Arrow B - Specifications：M12×...
  • Page 105 X25 2015 Engine Bolt -Arrow A- tool:13mm combination wrench Tips Adjust engine orientation to remove the transmission suspension. Installation Install in reverse order of removal procedures. Repair Group 10 - Engine Assembly 95...

  • Page 106: Removal And Installation Of The Rear Mounting Cushion

    X25 2015 Engine 6.3 Removal and Installation of the Rear Mounting Cushion Removal 1. Lift the vehicle to a proper height 2. Unscrew the fixing bolts - arrow A-, bolt - arrow B-, bolt - arrows C-, and remove the rear suspension cushion assembly -1- and rear suspension bracket assembly -2-.

  • Page 107: Belt

    X25 2015 Engine 7 Belt 7.1 Overview on Accessory Transmission 1 - A/C compressor belt 2 - Water pump pulley   Check, replace as necessary Check, replace as necessary 3 - Generator pulley 4 - Belt   Check, replace as necessary Removal and installation=>Refer to Page 98 5 - Crankshaft pulley...

  • Page 108: Removal And Installation Of The Belt

    X25 2015 Engine 7.2 Removal and Installation of the Belt Removal 1. Loosen the fixing bolt -Arrow B- and -Arrow C- of the generator. Bolt - Arrow B - Specifications：M8× 1.25× 40 Bolt -Arrow B- tightening torque: 19 - 25 Nm Bolt -Arrow B- tool: 12mm hexagon sleeve Bolt - Arrow C - Specifications：M10×...

  • Page 109: Check The Belt Tension

    X25 2015 Engine 7.3 Check the Belt Tension 1. After installation, apply a force of 100 N to the belt in the position of -Arrow-.Measure to check whether the belt deformation is within the standard deviation range . Items Adjustment Replacement Vibration frequency 148～164...

  • Page 110: Cylinder Head And Timing Device

    X25 2015 Engine 11 Cylinder Head and Timing Device 1 Overview The cylinder head in this engine model is made entirely of aluminum, and thus features good heat radiation, light weight and easy processing. The cylinder head is designed to close the cylinder, form the combustion chamber, install air intake and exhaust valves, and support air intake and exhaust camshaft components.The air intake valve inlet and the exhaust valve outlet are connected to air intake manifold and exhaust manifold, respectively.

  • Page 111: Check And Diagnosis

    X25 2015 Engine 2 Check and Diagnosis 2.1 Common Fault Checking and Eliminating 2.1.1 Abnormal Noise of Valve Mechanism Inspection steps Check results Preliminary Inspection Normal There's a fault Operation methods Camshaft journal and bearing seat is worn, Replace the camshaft or Check the camshaft Proceed to Step 1.
  • Page 112 X25 2015 Engine Inspection steps Check results Check whether the chain Chain guide plate loose Replace the damaged Proceed to Step 3. guide plate is normal or severely worn part and tighten the bolt Check the crankshaft Normal There's a fault Operation methods timing sprocket Check whether the...

  • Page 113: Technical Parameters

    X25 2015 Engine 3 Technical Parameters Torque Name Specification Grade Tools 10mm Hexagon — Cylinder head cover fixing bolt 8～10 Sleeve 19mm — — Coolant temperature sensor (ECT sensor) 10～14 combination wrenches M10× 1.25× 50 14mm Hexagon — Timing sprocket shell fixing bolt (M10) 35.5～43.5 M10×...

  • Page 114: Cylinder Head Cover

    X25 2015 Engine 4 Cylinder Head Cover 4.1 Overview on Cylinder Head Cover 1 - Ignition coil fastening bolt 2 - Ignition coil Removal and installation=>Refer to Page 436 Specification：M6× 1.0× 18 Total: 4 Tightening torque：7～12 Nm 3 - Spark plug 4 - Cylinder head cover Removal and installation=>Refer to Page 439...
  • Page 115 X25 2015 Engine 2. Unscrew the fixing clamp -Arrow B- of the air outlet pipe, pry up the fixing clip -Arrow A- of the air filter upper shell and remove the air filter upper shell -1-. Clamp -Arrow - tightening torque: 5 - 7 Nm 3.
  • Page 116 X25 2015 Engine 6. Disengage engine wiring harness clip -Arrow A- and -Arrow B- and put aside the engine wiring harness -1-. 7. Unscrew fixing bolts -Arrow- of the cylinder head cover in the illustrated order (1~10). Bolt -Arrow - tightening torque: 8 - 10 Nm Bolt -Arrow- tool: E10 splined sleeve 8.
  • Page 117 X25 2015 Engine 3. Tighten the fixing bolts -Arrow- on the cylinder head cover -1- in reverse sequence as shown in the picture(10-1). Bolt -Arrow - tightening torque: 8 - 10 Nm Bolt -Arrow- tool: E10 splined sleeve Repair Group 11 - Cylinder Head and Timing Device 107...

  • Page 118: Removal And Installation Of Intake And Exhaust Camshafts

    X25 2015 Engine 5 Removal and Installation of Intake and Exhaust Camshafts Removal 1. Remove the timing sprocket shell=>Refer to Page 114 2. Press the tension adjusting bar assembly -1- along the direction -Arrow B- and fix the chain tensioner with the fixing pin -2- (the fixing pin is self-provided).
  • Page 119 X25 2015 Engine 7. Fix the hexagonal part of the intake camshaft with a wrench, unscrew bolts -Arrow- of V.V.T sprocket assembly and remove the V.V.T sprocket assembly -1-. Bolt -Arrow - tightening torque: 59 - 70 Nm Bolt -Arrow- tool: 14mm hexagon sleeve 8.
  • Page 120 X25 2015 Engine 1. Tighten fixing bolts of intake and exhaust camshaft bearing caps to the specified torque in the order reverse to the illustrated order and then Identificat ion Mark Number tighten fixing bolts of the camshaft front bearing cap to the specified torque.

  • Page 121: Removal And Installation Of The Cylinder Head

    X25 2015 Engine 6. Removal and Installation of the Cylinder Head Removal Tips  For removal and installation steps of the cylinder head, please refer to disassembly of the engine assembly component: => Refer to Page Repair Group 11 - Cylinder Head and Timing Device 111...

  • Page 122: Timing Device

    X25 2015 Engine 7. Timing Device 7.1 Overview on Timing Device 1 - Exhaust camshaft sprocket 2 - V.V.T sprocket   Removal and installation=>Refer to Page 123 Removal and installation=>Refer to Page 125 3 - V.V.T sprocket bolt 4 - Chain guide rail assembly ...
  • Page 123 X25 2015 Engine 9 - Timing chain tensioner 10 - Bolts of camshaft sprocket   Check, replace as necessary Total: 1  Tightening torque：78～98 Nm 11 - Timing chain housing. 12 - Timing chain   Removal and installation=>Refer to Page 114 Removal and installation=>Refer to Page 117 Repair Group 11 - Cylinder Head and Timing Device 113...

  • Page 124: Removal And Installation Of Timing Chain Housing

    X25 2015 Engine 7.2 Removal and Installation of Timing Chain Housing 1. Remove the engine drive belt => Refer to Page Tips Mark the rotation direction of the belt before removing the compressor belt. 2. Remove the front wheel cover mudguard=>Body and Paint;...
  • Page 125 X25 2015 Engine 6. Unscrew the fixing bolt -Arrow- on the water pump assembly, and remove the water pump assembly-1-. Bolt - Arrow - Specifications：M6× 1.0× 45 Bolt -Arrow - tightening torque: 8 - 10 Nm Bolt -Arrow- tool: 10mm hexagon sleeve 7.
  • Page 126 X25 2015 Engine 11. Unscrew the fixing bolt -Arrow- of the oil level gauge conduit assembly and extract the oil level gauge conduit assembly -1-. Bolt - Arrow - Specifications：M6× 1.0× 12 Bolt -Arrow - tightening torque: 8 - 10 Nm Bolt -Arrow- tool: 10mm hexagon sleeve Tips Sealing rubber ring of the oil level gauge conduit must be replaced.

  • Page 127: Removal And Installation Of Timing Chain

    X25 2015 Engine Bolt - Arrow D- tightening torque: 35.5 - 43.5 Nm Bolt -Arrow D- tool: 14mm hexagon sleeve Bolt - Arrow E- Specifications：M10× 1.25× 90 Bolt -Arrow E- tightening torque: 35.5 - 43.5 Nm Bolt -Arrow E- tool: 14mm hexagon sleeve Installation Install in reverse order of removal procedures and please note the following:...
  • Page 128 X25 2015 Engine 3. Press the tension adjusting bar assembly -1- along the direction -Arrow B- and fix the chain tensioner with the fixing pin -2- (the fixing pin is self-provided). 4. Unscrew the fixing bolt -Arrow A- on the chain tensioner -3-, and remove the tensioner.
  • Page 129 X25 2015 Engine 1. Check if the positioning pin -Arrow A- for the exhaust camshaft sprocket and the mark -Arrow B- on the V.V.T sprocket assembly is facing upwards; if not, rotate the camshaft with a wrench till the positioning pin and mark faces upwards. 2.
  • Page 130 X25 2015 Engine 5. Align the mark -Arrow- on the V.V.T sprocket assembly and the blue joint -1- of the timing chain. 6. Align the blue mark -2- on the timing chain with the timing mark -1- on the crankshaft sprocket. 7.
  • Page 131 X25 2015 Engine 11. Use a wrench to fix the camshaft in the square-shape part, and tighten the camshaft sprocket bolt -Arrow-. Bolt - Arrow - Specifications：M12× 1.25× 30 Bolt -Arrow - tightening torque: 78 - 98 Nm Bolt -Arrow- tool: 17mm 6 angles sleeve 12.
  • Page 132 X25 2015 Engine Note When the installation of tensioner is completed, check the alignment of the timing marks again. If the timing marks are not aligned, re-install the timing chain following the correct procedures. 122 Repair Group 11 - Cylinder Head and Timing Device...

  • Page 133: Removal And Installation Of Exhaust Camshaft Timing Sprocket

    X25 2015 Engine 7.4 Removal and Installation of Exhaust Camshaft Timing Sprocket Removal 1. Turn the crankshaft to the top dead center position of Cylinder 1 in the engine running direction. 2. Remove the timing sprocket shell=>Refer to Page 114 3.
  • Page 134 X25 2015 Engine 1. Before installing the timing chain tensioner, press in the plunger of the tensioner and lock it with a locking pin. 2. Install the timing chain tensioner, and pull out the locking pin. Note When the installation of tensioner is completed, check the alignment of the timing marks.If the timing marks are not aligned, re-install the timing chain following the correct procedures.

  • Page 135: Removal And Installation Of V.v.t Sprocket

    X25 2015 Engine 7.5 Removal and Installation of V.V.T Sprocket Removal 1. Remove the timing chain=>Refer to Page 117. 2. Use a wrench to tighten the hexagon part of the camshaft, remove bolt -Arrow- on the V.V.T sprocket, and remove the V.V.T sprocket. Bolt -Arrow - tightening torque: 59 - 70 Nm Bolt -Arrow- tool: 14mm hexagon sleeve Installation...
  • Page 136 X25 2015 Engine Note When the installation of tensioner is completed, check the alignment of the timing marks.If the timing marks are not aligned, re-install the timing chain following the correct procedures. Other Installation is in reverse order of removal procedures. 126 Repair Group 11 - Cylinder Head and Timing Device...

  • Page 137: Chain Tensioner

    X25 2015 Engine 8 Chain Tensioner 8.1 Removal and Installation of Chain Tensioner Removal 1. Remove the timing sprocket shell=>133 2. Press the tension adjusting bar assembly -1- along the direction -Arrow B- and fix the chain tensioner with the fixing pin -2- (the fixing pin is self-provided).

  • Page 138: Crankshaft, Link Mechanism

    X25 2015 Engine 12 Crankshaft, Link Mechanism 1 Overview The crankshaft and connecting rod of the engine are designed to change the direction of force, convert the reciprocating movement of the piston into the revolving movement of the crankshaft, and perform work externally. The front end of the crankshaft mainly drives such accessory mechanisms as valve mechanism, water pump, oil pump, A/C compressor, etc.

  • Page 139: Check And Diagnosis

    X25 2015 Engine 2 Check and Diagnosis 2.1 Common Fault Checking and Eliminating 2.1.1 Crankshaft and Link Mechanism Noise Inspection steps Check results Preliminary Normal There's a fault Operation methods Inspection Further overhaul the related parts to confirm There is impact caused by limited engine Proceed to Step whether there is Check engine oil...

  • Page 140: Cylinder Pressure Too Low

    X25 2015 Engine Inspection steps Check results Engine sound is clear at intermediate Change the engine speed and not clear at high speed; the RPM while sound is the largest at the moment of listening to check Replace the rod engine cold start and especially clear whether there is Proceed to Step...
  • Page 141 X25 2015 Engine Inspection steps Check results Carbon has accumulated on the valve or valve seat, causing improper sealing when closed The valve or valve seat has been Clear off the carbon, Check the valve and the Proceed to repaired improperly, causing overhaul or replace the valve seat Step 4.

  • Page 142: Technical Parameters

    X25 2015 Engine 3 Technical Parameters Torque Name Specification Grade Tools 13～ 8mm 12 angles — — 17→90°to Connecting rod bolt sleeve 94° — — — Fixing bolt for sensor gear ring 8～10 33～ E12 splined — — 37→60°to Crankshaft bearing cap bolt socket 64°...

  • Page 143: Removal And Installation Of Cylinder Block

    X25 2015 Engine 4 Removal and Installation of Cylinder Block Removal 1. Disassemble the engine assembly => Refer to Page 2. Remove the fixing bolt -Arrow- on the crankshaft rear oil seal cover -1-, and remove the oil seal cover. Bolt - Arrow - Specifications：M6×...
  • Page 144 X25 2015 Engine Note  In order avoid mixing up the installation sequence of the piston and connecting rod components during cleaning and assembly, once a piston and connecting rod component are removed, assemble the piston and connecting rod and mark the component at the bigger end of the connecting rod with the corresponding cylinder number.
  • Page 145 X25 2015 Engine Installation Install in reverse order of removal procedures and please note the following: Note During assembly, lubricate all parts that need lubrication. 1. Thoroughly clean the cylinder block before installing it. Clean the internal and external dirt off using a volatile solvent and a brush. Using a high-pressure air gun, blow air on all water channels (such as the water channel around the cylinder sleeve), threaded holes (such as the fixing threaded hole of the cylinder head) and oil channel (such as crankshaft oil channel), etc., dry.
  • Page 146 X25 2015 Engine  Apply engine oil to piston periphery, piston ring and oil ring. 6. Use a piston guide -T61131204- to compress the piton ring, install the piton and connecting rod assembly to the cylinder block, and ensure the forward mark on at the top of the piston faces against the camshaft pulley.

  • Page 147: Removal And Installation Of Piston And Connecting Rod Components

    X25 2015 Engine 5 Removal and Installation of Piston and Connecting Rod Components Special Tools and Maintenance Equipment Required: T61131204- Piston guide Removal 1. Disassemble the engine assembly => Refer to Page 43. 2. Unscrew the fixing bolt -Arrow- of the connecting rod bearing cap and remove the connecting rod bearing cap component (with connecting rod bearing bush) -1-.
  • Page 148 X25 2015 Engine Note  In order avoid mixing up the installation sequence of the piston and connecting rod components during cleaning and assembly, once a piston and connecting rod component are removed, assemble the piston and connecting rod and mark the component at the bigger end of the connecting rod with the corresponding cylinder number.
  • Page 149 X25 2015 Engine 5. Use a piston guide -T61131204- to compress the piton ring, install the piton and connecting rod assembly to the cylinder block, and ensure the forward mark on at the top of the piston faces against the camshaft pulley.

  • Page 150: Removal And Installation Of Crankshaft

    X25 2015 Engine 6 Removal and Installation of Crankshaft Removal 1. Disassemble the engine assembly => Refer to Page 2. Remove the fixing bolt -Arrow- on the crankshaft rear oil seal cover -1-, and remove the oil seal cover. Bolt - Arrow - Specifications：M6× 1.0× 20 Bolt -Arrow - tightening torque: 8 - 10 Nm Bolt -Arrow- tool: 10mm hexagon sleeve 3.
  • Page 151 X25 2015 Engine 5. Remove the thrust bearing -Arrow-. Tips Install the thrust bearing onto the No. 4 bearing of the cylinder block. Apply engine oil to the thrust bearing for easy installation. 6. Take the crankshaft -1- out of the cylinder block. 7.
  • Page 152 X25 2015 Engine 2. Apply some engine oil on the crankshaft thrust bearing, and install the thrust bearing to the position for the fourth bearing in the cylinder block. Tips During the installation, the groove on the thrust bearing should face agaisnt the crankshaft crank arm.

  • Page 153: Air Intake/Exhaust System

    X25 2015 Engine 13 Air Intake/Exhaust System 1 Overview Air Intake System The air intake system is designed to supply sufficient amounts of clean air and ensure the quality of the combustible gas mixture. Air enters the air filter assembly in the engine compartment that filters out impurities in the air through its filter element and keeps on the surface of the filter element intake side.

  • Page 154: Check And Diagnosis

    X25 2015 Engine 2 Check and Diagnosis 2.1 Common Fault Checking and Eliminating 2.1.1 Air Intake Backfire Inspection steps Check results Preliminary Inspection Normal There's a fault Operation methods Does the engine works The engine temperature Avoid extended periods with a heavy load for an Proceed to Step 1.
  • Page 155 X25 2015 Engine Inspection steps Check results Replace with fuel that meets all specifications. The fuel is of poor If the fuel is mixed with Check if the fuel is normal Proceed to Step 2. quality or mixed with water, clean the fuel water system and replace the fuel filter...

  • Page 156: Technical Parameters

    X25 2015 Engine 3 Technical Parameters Air Intake System Torque Name Specification Grade Tools 8mm Hexagon Air filter intake pipe fixing bolt M6× 1.0× 12 4～6 Sleeve 10mm Hexagon Fixing bolt of the air filter shell assembly M6× 1.0× 35 4～6 Sleeve 10mm Hexagon...

  • Page 157: Air Intake System

    X25 2015 Engine 4 Air Intake System 4.1 Removal and Installation of the Air Filter Assembly Removal 1. Unscrew the fixing bolt -Arrow- of the air filter intake pipe and remove the air filter intake pipe -1-. Bolt - Arrow - Specifications：M6× 1.0× 12 Bolt -Arrow - tightening torque: 4 - 6 Nm Bolt -Arrow- tool: 8mm hexagon sleeve 2.

  • Page 158: Air Intake Manifold

    X25 2015 Engine 4.2 Air Intake Manifold 4.2.1 Removal and Installation of Intake Manifold Removal 1. Turn off the ignition and all electrical equipment. 2. Disconnect the battery negative cable=>Electrical Equipment: Repair Group: 60; Power Distribution; Battery: Battery Cables: Disconnection and Connection of Battery Negative Cable.
  • Page 159 X25 2015 Engine 6. Disconnect the connecting plug -Arrow A- of the electronic throttle and disengage the connection between cooling water pipe -3- and the bracket. 7. Loosen the retaining clamp -Arrow B-, disconnect the outlet pipe -1- and the throttle. 8.

  • Page 160: Detection Of The Intake Manifold

    X25 2015 Engine 12. Loosen the fixing clamp -Arrow- of the vacuum hose and disengage the connection between the vacuum hose -1- and the venting hose -2- of the carbon canister solenoid valve with the intake manifold. 13. Disconnect the connecting plug -Arrow B- of the intake air pressure and temperature sensor, unscrew the fixing bolt -Arrow A- of the intake air pressure and temperature sensor and remove the intake air temperature and pressure sensor -1-.
  • Page 161 X25 2015 Engine  Damage of the sealing junction surface of the intake manifold leads to poor sealing.  Damage of installation hole of the fuel injector leads to untight installation or air leakage of the fuel injector. Clean the pipeline in case of excessive oil sludge and carbon deposit inside the intake manifold pipeline. Repair Group 13 –...

  • Page 162: Air Intake/Exhaust System

    X25 2015 Engine 5 Air Intake/Exhaust System 5.1 Intake/Exhaust Manifold 5.1.1 Removal and Installation of Exhaust Manifold Removal Note As the exhaust system pipeline is quite hot while the engine is operating, it is necessary to shut down the engine and remove its exhaust manifold when it cools to the room temperature, or otherwise the hot parts is likely to cause personal injury.
  • Page 163 X25 2015 Engine 4. Unscrew the fixing bolts -Arrow A- and -Arrow B- on the exhaust manifold bracket-1-, and remove the intake manifold bracket. Bolt - Arrow A - Specifications：M10× 1.25× 20 Nut -Arrow A- tightening torque: 31 - 39 Nm Bolt -Arrow A- tool: 14mm hexagon sleeve Bolt - Arrow B - Specifications：M8×...

  • Page 164: Check On Exhaust Manifold

    X25 2015 Engine 5.1.2 Check on Exhaust Manifold Visual Inspection Check the exhaust manifold for the following conditions, and replace it if necessary  Structural damage or surface cracks occur in the exhaust manifold.  Damage of sealing junction surface of the exhaust manifold leads to poor sealing. Clean the pipeline in case of excessive oil sludge and carbon deposit inside the exhaust manifold pipeline.

  • Page 165: Exhaust Pipe

    X25 2015 Engine 5.2 Exhaust Pipe 5.2.1 Removal and Installation of Catalytic Converter Assembly Removal Note As the exhaust system pipeline is quite hot while the engine is operating, it is necessary to shut down the engine and remove its exhaust manifold when it cools to the room temperature, or otherwise the hot parts is likely to cause personal injury.
  • Page 166 X25 2015 Engine 6. Disengage the clip -Arrow- of the front oxygen sensor connector. 7. Disengage the dustproof rubber cover -1- of the front oxygen sensor. 8. Disconnect the connecting plug -Arrow- of the front oxygen sensor and unscrew the front oxygen sensor -1- with removal and installation tool -T41132201- for oxygen sensor.
  • Page 167 X25 2015 Engine 10. Disconnect the connector -Arrow- of the rear oxygen sensor and unscrew the rear oxygen sensor -1- with removal and installation tool -T41132201- for oxygen sensor. Tightening torque of the rear oxygen sensor -1-: 40～60 Nm 11. Unscrew the fixing bolt -Arrow- of the catalytic converter assembly and the exhaust manifold assembly and disengage the hook washer -1-.

  • Page 168: Removal And Installation Of The Auxiliary Silencer

    X25 2015 Engine Tips The sealing gasket is disposable that must be replaced after removal. 5.2.2 Removal and installation of the auxiliary silencer Removal Note As the exhaust system pipeline is quite hot when the engine just stops, it is required to shut down the engine and remove its auxiliary silencer assembly only after it cools to the room temperature, or otherwise the hot parts is likely to cause personal injury.

  • Page 169: Removal And Installation Of The Main Silencer Assembly

    X25 2015 Engine 5.2.3 Removal and Installation of the Main Silencer Assembly Removal Note As the exhaust system pipeline is quite hot while the engine is operating, it is necessary to shut down the engine and remove its exhaust manifold when it cools to the room temperature, or otherwise the hot parts is likely to cause personal injury.

  • Page 170: Check And Adjustment Of Exhaust System

    X25 2015 Engine 5.3 Check and Adjustment of Exhaust System Check  Check the various parts in the exhaust system for cracks, broken welding seams, stripped threads and excessive corrosion of the connecting bolt and nut.  Check whether the lifting lugs in the exhaust system are sturdy, and check the lug gaskets for excessive deformation, aging or other damage.

  • Page 171: Lubrication System

    X25 2015 Engine 14 Lubrication System 1 Overview The medium of the engine lubrication system is the engine oil, which performs the functions of lubrication, cleaning, cooling, sealing and anti-corrosion for the engine parts. When the lubrication system is working properly, the engine oil pump sucks the engine oil from the oil pan via the engine oil strainer, and delivers it to all the parts that require lubrication, through pipes or oil channels inside the unit.

  • Page 172: Check And Diagnosis

    X25 2015 Engine 2 Check and Diagnosis 2.1 Common Fault Checking and Eliminating 2.1.1 Low Oil Pressure Inspection steps Check results Preliminary Inspection Normal There's a fault Operation methods The engine oil used doesn't meet the Replace it with a Check whether the engine Proceed to Step 1.

  • Page 173: Exceptional Engine Oil Consumption

    X25 2015 Engine 2.1.2 Exceptional Engine Oil Consumption Inspection steps Check results Preliminary Inspection Normal There's a fault Operation methods There is a broken oil pan or leakage at the Check the engine assembly Replace the damaged connection of the for possible leakage of Proceed to Step 1.

  • Page 174: Technical Parameters

    X25 2015 Engine 3 Technical Parameters Torque Name Specification Grade Tools 12mm Hexagon Bolts of the oil filter seat M8× 1.25× 30 18～22 Sleeve 10mm Hexagon Oil pan bolt M6× 1.0× 10 7～9 Sleeve 10mm Hexagon Oil dipstick assembly bolt M6×...

  • Page 175: Removal And Installation Of Oil Filter Seat

    X25 2015 Engine 4 Removal and Installation of Oil Filter Seat Removal 1. Remove the oil filter => General; Repair group: 01: General information; Maintenance: Work description: Engine oil and oil filter: Replace. 2. Unscrew the fixing bolt -Arrow- of the oil filter bracket -1-, and remove the filter bracket.

  • Page 176: Oil Pressure Switch

    X25 2015 Engine 5.3 Oil Pressure Switch 5.1 Removal and Installation of the Oil Pressure Switch Special Tools and Maintenance Equipment Required: T41131401-Oil pressure switch sleeve T21451401-Oil pressure measuring tool Removal 1. Turn off the ignition and all electrical equipment. 2.
  • Page 177 X25 2015 Engine 5. Unscrew the fixing screw -Arrow A- of the oil pressure sensor insert and remove the oil pressure sensor insert-1-. Bolt -Arrow - tightening torque: 0.5 - 1.5 Nm 6. Unscrew the oil pressure sensor -2-. Tightening torque of oil pressure sensor -2-: 9～11 Nm Tool of oil pressure sensor -2-: 24mm hexagonal sleeve Note ...

  • Page 178: Check On Engine Oil Pressure Switch

    X25 2015 Engine 5.2 Check on Engine Oil Pressure Switch Tips A simple test of the engine oil pressure switch is outlined below.If specialized tools are available, the test should follow the manufacturer instructions. 1. Set the multimeter to ohm mode, and connect the probes of the multimeter to the housing and connector terminal of the engine oil pressure switch -1-.If the multimeter shows anything other than zero, it means the engine oil pressure switch has proper conduction.

  • Page 179: Removal And Installation Of Oil Pump

    X25 2015 Engine 6 Removal and Installation of Oil Pump Tips No accessory is provided for the oil pump for the present; if damaged, replace the timing sprocket shell assembly=>Refer to Page 114. Repair Group 14 - Lubrication System 169...

  • Page 180: Removal And Installation Of Oil Pan

    X25 2015 Engine 7 Removal and Installation of Oil Pan Special Tools and Maintenance Equipment Required Torque wrench T61131401- Removal tool of the oil pan Removal 1. Drain the engine oil=>General Description; Repair Group 01; General Information; Engine Oil Draining and Filling.
  • Page 181 X25 2015 Engine 4. Use the oil pan assembler/disassembler -T61131401- to remove the oil pan -1-. Installation Install in reverse order of removal procedures and please note the following: Note  Clean the installation surfaces on the oil pan and the cylinder block with a strong solvent (such as gasoline).

  • Page 182: Removal And Installation Of Oil Strainer

    X25 2015 Engine 8 Removal and Installation of Oil Strainer Removal 1. Remove the oil pan=>Refer to Page 170. 2. Unscrew the fixing bolts -Arrow A- and -Arrow B- on the oil strainer -1- and remove the oil strainer. Bolt -Arrow A- specification:M8× 1.25× 20 Nut -Arrow A- tightening torque: 10.5 - 12.5 Nm Bolt -Arrow A- tool: 12mm hexagon sleeve Bolt - Arrow B - Specifications：M6×...

  • Page 183: Removal And Installation Of The Oil Level Gauge Conduit Assembly

    X25 2015 Engine 9 Removal and Installation of the Oil Level Gauge Conduit Assembly Removal 1. Unscrew the fixing bolt -Arrow- of the oil level gauge conduit assembly and extract the oil level gauge conduit assembly -1-. Bolt - Arrow - Specifications：M6× 1.0× 12 Bolt -Arrow - tightening torque: 8 - 10 Nm Bolt -Arrow- tool: 10mm hexagon sleeve Tips...

  • Page 184: Removal And Installation Of Crankshaft Front Oil Seal

    X25 2015 Engine 10 Removal and Installation of Crankshaft Front Oil Seal Special Tools and Maintenance Equipment Required: Torque wrench T61131203-Crankshaft front oil seal conduit T61131207-Tool for fixing crankshaft pulley T61131202-Crankshaft front oil seal installer Removal 1. Remove the drive belt => Refer to Page 98 2.
  • Page 185 X25 2015 Engine 4. Carefully pry out the crankshaft front oil seal -1- with a screwdriver. Note Cover the head of the screwdriver with tape or flexible cloth to avoid damaging the timing sprocket shell. Note Replace the crankshaft front oil seal once removed. Installation 1.

  • Page 186: Removal And Installation Of Crankshaft Rear Oil Seal Cover

    X25 2015 Engine 11 Removal and Installation of Crankshaft Rear Oil Seal Cover Tips No accessory is provided separately for the rear oil seal of the crankshaft for the present; if damaged, replace the rear oil seal of the crankshaft. Removal Applicable to the manual transmission 1.
  • Page 187 X25 2015 Engine 6. Unscrew the fixing bolt -Arrow- of the bell housing -1- and remove the bell housing -1-. Bolt - Arrow - Specifications：M6× 1.0× 16 Bolt -Arrow - tightening torque: 8 - 10 Nm Bolt -Arrow- tool: 10mm hexagon sleeve 7.
  • Page 188 X25 2015 Engine 9. Fasten the flywheel with a flywheel stopper (Tool No.:T61131201). 10. Loosen the fixing bolt -Arrow- of the flywheel but do not unscrew it, remove the flywheel stopper -T61131201-, unscrew flywheel fixing bolt -Arrow- and remove the flywheel -1-. (AT) Bolt -Arrow- Size: M11×...
  • Page 189 X25 2015 Engine 12. Remove the fixing bolt -Arrow- on the crankshaft rear oil seal cover -1-, and remove the oil seal cover. Bolt - Arrow - Specifications：M6× 1.0× 20 Bolt -Arrow - tightening torque: 8 - 10 Nm Bolt -Arrow- tool: 10mm hexagon sleeve Installation 1.

  • Page 190: Cooling System

    X25 2015 Engine 15 Cooling System 1 Overview The internal combustion engine generates large amounts of heat.At present, the heat conversion efficiency of gasoline engines is around 28%, and up to 72% of the energy is radiated into the atmosphere as heat. If the heat isn't radiated timely, the engine will suffer from ineffective lubrication, piston scuffing, burnt crankshaft bushings and other serious damage due to overheating.

  • Page 191: Check And Diagnosis

    X25 2015 Engine 2 Check and Diagnosis 2.1 Common Fault Checking and Eliminating 2.1.1 Engine Water Temperature Is High Inspection steps Check results Preliminary Inspection Normal There's a fault Operation methods Check the level of coolant Proceed to Step 1. Insufficient coolant Top off the coolant Check the radiator...
  • Page 192 X25 2015 Engine Inspection steps Check results Check the circuit, fuse, solenoid valve and fan motor; replace the Check whether the The electronic fan turns defective parts. Check Proceed to Step 2. electronic fan is normal constantly whether the air conditioning system is faulty and eliminate the fault...

  • Page 193: Technical Parameters

    X25 2015 Engine 3 Technical Parameters Torque Name Specification Grade Tools 10mm Hexagon Fixing bolt of the thermostat shell M6× 1.0× 22 8～10 Sleeve 10mm Hexagon Condenser fixing bolt M6× 1.0× 16 9～12 Sleeve — — — Fixing screw of the auxiliary radiator 9～11 —...

  • Page 194: Cooling System Piping Diagram

    X25 2015 Engine 4 Cooling System Piping Diagram 1 - Water pump assembly 2 - Engine assembly   Removal and installation=>Refer to Page 194 Removal and installation=>Refer to Page 35 3 - Heater core 4 - Throttle assembly  ...

  • Page 195: Thermostat

    X25 2015 Engine 5 Thermostat 5.1 How it works The thermostat is the valve controlling coolant path and flow that is generally installed at the engine water inlet (connected with water outlet hose of the radiator). It is a kind of wax thermostat that is able to adjust automatically coolant path and flow by water temperature to form large and small circulations of the cooling system.

  • Page 196: Removal And Installation Of Thermostat

    X25 2015 Engine 5.2 Removal and Installation of Thermostat Removal 1. Drain the coolant=>Overview; Repair Group:01: General Information; Service and Maintenance: Work Description: Coolant: Replace. 2. Loosen the fixing clamp -Arrow A- of the radiator drain pipe and disengage the connection between the drain pipe -1- and the thermostat shell -2-.

  • Page 197: Check On Thermostat

    X25 2015 Engine 6. Take out the thermostat sealing ring -1-. Installation Install in reverse order of removal procedures. 5.3 Check on Thermostat 1. Immerse the thermostat and a thermometer into water and slowly heat the water. 2. During heating the water, observe the temperature shown on the thermometer when the thermostat valve is open.
  • Page 198 X25 2015 Engine Tips If the openness "a" or closing of the thermostat doesn't meet the standard, replace the thermostat. 188 Repair Group 15 - Cooling System...

  • Page 199: Radiator

    X25 2015 Engine 6 Radiator 6.1 Removal and Installation of the Radiator Note  To avoid damaging the pipeline and the pipe connectors, don't excessively stretch or bend the pipes.  Once disconnected, seal the pipe connectors in order to prevent impurities from entering the pipes. Removal 1.
  • Page 200 X25 2015 Engine 9. Loosen the fixing clamp -Arrow- of the radiator drain pipe and disengage the radiator drain pipe -1-. Tips  Collect the spilt automatic transmission oil with a proper container.  Wrap and seal the pipeline after disconnection of the oil pipe for fear of entry of impurities into the pipeline.

  • Page 201: Cleaning And Checking Radiator

    X25 2015 Engine 6.2 Cleaning and Checking Radiator Cleaning In normal driving, as the radiator is located at the front of the vehicle and the air inflow is great, significant amounts of dirt and impurities tend to build up on the surface of the radiator. A clean radiator surface ensures good radiation performance.

  • Page 202: Removal And Installation Of Auxiliary Radiator

    X25 2015 Engine 7 Removal and Installation of Auxiliary Radiator Removal Note  Once disconnected, seal the pipe connectors in order to prevent impurities from entering the pipes. 1. Unscrew the fixing bolt -Arrow- of the air filter intake pipe and remove the air filter intake pipe -1-.
  • Page 203 X25 2015 Engine 4. Loosen the lower fixing screw -Arrow- of the auxiliary radiator assembly and remove the auxiliary radiator assembly -1-. Screw -Arrow - tightening torque: 9 - 11 Nm Installation Install in reverse order of removal procedures and please note the following: ...

  • Page 204: Water Pump

    X25 2015 Engine 8 Water Pump 8.1 Removal and Installation of Water Pump Special Tools and Maintenance Equipment Required T41131501-Fixing tool of the water Removal 1. Drain the coolant=>Overview; Repair Group:01: General Information; Service and Maintenance: Work Description: Coolant: Replace. 2.
  • Page 205 X25 2015 Engine 6. Unscrew the fixing bolt -Arrow- on the water pump assembly -1-, and remove the water pump assembly. Bolt - Arrow - Specifications：M6× 1.0× 45 Bolt -Arrow - tightening torque: 8 - 10 Nm Bolt -Arrow- tool: 10mm hexagon sleeve Installation Install in reverse order of removal procedures and please note the following: Tips...

  • Page 206: Check The Water Pump

    X25 2015 Engine 8.2 Check the Water Pump 1. Check whether appearance and shell of the water pump -1- have such damages as crack, collision, unevenness, etc. 2. Check whether there is any trace of coolant leakage at the position -Arrow- of the water pump bearing.

  • Page 207: Removal And Installation Of Electronic Fan Assembly

    X25 2015 Engine 9 Removal and Installation of Electronic Fan Assembly Removal Danger The electronic fan may engage at any time. So, don't touch it before disconnecting its power supply. 1. Turn off the ignition and all electrical equipment. 2. Disconnect the battery negative cable=>Electrical Equipment: Repair Group: 60;...
  • Page 208 X25 2015 Engine Applicable to the automatic transmission 7. Disengage the transmission oil cooler hose -1-. Applicable to all models 8. Disengage the auxiliary radiator hose -1- and carefully remove the electronic fan assembly -2-. Installation Install in reverse order of removal procedures. 198 Repair Group 15 - Cooling System...

  • Page 209: Electronic Control System

    X25 2015 Engine 20 Electronic Control System 1 Overview 1.1 System Overview Diagnosis Diagnosis Sensor Actuators Engine The Engine Electronic Control System is comprised primarily of the sensor, microprocessor (ECU), and the actuator, which controls the air quantity, oil quantity and ignition advance angle. In the engine electronic control system, the sensor is as an input part, used to measure various physical signals (temperature, pressure, etc.), and converts them into an electric signal;...
  • Page 210 X25 2015 Engine  Electronic accelerator pedal  Injector  Air intake temperature/pressure sensor  Electronic fuel pump  Coolant temperature sensor (ECT sensor)  Fuel pressure regulator  Electronic throttle body  Camshaft position sensor  Crankshaft position sensor ...

  • Page 211: Electronic Control System I/O Signals

    X25 2015 Engine 1.2 Electronic Control System I/O Signals Electronic Control System I/O Signals The main sensor input signals of ECU include:  Intake pressure signal  Accelerator pedal signal  Intake temperature signal  Throttle angle signal  Coolant temperature signal ...

  • Page 212: Introduction To System Functions

    X25 2015 Engine 1.3 Introduction to System Functions 1.3.1 Starter Control During the starting process, special calculations are adopted to control the volume of charged gas, fuel injection and ignition timing. The air in the intake manifold is stationery at the beginning of the process and the internal pressure displayed in the intake manifold is the pressure of ambient atmosphere.

  • Page 213: Idle Speed Control

    X25 2015 Engine 1.3.4 Idle Speed Control During the idling, the engine provides no torque to the flywheel. To guarantee a stable operation of the engine at a most-possibly low idling speed, the closed-loop idle control system must keep balance between the torque generated and the "power consumed"...
  • Page 214 X25 2015 Engine The system achieves phase control through inlet/exhaust camshaft, which effectively reduces the low-speed emission of the engine and improves the high-speed torque of the engine. The ECU works out the target phase of the inlet/exhaust camshaft according to the working conditions of the vehicle as well as the driving instructions of the driver; meanwhile, it derives the phase information from the phase sensor.

  • Page 215: Dtc Diagnostic Trouble Code

    X25 2015 Engine 2 DTC Diagnostic Trouble Code 2.1 List of Engine DTC Faults Fault Code Definition P000A26 Operating fault of intake VVT (delay) P000A29 Operating fault of intake VVT (jamming) P001013 Fault of VVT intake control valve circuit P001200 The Intake VVT Is not in the Default Position at Starting Deviation of relative position between crankshaft and intake camshaft lower than the P001621...
  • Page 216 X25 2015 Engine Fault Code Definition P013217 Upstream oxygen sensor signal circuit voltage too high P013300 Upstream oxygen sensor aging P013400 Upstream oxygen sensor circuit signal circuit fault P013600 Downstream oxygen sensor signal not reasonable P013716 Downstream oxygen sensor signal low voltage P013817 Downstream oxygen sensor signal circuit voltage too high P014000...
  • Page 217 X25 2015 Engine Fault Code Definition P030229 Occurrence of second cylinder fire in the first statistic cycle of fire detection P030321 Occurrence of third cylinder fire leading to ultra-limit emission P030322 Occurrence of third cylinder fire leading to catalytic converter damage P030329 Occurrence of third cylinder fire in the first statistic cycle of fire detection P030421...
  • Page 218 X25 2015 Engine Fault Code Definition Fault of electronic throttle security monitoring function (ignition angle signal, wiring P060661 harness or ECU fault) Fault of electronic throttle security monitoring function (reasonableness fault of P060662 second layer accelerator pedal signal) Fault of electronic throttle security monitoring function (reasonableness fault of P060663 second layer accelerator pedal signal) Fault of electronic throttle security monitoring function (load signal, wiring harness...

  • Page 219: P210612 Power Drive Level Fault Of Electronic Throttle

    X25 2015 Engine Fault Code Definition P070400 Fault of clutch pedal switch voltage P133600 Safety monitor torque of electronic throttle limits the function P154500 DVE position deviation fault P154521 Throttle body DLR adjustment lower than the minimum limit value P154522 Throttle body DLR adjustment higher than the minimum limit value P155900 Second self-learning fault of throttle lower mechanical dead center...
  • Page 220 X25 2015 Engine Fault Code Definition P219500 Upstream oxygen sensor aging-signal constantly thick P219600 Upstream oxygen sensor aging-signal constantly thin P227000 Downstream oxygen sensor aging- signal constantly thin P227100 Downstream oxygen sensor aging- signal constantly thick P305400 Engine stalling or starter and flywheel not meshing fault Feedback voltage signal line (KL50r) of key starting switch (KL50r) short to ground P305500 fault...

  • Page 221: (Open) P210629 Load Monitoring Fault

    X25 2015 Engine 2.2 P010528 Intake air pressure sensor signal not fluctuating (freezing) P010600 Signal of intake air pressure sensor unreasonable P010711 Intake air pressure sensor signal circuit undervoltage P010812 Intake air pressure sensor signal circuit overvoltage P210612 Power drive level fault of electronic throttle (short) P210619 Power drive level fault of electronic throttle (overheat or overcurrent) P210692 Power drive level fault of electronic throttle (SPI bus or signal) P210613 Power drive level fault of electronic throttle (open) P210629 Load monitoring fault...
  • Page 222 X25 2015 Engine DTC testing DTC Definition DTC trigger conditions Possible causes conditions  Wiring harness or plug fault Power drive level fault  Intake manifold of electronic throttle — — P210619 absolute (overheat or pressure/atmospheri overcurrent) c pressure sensor fault ...
  • Page 223 X25 2015 Engine 2. Connect the intake manifold pressure temperature sensor connector; switch the digital multimeter to the DC voltage mode, and connect the black probe to the ground and the red probe to pin 2 and pin 4 respectively. Under idling condition, pin 2 should have 5V reference voltage, and the voltage on pin 4 is about 1.3V (depends on the car type);...
  • Page 224 X25 2015 Engine 5. With the ignition under LOCK status, check whether the wire between pin T4g/4 of the intake manifold pressure and temperature sensor connector and pin T112/91 of the engine control unit connector is conductive. − Yes Proceed to Step 6. −...
  • Page 225 X25 2015 Engine 7. Check whether pin T4g/4 of the intake manifold pressure and temperature sensor connector is short to positive terminal of the battery. − Yes Repair the faulty wire. − No Proceed to step 8. 8. Check whether pin T4g/4 of the intake manifold pressure and temperature sensor connector is short to the body ground.

  • Page 226: P011216 Signal Circuit Of Intake Air Temperature Sensor Undervoltage P011317 Signal Circuit Of Intake Air Temperature Sensor Overvoltage P011629 Signal Of Intake Air Temperature Sensor Unreasonable

    X25 2015 Engine 2.3 P011216 Signal circuit of intake air temperature sensor undervoltage P011317 Signal circuit of intake air temperature sensor overvoltage P011629 Signal of intake air temperature sensor unreasonable DTC testing DTC Definition DTC trigger conditions Possible causes conditions ...
  • Page 227 X25 2015 Engine 3. With the ignition under LOCK status, check whether the wire between pin T4g/2 of the intake manifold pressure and temperature sensor connector and pin T112/109 of the engine control unit connector is conductive. − Yes Proceed to Step 4. −...
  • Page 228 X25 2015 Engine 5. Check whether the resistance between pin T4g/2 and pin T4g/3 of the intake manifold pressure and temperature sensor connector is the normal resistance. − Yes Proceed to Step 6. − No The sensor is at fault and replace the intake manifold pressure and temperature sensor 6.
  • Page 229 X25 2015 Engine 7. Check whether the wire between pin T4g/1 of the intake manifold pressure and temperature sensor connector and the body grounding is short. − Yes-Repair the faulty wire. − No Proceed to step 8. 8. Replace the intake manifold pressure and temperature sensor, carry out road test, re-diagnose and read the fault code to see whether it still exists.

  • Page 230: P011716 Engine Coolant Temperature Sensor Circuit Undervoltage P011817 Engine Coolant Temperature Sensor Circuit Overvoltage

    X25 2015 Engine 2.4 P011716 Engine coolant temperature sensor circuit undervoltage P011817 Engine coolant temperature sensor circuit overvoltage DTC testing DTC Definition DTC trigger conditions Possible causes conditions   In excess of the upper limit Wiring harness or The engine coolant value, short to ground plug fault temperature sensor...
  • Page 231 X25 2015 Engine 4. When the ignition switch is in the LOCK position, check if there's electricity between pin 3 on the engine coolant temperature sensor connector T3g and pin 85 on the engine control unit connector T112. − Yes Proceed to Step 5. −...
  • Page 232 X25 2015 Engine 6. With the ignition under LOCK status, check whether the wire between pin T3g/3 of the engine coolant temperature sensor connector and the body is short. − Yes-Repair the faulty wire. − No Proceed to step 7. 7.

  • Page 233: P032716 Knock Sensor Signal Circuit Voltage Is Too Low

    X25 2015 Engine 2.5 P032716 Knock sensor signal circuit voltage is too low DTC trigger DTC Definition DTC testing conditions Possible causes conditions  Speed not dynamic   Load not dynamic Detected signal  The explosion and scope lower ...
  • Page 234 X25 2015 Engine 4. When the ignition switch is in the LOCK position, check if there's electricity between pin 1 on the knock sensor connector T2o and pin 90 on the engine control unit connector T112. − Yes Proceed to Step 5. −...
  • Page 235 X25 2015 Engine 6. Disconnect the battery negative cable, and check if there's electricity between pin 1 and pin 2 on the knock sensor connector T2o and the battery positive electrode. − Yes-Repair the faulty wire. − No Proceed to step 7. 7.

  • Page 236: P034100 Phase Sensor Signal Is Implausible

    X25 2015 Engine 2.6 P034100 Phase sensor signal is implausible DTC testing DTC Definition DTC trigger conditions Possible causes conditions  Wiring harness or  Poor contact plug fault   Phase sensor signal is Phase signal register value Camshaft position —...
  • Page 237 X25 2015 Engine 3. Disconnect the electronic engine control unit connector T112. 4. With the ignition under LOCK status, check whether the wire between pin T3a/2 of the camshaft position sensor connector and pin T112/93 of the electronic engine control unit connector is conductive. −...
  • Page 238 X25 2015 Engine 6. With the ignition under LOCK status, check whether the wire between pin T3a/1 of the camshaft position sensor connector and pin T112/98 of the electronic engine control unit connector is conductive. − Yes Proceed to Step 7. −...
  • Page 239 X25 2015 Engine 8. Check whether the wire between pin T3a/2 of the camshaft position sensor connector and the body grounding is short. − Yes-Repair the faulty wire. − No Proceed to step 9. 9. Replace the camshaft position sensor, carry out another road test, and read the fault code to see whether it still exists. −...

  • Page 240: P048014 Control Circuit Fault Of Cooling Fan Relay

    X25 2015 Engine 2.7 P048014 Control circuit fault of cooling fan relay (low speed) P048114 Control circuit fault of cooling fan relay (high speed) P069212 Control circuit of cooling fan relay short to power supply (low speed) P069311 Control circuit of cooling fan relay short to ground (high speed) P069412 Control circuit of cooling fan relay short to power supply (high speed) DTC testing...
  • Page 241 X25 2015 Engine 2. Turn off the ignition, remove the electronic fan relays J101 and J102 from the front compartment electric box, and check if the relay is normal. Multimeter Conditions Rated value connecting pins Common status Constant state Connectivity 85-86 Between pin 85 and pin 86, apply supply...
  • Page 242 X25 2015 Engine 4. With the ignition under LOCK status, check whether the wire between pin T14a/8 of low speed fan connector of the front compartment electrical box and pin T4c/C of the electronic fan connector and the wire between pin T20a/10 of the front compartment electrical box connector and pin T4c/D of the electronic fan connector are conductive.
  • Page 243 X25 2015 Engine 6. Check whether the wires between pins T112/56 and T112/31 of the engine control unit connector and the body grounding are short. − Yes-Repair the faulty wire. − No Proceed to step 7. 7. Replace the engine control unit; perform road test again, read the fault code, and check if it is still present. −...

  • Page 244: P032200 Vehicle Speed Sensor Signal Fault

    X25 2015 Engine 2.8 P032200 Vehicle speed sensor signal fault DTC testing DTC Definition DTC trigger conditions Possible causes conditions  Wiring harness or  No speed is detected plug fault after certain phase  Vehicle speed sensor Engine speed too Crankshaft position P032200 speed sensor...
  • Page 245 X25 2015 Engine 3. Disconnect the engine control unit connector T112 and check whether the wire between pin T3h/2 of the crankshaft position sensor and pin T112/96 of the engine control unit connector is conductive with the ignition under LOCK status. −...
  • Page 246 X25 2015 Engine 5. With the ignition under LOCK status, check whether the wires between pins T3h/1, T3h/2 and T3h/3 of the crankshaft position sensor connector and positive terminal of the battery are short. − Yes-Repair the faulty wire. − No Proceed to step 6.

  • Page 247: P070400 Fault Of Clutch Pedal Switch Voltage

    X25 2015 Engine 2.9 P070400 Fault of clutch pedal switch voltage DTC testing DTC Definition DTC trigger conditions Possible causes conditions   Detect gearshift Wiring harness or The vehicle speed is times plug fault   Fault of clutch pedal over 50km/h and the The times of clutch Clutch pedal switch...
  • Page 248 X25 2015 Engine 3. Check whether the wire between pin T6e/C of the clutch switch connector and positive terminal of the battery is short. − Yes-Repair the faulty wire. − No Proceed to step 4. 4. Check whether the wire between pin T6e/C of the clutch switch connector and the body grounding is short.
  • Page 249 X25 2015 Engine 5. Check whether the wire between pin T6e/D of the clutch switch connector and the body grounding is conductive. − Yes Proceed to Step 6. − No - Repair the faulty line. 6. Replace the clutch switch, carry out another road test, and read the fault code to see whether it still exists. −...

  • Page 250: P000A26 Operating Fault Of Intake Vvt (Delay)

    X25 2015 Engine 2.10 P000A26 Operating fault of intake VVT (delay) P000A29 Operating fault of intake VVT (jamming) P001013 Fault of VVT intake control valve circuit P001200 Intake VVT not at the default position at start P208811 VVT intake control valve circuit undervoltage P208912 VVT intake control valve circuit overvoltage P210612 Power drive level fault of electronic throttle (short) DTC trigger...
  • Page 251 X25 2015 Engine DTC trigger DTC Definition DTC testing conditions Possible causes conditions  VVT self-learning completed  Oil temperature： （-40～130）  Wiring harness or  Water temperature： Difference between plug fault （0～130） The Intake VVT Is not  the actual angle and VVT intake control ...
  • Page 252 X25 2015 Engine 3. When the ignition switch is in the LOCK position, check if there's electricity between pin 2 on the VVT intake control valve T2ef and pin 71 on the engine control unit connector T112. − Yes Proceed to Step 4. −...
  • Page 253 X25 2015 Engine 5. Disconnect negative terminal of the battery and check whether the wires between pins T2ef/1 and T2ef/2 of VVT intake control valve connector and positive terminal of the battery are short. − Yes-Repair the faulty wire. − No Proceed to step 6.

  • Page 254: P001621 Deviation Of Relative Position Between Crankshaft And Intake Camshaft Lower Than The Minimum

    X25 2015 Engine 2.11 P001621 Deviation of relative position between crankshaft and intake camshaft lower than the minimum limit P001622 Deviation of relative position between crankshaft and intake camshaft higher than the maximum limit P001629 Signal of relative position deviation between crankshaft and intake camshaft unreasonable DTC testing DTC Definition...
  • Page 255 X25 2015 Engine DTC testing DTC Definition DTC trigger conditions Possible causes conditions  Camshaft position sensor signal unstable  Crankshaft position sensor fault  Camshaft position Relative position  Crankshaft and Difference sensor fault deviation signal  camshaft crankshaft and camshaft Impulse ring of the P001629 between crankshaft and...

  • Page 256: P066013 Variable Intake Manifold Solenoid Valve

    X25 2015 Engine 2.12 P066013 Variable intake manifold solenoid valve circuit open P066111 Variable intake manifold solenoid valve circuit short to ground P066212 Variable intake manifold solenoid valve circuit short to power supply DTC testing DTC Definition DTC trigger conditions Possible causes conditions ...
  • Page 257 X25 2015 Engine 3. Disconnect the connecting plug T2ef of the intake manifold length switch. 4. Check whether pin T112/70 of the engine control unit connector and pin T2ef/2 of the intake manifold length switch connector is open. − Yes Repair the faulty line −...

  • Page 258: P05711C Brake Signal Unreasonable P057129 Brake Signal Unreasonable

    X25 2015 Engine 7. Check whether pin T2ef/2 of the intake manifold length switch connector is short to the body grounding. − Yes Repair the faulty line − No Proceed to step 8. 8. Check whether power supply and grounding circuits of the intake manifold length switch are normal. −...
  • Page 259 X25 2015 Engine DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions  Wiring harness or Brake signal plug fault — — P057129  unreasonable Brake switch fault  The fuse is damaged Diagnostic steps: 1. Disconnect the connector T4h of the braking switch, check the connector T4h for crack and abnormality and check its pins for corrosion and rust.
  • Page 260 X25 2015 Engine 4. Check whether the wire between pin T16d/5 of the engine compartment electrical box fuse connector and pin T4h/4 of the vehicle switch is conductive. − Yes Proceed to Step 5. − Yes Repair the faulty wire. 5.
  • Page 261 X25 2015 Engine 6. Disconnect the engine control unit connector T112 and check whether the wire between pin T4h/1 of the brake switch connector and pin T112/2 of the engine control unit connector is conductive. − Yes Proceed to Step 7. −...
  • Page 262 X25 2015 Engine 8. Check whether the wires between pins T4h/2 and T4h/1 of the brake switch connector and the body grounding are short. − Yes Repair the faulty wire. − No Proceed to step 9. 9. Replace the brake switch, carry out another road test, and read the fault code to see whether it still exists. −...

  • Page 263: P012129 Electronic Throttle Position Sensor 1 Signal

    X25 2015 Engine 2.14 P012129 Electronic throttle position sensor 1 signal unreasonable PP012216 Electronic throttle position sensor 1 signal circuit undervoltage P012317 Electronic throttle position sensor 1 signal circuit overvoltage P022129 Electronic throttle position sensor 2 signal unreasonable P022216 Electronic throttle position sensor 2 signal circuit undervoltage P022317 Electronic throttle position sensor 2 signal circuit overvoltage P060100 Fault of electronic throttle security monitoring function (ECU EEPROM fault) P060600 Fault of electronic throttle security...

  • Page 264: Monitoring Function

    X25 2015 Engine DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions   Signal circuit voltage In excess of the lower Wiring harness or of Electronic Throttle limit plug fault P012216 12s after start   Position Sensor 1 is too Signal voltage TPS1 Electronic throttle...
  • Page 265 X25 2015 Engine DTC detection DTC trigger DTC Definition Possible fault causes conditions conditions Fault of electronic throttle  Wiring harness or plug security monitoring — — P060655 fault function (deformation code  Electronic throttle fault monitoring fault) Fault of electronic throttle ...
  • Page 266 X25 2015 Engine DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions  Monitoring of PID setting range, duty ratio is more than  Throttle body DLR Wiring harness or adjustment lower than plug fault —  P154521 Monitoring of ...
  • Page 267 X25 2015 Engine DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions  Water  temperature Check spring open higher than reasonableness  Closing time ＞0.3s 5.3℃   Intake air Test threshold value:  Wiring harness or Return resistance of the temperature 2.49%...
  • Page 268 X25 2015 Engine 3. Manually move the throttle valve flap, measure the resistances between pin T6a/2 and pin T6a/5 when closed, completely open, and from closed to completely open, and see if there's any change. − Yes Proceed to Step 4. −...
  • Page 269 X25 2015 Engine 5. Measure whether pin T6a/1 and pin T6a/4 on the throttle position sensor connector is connected. − Yes Proceed to Step 6. − No There is fault in throttle position drive motor; replace the throttle. 6. Disconnect the engine control unit connector T112, check if there's electricity between pin 2 on the electronic throttle T6a and pin 86 on the engine control unit connector T112.
  • Page 270 X25 2015 Engine 7. Check if there's electricity between pin 6 on the electronic throttle T6a and pin 77 on the engine control unit connector T112. − Yes Proceed to Step 8. − Yes Repair the faulty wire. 8. Check if there's electricity between pin 5 on the electronic throttle T6a and pin 78 on the engine control unit connector T112.
  • Page 271 X25 2015 Engine 9. Check if there's electricity between pin 3 on the electronic throttle T6a and pin 107 on the engine control unit connector T112. − Yes Proceed to Step 10. − Yes Repair the faulty wire. 10. Check if there's electricity between pin 4 on the electronic throttle T6a and pin 75 on the engine control unit connector T112.
  • Page 272 X25 2015 Engine 11. Check if there's electricity between pin 1 on the electronic throttle T6a and pin 87 on the engine control unit connector T112. − Yes Proceed to Step 12. − Yes Repair the faulty wire. 12. Disconnect the battery negative cable, and check if there's electricity between pin T6a/5 and pin T6a/6 on the throttle position sensor connector and the battery positive electrode.
  • Page 273 X25 2015 Engine 13. Measure whether pin T6a/5 and pin T6a/6 on the throttle position sensor connector is connected to the vehicle ground. − Yes Repair the faulty wire. − No Proceed to step 14. 14. Replace the engine control unit; perform road test again, read the fault code, and check if it is still present. −...

  • Page 274: P212216 Electronic Accelerator Pedal Position

    X25 2015 Engine 2.15 P212216 Electronic accelerator pedal position sensor 1 signal undervoltage P212317 Electronic accelerator pedal position sensor 1 signal overvoltage P212716 Electronic accelerator pedal position sensor 2 signal undervoltage P212817 Electronic accelerator pedal position sensor 2 signal overvoltage P213800 Electronic accelerator pedal position sensor signal unreasonable P213829 Electronic accelerator pedal position sensor signal unreasonable DTC detection...
  • Page 275 X25 2015 Engine 2. Disconnect the connecting plug, set the multimeter to ohm position and use the multimeter to check whether the resistance between pin T6c/1n and pin T6c/5 of the electronic accelerator pedal position sensor connector is normal. 3. Use the multimeter to check whether the resistance between pin T6c/2 and pin T6c/3 of the electronic accelerator pedal position sensor connector is normal.
  • Page 276 X25 2015 Engine 6. Check whether the wire between pin T6c/2 of the electronic accelerator pedal position sensor connector and T112/37 of the engine control unit connector is conductive. − Yes Proceed to Step 7. − Yes Repair the faulty wire. 7.
  • Page 277 X25 2015 Engine 8. Check whether the wire between pin T6c/4 of the electronic accelerator pedal position sensor connector and T112/45 of the engine control unit connector is conductive. − Yes Proceed to Step 9. − Yes Repair the faulty wire. 9.
  • Page 278 X25 2015 Engine 10. Check whether the wire between pin T6c/6 of the electronic accelerator pedal position sensor connector and T112/30 of the engine control unit connector is conductive. − Yes Proceed to Step 11. − Yes Repair the faulty wire. 11.
  • Page 279 X25 2015 Engine 12. Check whether pins T6c/4 and T6c/6 of the electronic accelerator pedal position sensor connector are short to the body grounding. − Yes Repair the faulty wire. − No Proceed to step 13. 13. Replace the electronic accelerator pedal position sensor, carry out another road test, and read the fault code to see whether it still exists.

  • Page 280: P044413 Control Circuit Fault Of Carbon Canister Control Valve P045816 Control Circuit Of Carbon Canister Control Valve Undervoltage P045917 Control Circuit Of Carbon Canister Control Valve Overvoltage

    X25 2015 Engine 2.16 P044413 Control circuit fault of carbon canister control valve P045816 Control circuit of carbon canister control valve undervoltage P045917 Control circuit of carbon canister control valve overvoltage DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions ...
  • Page 281 X25 2015 Engine 3. Disconnect the engine control unit connector T112 and check whether the wire between pin T2y/2 of the carbon canister control valve and pin T112/94 of the engine control unit connector is conductive. − Yes Proceed to Step 4. −...
  • Page 282 X25 2015 Engine 5. Disconnect negative cable of the battery and check whether the wire between pin T2y/2 of the carbon canister control valve and positive terminal of the battery is short. − Yes Repair the faulty wire. − No Proceed to step 6. 6.

  • Page 283: P003013 Heating Control Circuit Fault Of Upstream

    X25 2015 Engine 2.17 P003013 Heating control circuit fault of upstream oxygen sensor P003111 Heating control circuit of upstream oxygen sensor undervoltage P003212 Heating control circuit of upstream oxygen sensor overvoltage P00531E Heating internal resistance of upstream oxygen sensor unreasonable DTC detection DTC Definition DTC trigger conditions...
  • Page 284 X25 2015 Engine 3. Check whether the resistance between pin T4e/D and pin T4e/C of the front oxygen sensor connector is normal − Yes Proceed to Step 4. − No The front oxygen sensor is faulty, and replace it. 4. Check if the voltage between pin 4 on the front oxygen sensor connector T4e and the vehicle ground is the same as the battery voltage.
  • Page 285 X25 2015 Engine 5. With the ignition under OFF status, check whether the wire between pin T4e/D of the front oxygen sensor and pin T20a/3 of the front compartment fuse box connector is conductive. − Yes Proceed to Step 6. −...
  • Page 286 X25 2015 Engine 7. Disconnect negative cable of the battery, and check whether the wire between pin T4e/B of the front oxygen sensor and positive terminal of the battery is short. − Yes Repair the faulty wire. − No Proceed to step 8. 8.
  • Page 287 X25 2015 Engine 9.Disconnect negative cable of the battery, and check whether the wire between pin T4e/A of the front oxygen sensor and positive terminal of the battery is short. − Yes Repair the faulty wire. − No Proceed to step 10. 10.

  • Page 288: Of Downstream Oxygen Sensor Unreasonable

    X25 2015 Engine 2018 P003613 Heating control circuit fault of downstream oxygen sensor P003711 Heating control circuit of downstream oxygen sensor undervoltage P003812 Heating control circuit of downstream oxygen sensor overvoltage P00541E Heating internal resistance of downstream oxygen sensor unreasonable DTC detection DTC Definition DTC trigger conditions...
  • Page 289 X25 2015 Engine 3. Check whether the resistance between pin T4f/C and pin T4f/D of the rear oxygen sensor connector is normal. − Yes Proceed to Step 4. − No The rear oxygen sensor is faulty, and replace it. 4. With the ignition under OFF status, check whether the wire between pin T4f/C of the rear oxygen sensor and pin T20a/3 of the front compartment fuse box connector is conductive.
  • Page 290 X25 2015 Engine 5. With the ignition under ON status, check whether the voltage between pin T4f/C of the rear oxygen sensor and the body grounding is the battery voltage. − Yes Proceed to Step 6. − Yes Repair the faulty wire. 6.
  • Page 291 X25 2015 Engine 7. Disconnect negative cable of the battery, and check whether the wire between pin T4f/D of the rear oxygen sensor and positive terminal of the battery is short. − Yes Proceed to Step 8. − Yes Repair the faulty wire. 8.

  • Page 292: Aging-Signal Constantly Thin

    X25 2015 Engine 2.19 P013000 Upstream oxygen sensor signal unreasonable P013116 Upstream oxygen sensor signal undervoltage P013217 Upstream oxygen sensor signal circuit overvoltage P013300 Upstream oxygen sensor aging P013400 Signal circuit fault of upstream oxygen sensor P219500 Upstream oxygen sensor aging-signal constantly thick P219600 Upstream oxygen sensor aging-signal constantly thin DTC detection DTC Definition...
  • Page 293 X25 2015 Engine DTC trigger DTC Definition DTC detection conditions Possible fault causes conditions  Valid counting cycle larger than 12  Closed-loop control of front oxygen sensor activated  No fault on pressure sensor Upstream signal   No fault on water delay through filter is Wiring harness or temperature sensor...
  • Page 294 X25 2015 Engine DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions  The vehicle speed keeps around gear V, 70km/h  Catalytic  Rear oxygen control  converter Wiring harness or integral is beyond the Upstream oxygen fault-free plug fault lower limit.
  • Page 295 X25 2015 Engine 5. With the ignition under ON status, check whether the voltage between pin T4e/D and pin T4e/C of front oxygen sensor is normal − Yes Replace the front oxygen sensor. − No Proceed to step 6. 6. Disconnect the engine control unit connector T112, check if there's electricity between pin B on the front oxygen sensor connector T4e and pin 104 on the engine control unit connector T112.
  • Page 296 X25 2015 Engine 7. Check whether the wire between pin T4e/A of the front oxygen sensor and pin T112/80 of the engine control unit connector is conductive. − Yes Proceed to Step 8. − Yes Repair the faulty wire. 8. Disconnect negative cable of the battery, and check whether the wires between pins T4e/B and T4e/A of the front oxygen sensor and positive terminal of the battery are short.
  • Page 297 X25 2015 Engine 9. Check whether the wires between pins T4e/B and T4e/A of the front oxygen sensor and the body grounding are short. − Yes Repair the faulty wire. − No Proceed to step 10. 10. Replace the engine control unit; perform road test again, read the fault code, and check if it is still present. −...

  • Page 298: Constantly Thick

    X25 2015 Engine 2.20 P013600 Downstream oxygen sensor signal unreasonable P013716 Downstream oxygen sensor signal undervoltage P013817 Downstream oxygen sensor signal circuit overvoltage P014000 Fault of downstream oxygen sensor circuit signal P227000 Downstream oxygen sensor aging-signal constantly thin P227100 Downstream oxygen sensor aging-signal constantly thick DTC detection DTC Definition DTC trigger conditions...
  • Page 299 X25 2015 Engine DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions   Rear oxygen voltage Wiring harness or Downstream oxygen is constantly lower plug fault —   P227100 sensor aging-signal Voltage rear Rear oxygen sensor ＜...
  • Page 300 X25 2015 Engine 6. Disconnect the engine control unit connector T112, check if there's electricity between pin B on the front oxygen sensor connector T4f and pin 92 on the engine control unit connector T112. − Yes Proceed to Step 7. −...
  • Page 301 X25 2015 Engine 8. Disconnect negative cable of the battery, and check whether the wires between pins T4f/A and T4f/B of the front oxygen sensor and positive terminal of the battery are short. − Yes Repair the faulty wire. − No Proceed to step 9.

  • Page 302: P020113 Control Circuit Fault Of First Cylinder Fuel Injector P026111 Control Circuit Of First Cylinder Fuel Injector Undervoltage P026212 Control Circuit Of First Cylinder Fuel Injector Overvoltage

    X25 2015 Engine 2.21 P020113 Control circuit fault of first cylinder fuel injector P026111 Control circuit of first cylinder fuel injector undervoltage P026212 Control circuit of first cylinder fuel injector overvoltage DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions ...
  • Page 303 X25 2015 Engine 3. With the ignition under ON status, check whether the voltage between pin T2x/1 of the first cylinder fuel injector connector and the body grounding is the battery voltage. − Yes Proceed to Step 4. − Yes Repair the faulty wire. 4.
  • Page 304 X25 2015 Engine 5. Disconnect the engine control unit connector T112, and check if the connector T112 has cracks or other abnormality, and if the pins are corroded or rusted. 6. With the ignition under LOCK status, check whether the wire between pin T2x/2 of the first cylinder fuel injector connector and pin T112/68 of the engine control unit connector is conductive.
  • Page 305 X25 2015 Engine 8. Disconnect the battery negative cable, and check if there's electricity between pin 2 on the cylinder-1 injector connector T2x and the battery positive electrode. − Yes Repair the faulty wire. − No Proceed to step 9. 9.

  • Page 306: P020213 Control Circuit Fault Of Second Cylinder Fuel Injector P026411 Control Circuit Of Second Cylinder Fuel Injector Undervoltage P026512 Control Circuit Of Second Cylinder Fuel Injector Overvoltage

    X25 2015 Engine 2.22 P020213 Control circuit fault of second cylinder fuel injector P026411 Control circuit of second cylinder fuel injector undervoltage P026512 Control circuit of second cylinder fuel injector overvoltage DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions ...
  • Page 307 X25 2015 Engine 3. With the ignition under ON status, check whether the voltage between pin T2w/1 of the second cylinder fuel injector connector and the body grounding is the battery voltage. − Yes Proceed to Step 4. − Yes Repair the faulty wire. 4.
  • Page 308 X25 2015 Engine 5. Disconnect the engine control unit connector T112, and check if the connector T112 has cracks or other abnormality, and if the pins are corroded or rusted. 6. With the ignition under LOCK status, check whether the wire between pin T2w/2 of the second cylinder fuel injector connector and pin T112/67 of the engine control unit connector is conductive.
  • Page 309 X25 2015 Engine 8. Disconnect the battery negative cable, and check if there's electricity between pin 2 on the cylinder-2 injector connector T2w and the battery positive electrode. − Yes Repair the faulty wire. − No Proceed to step 9. 9.

  • Page 310: P020313 Control Circuit Fault Of Third Cylinder Fuel Injector P026711 Control Circuit Of Third Cylinder Fuel Injector Undervoltage P026812 Control Circuit Of Third Cylinder Fuel Injector Overvoltage

    X25 2015 Engine 2.23 P020313 Control circuit fault of third cylinder fuel injector P026711 Control circuit of third cylinder fuel injector undervoltage P026812 Control circuit of third cylinder fuel injector overvoltage DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions ...
  • Page 311 X25 2015 Engine 3. With the ignition under ON status, check whether the voltage between pin T2v/1 of the third cylinder fuel injector connector and the body grounding is the battery voltage. − Yes Proceed to Step 4. − Yes Repair the faulty wire. 4.
  • Page 312 X25 2015 Engine 5. Disconnect the engine control unit connector T112, and check if the connector T112 has cracks or other abnormality, and if the pins are corroded or rusted. 6. With the ignition under LOCK status, check whether the wire between pin T2v/2 of the third cylinder fuel injector connector and pin T112/72 of the engine control unit connector is conductive.
  • Page 313 X25 2015 Engine 8. Disconnect negative cable of the battery and check whether the wire between pin T2v/2 of the third cylinder fuel injector connector and positive terminal of the battery is short. − Yes Repair the faulty wire. − No Proceed to step 9.

  • Page 314: P020413 Control Circuit Fault Of Fourth Cylinder Fuel Injector P027011 Control Circuit Of Fourth Cylinder Fuel Injector Undervoltage P027112 Control Circuit Of Fourth Cylinder Fuel Injector Overvoltage

    X25 2015 Engine 2.24 P020413 Control circuit fault of fourth cylinder fuel injector P027011 Control circuit of fourth cylinder fuel injector undervoltage P027112 Control circuit of fourth cylinder fuel injector overvoltage DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions ...
  • Page 315 X25 2015 Engine 3. Disconnect the connector T2u of the fourth cylinder fuel injector, check the connector T2u for crack and abnormality and check its pins for corrosion and rust. 4. With the ignition under ON status, check whether the voltage between pin T2u/1 of the fourth cylinder fuel injector connector and the body grounding is the battery voltage.
  • Page 316 X25 2015 Engine 6. Disconnect the engine control unit connector T112, and check if the connector T112 has cracks or other abnormality, and if the pins are corroded or rusted. 7. With the ignition under LOCK status, check whether the wire between pin T2u/2 of the fourth cylinder fuel injector connector and pin T112/74 of the engine control unit connector is conductive.
  • Page 317 X25 2015 Engine 9. Disconnect negative cable of the battery and check whether the wire between pin T2u/2 of the fourth cylinder fuel injector connector and positive terminal of the battery is short. − Yes Repair the faulty wire. − No Proceed to step 9.

  • Page 318: P030021 Occurrence Of Several Cylinder Fire

    X25 2015 Engine 2.25 P030021 Occurrence of several cylinder fire leading to ultra-limit emission P030022 Occurrence of several cylinder fire leading to catalytic converter damage P030029 Occurrence of several cylinder fire in the first statistic cycle of fire detection DTC detection DTC Definition DTC trigger conditions Possible fault causes...
  • Page 319 X25 2015 Engine DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions  Miss fire rate destroying the catalytic converter  Threshold value for fire rate leading catalytic converter damage (dependent on working conditions)  No diagnosis of ...
  • Page 320 X25 2015 Engine 1. Check for vacuum leakage at the channels and connections related to the intake system. − Yes Repair the air leakage fault. − No Proceed to step 2. 2. Check the injection volume and leakage of the nozzle. (Refer to relevant fault diagnosis of the fuel injector) −...

  • Page 321: Detection

    X25 2015 Engine 2.26 P030121 Occurrence of first cylinder fire leading to ultra-limit emission P030122 Occurrence of first cylinder fire leading to catalytic converter damage P030129 Occurrence of first cylinder fire in the first statistic cycle of fire detection P030221 Occurrence of second cylinder fire leading to ultra-limit emission P030222 Occurrence of second cylinder fire leading to catalytic converter damage P030229 Occurrence of second cylinder fire in the first statistic cycle of fire detection P030321 Occurrence of third cylinder fire leading to ultra-limit emission P030322...
  • Page 322 X25 2015 Engine DTC detection DTC trigger DTC Definition Possible fault causes conditions conditions  Ignition coil fault  Occurrence of second Spark plug fault — —  P030221 cylinder fire leading to Ignition coil circuit fault  ultra-limit emission Electronic engine control unit fault ...
  • Page 323 X25 2015 Engine DTC detection DTC trigger DTC Definition Possible fault causes conditions conditions  Ignition coil fault Occurrence of third  Spark plug fault cylinder fire in the first —  P030329 Ignition coil circuit fault statistic cycle of fire ...
  • Page 324 X25 2015 Engine 4. With the ignition under ON status, check whether the voltage between pins T2ea/1, T2eb/1, T2ec/1 and T2ed/1 of the ignition coil connector and the body grounding is the battery voltage. − Yes Proceed to Step 5. −...
  • Page 325 X25 2015 Engine 6. With the ignition under ON status, check whether the voltage between pins T2ea/2, T2eb/2, T2ec/2 and T2ed/2 of the ignition coil connector and the body grounding is the battery voltage. − Yes Repair the faulty wire. −...

  • Page 326: P021900 Engine Speed Higher Than The Maximum Speed Limit P050600 Idle Control Speed Lower Than Target Idle Speed P050700 Idle Control Speed Higher Than Target Idle Speed

    X25 2015 Engine 2.27 P021900 Engine speed higher than the maximum speed limit P050600 Idle control speed lower than target idle speed P050700 Idle control speed higher than target idle speed DTC trigger DTC Definition DTC detection conditions Possible fault causes conditions ...
  • Page 327 X25 2015 Engine 4. Remove the carbon canister solenoid valve and check whether the carbon canister solenoid valve is normally open. − Yes Replace the canister solenoid valve. − No Proceed to step 5. 5. Connect the diagnostic tester, start the engine and check whether dataflow of the intake manifold pressure sensor is normal.

  • Page 328: P056000 System Battery Voltage Signal

    X25 2015 Engine 2.28 P056000 System battery voltage signal unreasonable P056216 System battery undervoltage P056317 System battery overvoltage P062211 Generator load feedback signal undervoltage P062212 Generator load feedback signal overvoltage DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions ...
  • Page 329 X25 2015 Engine 4. Disconnect the generator connector T2s. 5. Check whether the wire between pin T112/106 of the engine control unit connector and pin T2s/2 of the generator connector is conductive. − Yes Proceed to Step 6. − Yes Repair the faulty wire. 6.

  • Page 330: P062713 Control Circuit Fault Of Oil Pump Relay P062811 Oil Pump Relay Control Circuit Short To Ground Or Open P062912 Oil Pump Relay Control Circuit Overvoltage

    X25 2015 Engine 2.29 P062713 Control circuit fault of oil pump relay P062811 Oil pump relay control circuit short to ground or open P062912 Oil pump relay control circuit overvoltage DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions ...
  • Page 331 X25 2015 Engine 3. Check whether oil pump relay J104 of the front compartment electrical box is normal. Multimeter Condition Specified valve connecting pins Normal state Normal state 85-86 Conductivity Between pin 85 and pin 86, apply supply 30-87 Conductivity voltage −...
  • Page 332 X25 2015 Engine 7. With the ignition under LOCK status, check whether the wire between pin T16d/9 of the front compartment electrical box connector and the body grounding is short. − Yes Repair the faulty wire. − No Proceed to step 8. 8.
  • Page 333 X25 2015 Engine 9. With the ignition under LOCK status, check whether the wire between pin T20a/9 of the front compartment electrical box connector and pin T112/5 of the engine control unit connector is conductive. − Yes Proceed to Step 10. −...
  • Page 334 X25 2015 Engine 11. When the ignition switch is in the ON state, measure whether the voltage between connector T18b/pin 2 of the front compartment electrical box and body ground is the battery voltage. − Yes Proceed to Step 12. −...

  • Page 335: P068800 Main Relay Output Voltage Unreasonable P068816 Fault Of Main Relay Output Voltage Signal

    X25 2015 Engine 2.30 P068800 Main relay output voltage unreasonable P068816 Fault of main relay output voltage signal DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions  Wire fault  The main relay output Check signal — ...
  • Page 336 X25 2015 Engine 4. With the ignition under LOCK status, check whether the wire between pin T20a/9 of the front compartment electrical box connector and pin T112/5 of the engine control unit connector is conductive. − Yes Proceed to Step 5. −...
  • Page 337 X25 2015 Engine 6. Disconnect negative terminal of the battery and check whether the wire between pin T20a/9 of the front compartment electrical box connector and positive terminal of the battery is short. − Yes Repair the faulty wire. − No Proceed to step 7.

  • Page 338: P064513 Control Circuit Fault Of A/C Compressor Relay P064611 Control Circuit Of A/C Compressor Relay Short To Ground P064712 Control Circuit Of A/C Compressor Relay Overvoltage

    X25 2015 Engine 2.31 P064513 Control circuit fault of A/C compressor relay P064611 Control circuit of A/C compressor relay short to ground P064712 Control circuit of A/C compressor relay overvoltage DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions ...
  • Page 339 X25 2015 Engine 4. Detect whether main relay J100 in front compartment electrical box is normal. Multimeter Condition Specified valve connecting pins Normal state Normal state 85-86 Conductivity Between pin 85 and pin 86, apply supply 30-87 Conductivity voltage − Yes Proceed to Step 5.
  • Page 340 X25 2015 Engine 8. With the ignition under LOCK status, check whether the wire between pin T20a/11 of the front compartment electrical box connector and pin T112/42 of the engine control unit connector is conductive. − Yes Proceed to Step 9. −...
  • Page 341 X25 2015 Engine 10. Disconnect negative terminal of the battery and check whether the wire between pin T112/42 of the engine control unit connector and positive terminal of the battery is short. − Yes Repair the faulty wire. − No Proceed to step 11. 11.
  • Page 342 X25 2015 Engine 12. With the ignition under LOCK status, check whether the wire between pin T20a/9 of the front compartment electrical box connector and pin T112/5 of the engine control unit connector is conductive. − Yes Proceed to Step 13. −...

  • Page 343: Air-Fuel Ratio

    X25 2015 Engine 2.32 P017000 Air-fuel ratio closed-loop control self-learning in off-line detection unreasonable P017100 Air-fuel ratio closed-loop control self-learning in off-line detection too thin P017200 Air-fuel ratio closed-loop control self-learning in off-line detection too thick P217700 Air-fuel ratio closed-loop control self-learning value higher than the upper limit (intermediate load zone) P217800 Air-fuel ratio closed-loop control self-learning value lower than the lower limit (intermediate load...
  • Page 344 X25 2015 Engine Diagnostic steps: 1. With the ignition under LOCK status, check whether the exhaust system has any internal hole, crack and blocking in both visual and physical manner. − No Proceed to step 2. − Yes Repair or replace as necessary. 2.
  • Page 345 X25 2015 Engine − Yes Identify other possible causes − No Replace the engine control unit. Repair Group 20 - Electronic Control System...

  • Page 346: P210612 Power Drive Level Fault Of Electronic

    X25 2015 Engine 2.33 P210612 Power drive level fault of electronic throttle (short) P210619 Power drive level fault of electronic throttle (overheat or overcurrent) P210692 Power drive level fault of electronic throttle (SPI bus or signal) P210613 Power drive level fault of electronic throttle (open) P2106 29 Load monitoring fault DTC detection DTC trigger...
  • Page 347 X25 2015 Engine 1. Disconnect accelerator pedal position sensor connector T6c, and check whether the connecting plug has cracks or abnormality, and whether there's corrosion or rust on the pin. − Yes Clean the connectors and pins. − No Proceed to step 2. 2.

  • Page 348: P305400 Engine Stalling Or Starter And Flywheel Not

    X25 2015 Engine 2.34 P305400 Engine stalling or starter and flywheel not meshing fault P305500 Feedback voltage signal line (KL50r) of key starting switch (KL50r) short to ground fault P305600 Feedback voltage signal line (KL50r) of key starting switch (KL50r) short to power supply fault P308800 Starter damaged or starter power supply circuit interrupted DTC detection DTC trigger...
  • Page 349 X25 2015 Engine 2. Check whether the starter relay J110 of the front compartment electrical box is normal. Multimeter Condition Specified valve connecting pins Normal state Normal state 85-86 Conductivity Between pin 85 and pin 86, apply supply 30-87 Conductivity voltage −...
  • Page 350 X25 2015 Engine 7. With the ignition under LOCK status, check whether the wire between pin T112/22 of the engine control unit connector and positive terminal of the battery is short. − Yes Repair the faulty wire. − No Proceed to step 8. 8.
  • Page 351 X25 2015 Engine 9. With the ignition under LOCK status, check whether the wire between pin T112/22 of the engine control unit connector and pin T1c/1 of the starter connecting plug is open. − Yes Repair the faulty wire. − No Proceed to step 10.
  • Page 352 X25 2015 Engine 11. With the ignition under LOCK status, check whether pins T20a/1 and T20a/13 of the front compartment electrical box connector are short to positive terminal of the battery. − Yes Repair the faulty wire. − No Proceed to step 12. 12.

  • Page 353: P061513 Starter Control Relay Open P061611 Starter Control Relay Undervoltage P061712 Starter Control Relay Overvoltage

    X25 2015 Engine 2.35 P061513 Starter control relay open P061611 Starter control relay undervoltage P061712 Starter control relay overvoltage DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions  Actuator fault Starter control relay — —  P061513 Wire fault open ...
  • Page 354 X25 2015 Engine 4. Disconnect the connecting plug T20a of the front compartment electrical box, check the connecting plug for crack and abnormality and check its pins for corrosion and rust. − Yes Clean the connectors and pins. − No Proceed to step 5. 5.
  • Page 355 X25 2015 Engine 7. Check whether pin T112/58 of the engine control unit connector is short to the body grounding. − Yes Repair the faulty line − No Proceed to step 8. 8. Replace the engine control unit; diagnose it again, read the fault code, and check if it is still present. −...

  • Page 356: U012287 Loss Of Communication With Brake Control Unit Abs/Esp U000188 Can Communication Related Diagnosis U014087 Loss Of Communication With Body Control Module Bcm

    X25 2015 Engine 2.36 U012287 Loss of communication with brake control unit ABS/ESP U000188 CAN communication related diagnosis U014087 Loss of communication with body control module BCM DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions Loss of communication ...
  • Page 357 X25 2015 Engine 4. With the ignition under LOCK status, check whether the wires between pins T112/1 and T112/17 of the engine control unit connector and pins T24a/17 and T24a/7 of the automatic transmission control unit connector are conductive. − Yes Proceed to Step 5.
  • Page 358 X25 2015 Engine 8. With the ignition under LOCK status, check whether wires between pins T112/1 and T112/17 of the engine control unit connector and pins T20b/16 and T20b/15 of the electronic power-assisted steering controller connector are open. − Yes Repair the faulty wire. −...

  • Page 359: P161000 Ecm Not Learning Secretkey P161100 Pin Code Input Error P161200 Ecm Not Receiving Immo P161300 The Last Immo Certification Is Responded Busy

    X25 2015 Engine 2.37 P161000 ECM not learning SecretKey P161100 PIN code input error P161200 ECM not receiving IMMO P161300 The last IMMO certification is responded Busy DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions ECM not learning CAN communication CAN communication —...
  • Page 360 X25 2015 Engine 5. Check whether power supply and bonding of the body controller are normal. − Yes Proceed to Step 6. − Yes Repair the faulty wire. 6. Replace the engine control unit; diagnose it again, read the fault code, and check if it is still present. −...

  • Page 361: P042000 Three Way Catalytic Converter Capacity Aging (Drain Over Limit)

    X25 2015 Engine 2.38 P042000 Three way catalytic converter capacity aging (drain over limit) DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions  Average amplitude of the rear oxygen  Exhaust Leak sensor corrected by  Failure critical catalytic three-way catalytic Vehicle speed gear IV...

  • Page 362: P060443 Electronic Control Unit Ram Fault P060543 Electronic Control Unit Rom Fault

    X25 2015 Engine 2.39 P060443 Electronic control unit RAM fault P060543 Electronic control unit ROM fault DTC detection DTC trigger DTC Definition Possible fault causes conditions conditions  Electronic engine control Control module RAM unit fault — — P060443  error Engine controller...

  • Page 363: P168300 Airbag Signal Unreasonable P152381 Airbag Exploded

    X25 2015 Engine 2.40 P168300 Airbag signal unreasonable P152381 Airbag exploded DTC detection DTC Definition DTC trigger conditions Possible fault causes conditions Airbag signal Airbag sends bus report, CAN bus poor contact or — P168300 unreasonable no response open — —...
  • Page 364 X25 2015 Engine 4. Disconnect connector T32b of SRS control unit. 5. Check whether wires between pins T40b/36 and T40b/37 of the body control unit connector and pins T32b/2 and T32b/17 of SRS control unit connector are open. − Yes Repair the faulty line. −...

  • Page 365: System: Basic Control Logic

    X25 2015 Engine 3 System: Basic Control Logic 3.1 Ignition Switch: Control Logic Turn the ignition to ON position Main relay is connected and oil pump operates for 1.5S Start and operate the engine Turn the ignition switch off Turn the ignition switch off System post-operation System shutdown System post-operation...

  • Page 366: Fuel Supply System: Control Logic

    X25 2015 Engine 3.2 Fuel Supply System: Control Logic Fuel pumps logic  Oil pump ON logic Once the ignition switch is activated, the fuel pump will run for 1.5 seconds.If no valid signal is detected for the crankshaft position, the fuel pump will stop running; after the engine starts running, once the ECU detects 2 valid signals for the crankshaft position, the fuel pump will get started.
  • Page 367 X25 2015 Engine  Acceleration thickening When the system detects substantial increase in readings of throttle position sensor (TPS) and intake air temperature and pressure sensor, it thickens oil to improve the overall power in order to prevent instantaneous engine thin oil. ...

  • Page 368: Ignition: Control Logic

    X25 2015 Engine 3.3 Ignition: Control Logic Coil Magnetizing Control The magnetizing time of the ignition coil determines the ignition power of the spark plug. Overlong magnetizing time can damage coil or coil driver; too short can cause a fire. Start Mode In start mode, the system uses a fixed ignition angle to ensure the mixture inside the cylinder is ignited and offers positive torque.
  • Page 369 X25 2015 Engine Including corrections in coolant, intake air temperature, altitude compensation, idle control, acceleration, power thickening, deceleration fuel stoppage, air-conditioning control.  Acceleration Correction Ignition advance angle acceleration adjustment is used to mitigate the engine speed fluctuations caused by drive system torque shock, and eliminate possible detonation during acceleration, making the acceleration smoother.

  • Page 370: Idling: Control Logic

    X25 2015 Engine 3.4 Idling: Control Logic Idle speed air flow control is that the engine control system maintains the target speed when throttle body is fully closed. The system maintains a smooth transition with the throttle body fully closed to prevent the stall. When the engine load changes at idle speed, system maintains a steady engine speed.

  • Page 371: Knock: Control Logic

    X25 2015 Engine  Speed Compensation & Deceleration Regulation To improve driving performance during deceleration and parking, the target idle speed while driving is 50 r/min higher than that during parking, which during parking and deceleration gradually drops to the target idle speed. 3.5 Knock: Control Logic Knock control function is used for eliminating engine knock which would occur during combustion and optimizing power performance of engine and economical efficiency of fuel.

  • Page 372: Air-Conditioning: Control Logic

    X25 2015 Engine 3.6 Air-conditioning: Control Logic The ECU monitors the inputs from the A/C and the A/C evaporator temperature sensor, and controls A/C compressor clutch via A/C relay. System can automatically identify air-conditioning system with plug-and-play manner. Air-conditioning working conditions The A/C system is enabled when all of the following conditions are met: ...

  • Page 373: Three-Way Catalytic Converter Protection: Control Logic

    X25 2015 Engine In order to reduce the impact on the normal combustion and doing work from the fuel vapor entering the cylinder, the following conditions must be met before the canister solenoid valve is open  9V < system voltage < 16V. ...

  • Page 374: Parts & Components

    X25 2015 Engine 4 Parts & Components The engine control system is composed subsystems of control, signal collecting, fuel supply, ignition, intake/emission control, failure diagnosis, communication, etc. 4.1 Engine Control Module (ECM) 4.1.1 Overview The engine control unit (ECU) applied to the vehicle uses a microprocessor with a single chip as its core that tests and calculates the required air-fuel mixing ratio and engine ignition advance angel according to the input data of different sensors to control directly intake airflow and corresponding fuel supply volume, fuel injection timing, high-pressure ignition timing, ignition closing angle and idle speed of the engine under different working conditions, as well as working status of...
  • Page 375 X25 2015 Engine 4. Disconnect the wiring harness connector -Arrow A- and -Arrow B- of the engine control unit (ECM). 5. Unscrew the fixing nut -Arrow C- of the engine control unit (ECM) and remove the engine control unit-1-. Nut - Arrow C- specification：M6× 1.0 Nut -Arrow C- tightening torque: 9~12 Nm Nut-Arrow C- tool: 10mm hexagon sleeve Tips...

  • Page 376: Crankshaft Position Sensor

    X25 2015 Engine 4.2 Crankshaft Position Sensor 4.2.1 Overview The model is equipped with a passive speed sensor which works without power supply and outputs sinusoidal voltage signals. Working principle of the passive sensor uses magneto-electric effect. When the crankshaft revolves, it drives the sensing signal gear to revolve with it and thus teeth on the sensing signal gear produce cutting effect to magnetic line of the sensor.
  • Page 377 X25 2015 Engine 3. Unscrew the fixing bolt -Arrow- on the A/C compressor, and suspend it on the body with a sturdy rope or wire. Bolt - Arrow - Specifications：M8× 1.25× 100 Bolt -Arrow B- tightening torque: 22~30 Nm Bolt -Arrow- tool: 10mm hexagon sleeve 4.

  • Page 378: Check The Crankshaft Position Sensor

    X25 2015 Engine Notes  Completely clean residual sealant on the crankshaft position sensor and the cylinder block surface before installing the crankshaft position sensor.  As shown in the figure blow, apply continuous beaded sealant with diameter of 1.2-2.2 mm to position -a- of the cylinder block. ...

  • Page 379: Intake Manifold Absolute Pressure Sensor

    X25 2015 Engine 4.3 Intake Manifold Absolute Pressure Sensor 4.3.1 Overview The air intake temperature/pressure sensor is designed to detect and sense the actual air intake condition of the engine when it is running. For the engine management system based on speed/density air intake measurement, the ECU quickly calculates the instant air intake volume of the engine based on the outputs of the sensor and the inputs of other sensors in the system.

  • Page 380: Removal And Installation Of The Intake Manifold Pressure And Temperature Sensor

    X25 2015 Engine Service & Maintenance  Avoid crashes, intense shocks, compression and other external impact  Keep the connectors clean and prevent liquid splashing into it  Don't pull the harness when the connector is connected  Keep the connectors firm and reliable ...

  • Page 381: Check On Air Intake Temperature Pressure Sensor

    X25 2015 Engine 4.5.3 Check on Air Intake Temperature Pressure Sensor Fault symptoms Shutdown and poor idle speed etc. Common Causes 1. Abnormal overvoltage or reserved large current occurs during use. 2. The pressure chip is damaged during repair. Temperature Sensor Part 1.

  • Page 382: Camshaft Position Sensor

    X25 2015 Engine 4.4 Camshaft position sensor 4.4.1 Overview Camshaft position sensor is a Hall-effect sensor which is installed in the vicinity of the intake camshaft, and works together with camshaft signal wheel. The signal wheel is corresponding to the specific engine position. ECM measures digital voltage signal through this sensor, therefore determining the working cylinder of the engine and implementing one-to-one control.

  • Page 383: Removal And Installation Of The Camshaft Position Sensor

    X25 2015 Engine 4.4.2 Removal and Installation of the Camshaft Position Sensor Removal 1. Close ignition switch and all the electrical equipments 2. Disconnect the battery negative cable=>Electrical Equipment: Repair Group: 60; Disconnection and Connection of Battery Negative Cable. 3. Remove the engine trim cover assembly -1-. 4.

  • Page 384: Check The Camshaft Position Sensor

    X25 2015 Engine Tips  It is only permitted to take the sensor out of the package before its installation.  Take the sensor out of the package and check it. Make sure it is not damaged or polluted.  Sealing ring -Arrow- of the camshaft position sensor shall be replaced as necessary.

  • Page 385: Coolant Temperature Sensor

    X25 2015 Engine 4.5 Coolant Temperature Sensor 4.5.1 Overview The coolant temperature sensor uses quickly responsive Negative Temperature Coefficient (NTC) thermistor as its core temperature sensing element, which contains two thermistors whose resistances drop with the increase of the coolant temperature, yet not in a linear relation. The coolant temperature sensor is mounted in the main water outlet of a cylinder head.

  • Page 386: Removal And Installation Of Coolant Temperature Sensor

    X25 2015 Engine 4.5.2 Removal and Installation of Coolant Temperature Sensor Removal 1. Close ignition switch and all the electrical equipments 2. Disconnect the battery negative cable=>Electrical Equipment: Repair Group: 60; Power Distribution; Battery: Battery Cables: Disconnection and Connection of Battery Negative Cable.
  • Page 387 X25 2015 Engine 1. Remove the coolant temperature sensor, set the multimeter to ohm mode and measure the coil resistance of the sensor -1- with the multimeter, as shown. Rated resistance：(25℃)：1.825～2.155Ω Tips Analogous method can be used during the measurement, that is, to put the work area of the sensor into the boiling water (notice: the soak time shall be sufficient), observe the changes of the sensor resistance, and at the moment, the resistance shall drop to 170Ω...

  • Page 388: Knock Sensor

    X25 2015 Engine 4.6 Knock Sensor 4.6.1 Overview The shock sensor is based on vibrational acceleration, which is installed on the most knock-sensitive part on the engine cylinder block: the lower part of the intake manifold. The EMS detects the knock strength with the knock sensor, corrects the ignition advance angle and effectively controls knock, which improves the dynamic performance, fuel economy and emission level of the engine.

  • Page 389: Check On Knock Sensor

    X25 2015 Engine 1. Close ignition switch and all the electrical equipments 2. Disconnect the battery negative cable=>Electrical Equipment: Repair Group: 60; Power Distribution; Battery: Battery Cables: Disconnection and Connection of Battery Negative Cable. 3. Disconnect the connector -Arrow A- of the knock sensor -1-. 4.
  • Page 390 X25 2015 Engine 2. Install the knock sensor, set the multimeter to mV mode, and connect it to the plug -Arrow- of the knock sensor.Slightly tap the cylinder block with a small hammer, near the knock sensor. At that time, the multimeter should detect weak voltage.

  • Page 391: Oxygen Sensor

    X25 2015 Engine 4.7 Oxygen Sensor 4.7.1 Overview The oxygen sensor is an important signature part in the closed-end fuel control system. It is used to detect the concentration of oxygen in the combustion waste gas emitted by the vehicle engine, in order to identify the actual air/fuel ratio during the real-time fuel supply of the engine.
  • Page 392 X25 2015 Engine Limit data Valve Description Unit Typical Maximum Exhaust gas at the — ℃ permissive end of ceramic temperature when tube the heating element is connected (at Cable metal most 10 minutes — ℃ buckle and every time, and connecting cable the accumulated time can be up to...

  • Page 393: Removal And Installation Of Front Oxygen Sensor

    X25 2015 Engine Service life of the oxygen sensor Lead content in the petroleum (g/L) Service life（km） ≤0.6 20000 ≤0.4 30000 ≤0.15 60000 Service & Maintenance  The threaded surface of new oxygen sensors is coated with an anti-sintering, once removed and re-installed, the sensor shall be re-coated with the anti-sintering additive.dditive.
  • Page 394 X25 2015 Engine 5. Lift up the carpet -1-, pry up the fixing clip -Arrow- of the front passenger foot rest and remove the front passenger foot rest -2-. 6. Disengage the clip -Arrow- of the front oxygen sensor connector. 7.

  • Page 395: Removal And Installation Of Rear Oxygen Sensor

    X25 2015 Engine 8. Disconnect the connecting plug -Arrow- of the front oxygen sensor and unscrew the front oxygen sensor -1- with removal and installation tool -T41132201- for oxygen sensor. Tightening torque of the front oxygen sensor -1-: 40～60 Nm Tips ...

  • Page 396: Check On Oxygen Sensor

    X25 2015 Engine 5. Disconnect the connector -Arrow- of the rear oxygen sensor and unscrew the rear oxygen sensor -1- with removal and installation tool -T41132201- for oxygen sensor. Tightening torque of the rear oxygen sensor -1-: 40～60 Nm Tips ...
  • Page 397 X25 2015 Engine 3. Remove the oxygen sensor, set the multimeter to ohm mode, and measure the resistance of pin 1 and pin 2 on the oxygen sensor-1- with the multimeter, as shown. Rated resistance (normal temperature): 7～11Ω Tips If the measurement doesn't comply with the standard value, replace the oxygen sensor.

  • Page 398: Engine Oil Control Valve

    X25 2015 Engine 4.8 Engine Oil Control Valve 4.8.1 Overview Working power supply of V.V.T valve is supplied by the main relay under EMS control. EMS controls bonding of the oil control valve by impulse width modulation signal to constantly change timing relationship between crankshaft and camshaft so as to allow the engine to have the optimal valve timing under different operating conditions and control the valve timing.
  • Page 399 X25 2015 Engine Installation Install in reverse order of removal procedures and please note the following: Notes 1. Replace the O-type sealing ring after it is removed. 2. Pay attention to avoid adhesion of foreign matters while installing V.V.T valve filter. 3.

  • Page 400: Throttle Control System

    X25 2015 Engine 4.9 Throttle Control System 4.9.1 Overview The major function of the electronic throttle body is to adjust the size of the air intake channel according to the driving purpose of the driver.In this way, it controls the volume of air intake flow, so as to meet the engine's intake requirement...

  • Page 401: Removal And Installation Of Electronic Throttle Body Assembly

    X25 2015 Engine 4.9.2 Removal and Installation of Electronic Throttle Body Assembly Removal 1. Close ignition switch and all the electrical equipments 2. Disconnect the battery negative cable=>Electrical Equipment: Repair Group: 60; Power Distribution; Battery: Battery Cables: Disconnection and Connection of Battery Negative Cable.
  • Page 402 X25 2015 Engine 8. Unscrew the fixing bolt -Arrow A- on the electronic throttle, and remove the retaining bracket -2- of the water pipe. Bolt - Arrow A - Specifications：M6× 1.0× 50 Bolt -Arrow A- tightening torque: 5~7 Nm Bolt -Arrow A- tool: 10mm hexagon sleeve 9.

  • Page 403: Removal And Installation Of Electronic Accelerator Pedal Assembly

    X25 2015 Engine 4.10 Removal and Installation of Electronic Accelerator Pedal Assembly Removal 1. Close ignition switch and all the electrical equipments 2. Disconnect the battery negative cable=>Electrical Equipment: Repair Group: 60; Power Distribution; Battery: Battery Cables: Disconnection and Connection of Battery Negative Cable.

  • Page 404: Emission Control System

    X25 2015 Engine 5 Emission Control System 5.1 Overview Engine emission control system consists of crankcase ventilating oil-gas separating system and fuel evaporation control system. Crankcase ventilating oil-gas separating system There is inevitable some blow-by while the engine is operating under normal conditions. However, such blow-by of the crankcase over a long time could cause condensation of fuel vapor and water vapor that mix with oil in the oil pan to deteriorate the oil and pollute engine parts.

  • Page 405: Crankcase Ventilating Oil-Gas Separating System395

    X25 2015 Engine 5.2 Crankcase Ventilating Oil-gas Separating System 5.2.1 Overview on Crankcase Ventilating Oil-gas Separating System 1 - Cylinder head cover assembly 2 - PCV valve   Removal and installation=>Refer to Page 104 Check=>Refer to Page 397 3 - PCV hose 4 - Air intake manifold ...
  • Page 406 X25 2015 Engine 1. Remove the engine trim cover assembly -1-. 2. Disengage venting pipe -1- of the PCV valve 3. Unscrew the PCV valve -1-. Tightening torque：4～6 Nm Installation Install in reverse order of removal procedures and please note the following: Tips The PCV gasket is a disposable part, which should be replaced after being removed.

  • Page 407: Check On Pcv Valve

    X25 2015 Engine 5.2.3 Check on PCV Valve Tips The PCV valve is a check valve in nature. 1. Connect the manual vacuum pump to one end of the PCV valve -1- and vacuumize the PCV valve -1- (the air flows inside the valve as shown by -Arrow A-).There should be no resistance, and no vacuum is formed.

  • Page 408: Fuel Evaporation Control System

    X25 2015 Engine 5.3 Fuel Evaporation Control System 5.3.1 Overview The engine management system used on modern vehicles controls fuel vapor to prevent environmental pollution caused by the gasoline vapor in the vehicle oil tank and improve fuel economy. The canister solenoid valve is one of the key components in the fuel vapor emission control system.

  • Page 409: Overview On Fuel Evaporation Pipeline

    X25 2015 Engine 5.3.2 Overview on Fuel Evaporation Pipeline 1 - Carbon canister 2 - Venting pipe of the carbon canister   Removal and installation=>Refer to Page 413 Check, replace as necessary 3 - Venting hose of the carbon canister 4 - Clamp ...

  • Page 410: Removal And Installation Of Carbon Canister

    X25 2015 Engine 13 - Nuts of the carbon canister fixing bracket  Specification：M8× 1.25  Total: 2  Tightening torque：11～15 Nm 5.3.3 Removal and Installation of Carbon Canister Removal 1. Close ignition switch and all the electrical equipments 2. Disconnect the battery negative cable=>Electrical Equipment: Repair Group: 60;...

  • Page 411: Check On Canister Solenoid Valve

    X25 2015 Engine 1. Close ignition switch and all the electrical equipments 2. Disconnect the battery negative cable=>Electrical Equipment: Repair Group: 60; Disconnection and Connection of Battery Negative Cable. 3. Unscrew the fixing clamp -Arrow B- of the air outlet pipe, pry up the fixing clip -Arrow A- of the air filter upper shell and remove the air filter upper shell -1-.
  • Page 412 X25 2015 Engine 1. Remove the canister solenoid valve, set the multimeter to ohm mode, connect the probes of the multimeter to the connector terminals of the canister solenoid valve -1-, and measure the coil resistance of the canister solenoid valve. Rated resistance:26Ω（20℃）...

  • Page 413: Fuel Supply System

    X25 2015 Engine 21 Fuel Supply System 1 Overview The fuel supply system includes two parts: the fuel supply and fuel injection. The fuel is sucked in from the fuel tank by the fuel pump, then filtered by the fuel filter and delivered to the fuel rail through the fuel piping.
  • Page 414 X25 2015 Engine  Before working on the fuel system, prepare fire-extinguishing equipment.  Fuel is highly volatile. Inhaling excessive fuel vapor will lead to dizziness, nausea and even coma. Therefore, it is important to ensure proper ventilation at the site. ...

  • Page 415: Cleaning Basics

    X25 2015 Engine 1.2 Cleaning Basics The following regulations on cleaning must be noted before operations of the fuel supply device to ensure the fuel system works normally and supplies oil stably:  Before disconnecting the fuel pipeline or removing the fuel system, clean its surface and surrounding impurities for fear that the fuel pipeline joint and the fuel system are polluted in removal and installation.

  • Page 416: Check And Diagnosis

    X25 2015 Engine 2 Check and Diagnosis 2.1 Common Fault Checking and Eliminating 2.1.1 Fuel Pressure Is Too Low Check procedures Check results Preliminary check Normal There's a fault Operation method Excessive bending of the fuel hose, cracks or other damage on the Replace the damaged Visually check whether the fuel pipe and other...
  • Page 417 X25 2015 Engine Check procedures Check results Check if the electronic Failure in the TPS Replace the throttle throttle position sensor is Proceed to Step 3. sensor position sensor. normal Check the fuel pressure. Normal There's a fault Operation method Check whether fuel system Fuel system pressure Replace the fuel...

  • Page 418: Technical Parameters

    X25 2015 Engine 3 Technical Parameters Torque Description Specification Grade Tools — — Fixing bolt on the top of fuel filler pipe M5× 0.8× 20 5～7 10mm Hexagon Filler pipe assembly fixing bolt M8× 1.25× 16 12～14 Sleeve 15mm Hexagon Fixing bolt of fuel tank binder M10×...

  • Page 419: Fuel Pressure Release

    X25 2015 Engine 4 Fuel Pressure Release When the engine is working, the fuel pressure in the fuel piping can reach about 350Kpa.For some time after the engine has stopped running, the fuel in the pipes remains at high pressure. Therefore, before disconnecting the fuel piping, it is necessary to release the fuel pressure in the fuel system, in order to prevent personal injury to the technicians due to fuel spraying.

  • Page 420: Removal And Installation Of Filler Pipe Assembly

    X25 2015 Engine 5 Removal and Installation of Filler Pipe Assembly Removal 1. Pull the open buckle -1- upwards, open filler cover panel. 2. Close ignition switch and all the electrical equipments 3. Unscrew the filler cap -1-. 4. Unscrew the fixing bolt -Arrow A- of the filler cap, disengage the clip -Arrow B- and remove the filler cap -1-.
  • Page 421 X25 2015 Engine 5. Loosen the clamp -Arrow A- and disconnect the connection between fuel filler pipe component -1- and venting connecting hose -2-. Clamp -Arrow A- tightening torque: 3 - 4 Nm 6. Loosen the clamp -Arrow B- and disconnect the connection between fuel filler pipe component -1- and fuel filler connecting hose -3-.

  • Page 422: Fuel Tank

    X25 2015 Engine 6 Fuel Tank 6.1 Draining of fuel tank Tips In case of excessive fuel in the fuel tank while removing and installing the fuel tank, drain the fuel tank with the following methods; in case of little fuel in the fuel tank, it is not necessary to drain the fuel tank but remove and install directly. 1.

  • Page 423: Removal And Installation Of Fuel Tank

    X25 2015 Engine 6.2 Removal and Installation of Fuel Tank Notes  Precautions for the removal and installation of the fuel tank:  Keep the workplace well-ventilated.  Prepare fire extinguishing equipment.  No flames or object that generates flame can be stored around the vehicle. ...
  • Page 424 X25 2015 Engine 9. Disengage the connection of fuel feed pipe assembly -1-and fuel return pipe assembly -2- with venting pipe assembly -3-. 10. Unscrew the fixing screw -Arrow A- and locking gasket -Arrow B- of the fuel tank thermal baffle and remove the fuel tank thermal baffle-1-.
  • Page 425 X25 2015 Engine Nut -Arrow B- tool: 15mm hexagon sleeve 13. Unscrew the fixing nut -Arrow A- for front binder assembly of the fuel tank and the fixing nut -Arrow B- of the fuel tank assembly. Nut - Arrow A- specification：M10× 1.5 Bolt -Arrow A- tightening torque: 38~54 Nm Nut -Arrow A- tool: 15mm hexagon sleeve Nuts - Arrow B - Specifications：M10×...
  • Page 426 X25 2015 Engine 16. Unscrew the snap ring -1- with removal and installation tool of the fuel pump cover. 17. Take out the fuel pump assembly -1-. Notes  Pay attention to buoyancy rod of fuel level sensor while removing the fuel pump assembly -1-.

  • Page 427: Removal And Installation Of The Fuel Pump Assembly

    X25 2015 Engine 7 Removal and Installation of the Fuel Pump Assembly Notes Precautions for the removal and installation of the fuel tank:  Keep the workplace well-ventilated.  Prepare fire extinguishing equipment.  No flames or object that generates flame can be stored around the vehicle. ...
  • Page 428 X25 2015 Engine 8. Unscrew the snap ring -1- with removal and installation tool of the fuel pump cover. 9. Take out the fuel pump assembly -1-. Notes  Pay attention to buoyancy rod of fuel level sensor while removing the fuel pump assembly -1-.

  • Page 429: Removal And Installation Of Fuel Filter

    X25 2015 Engine 8 Removal and Installation of Fuel Filter Removal 1. Release fuel pressure => Refer to Page 409. 2. Disconnect the connection between oil pipe -1- and fuel filter -3- -Arrow-A. 3. Disconnect the connection between oil pipe -2- and fuel filter -3- -Arrow-B.

  • Page 430: Overview Of The Fuel Pipeline

    X25 2015 Engine 9 Overview of the Fuel Pipeline 1 - Fuel tank 2 - Return pipe   Removal and installation=>Refer to Page 413 Check, replace as necessary 3 - Fuel feed pipe of fuel pump 4 - Fuel feed pipe of fuel pump ...

  • Page 431: Fuel Rail And Injector Assembly

    X25 2015 Engine 10 Fuel Rail and Injector Assembly 10.1 Overview The fuel injector is a ball valve device controlled by an solenoid switch. The EMS sends out electric pulses to the coil of the fuel injector, thus generating magnetic field force. When magnetic force increases to overcome resultant force from return spring pressure, needle valve gravity and friction, needle valve starts to lift and injection process...

  • Page 432: Removal And Installation Of Fuel Distribution Pipe And Fuel Injector Assembly

    X25 2015 Engine Valve Description Unit Typical — — Working pressure (pressure gap) — — Ω Injector resistance at 20℃ 12± 0.6 Service & Maintenance  Replace the O-ring at each removal and re-installation of the fuel injector. Do not damage the sealing surface of the fuel injector.
  • Page 433 X25 2015 Engine 4. Disengage PCV venting hose -1-. 5. Remove the fixing clamp -Arrow- of the fuel pipeline and disengage the fuel pipeline -1-. Tips Place a cloth at the connections before releasing the hoses, and then pull out the hoses carefully. Do not reuse the fixing clip but replace with a new one.

  • Page 434: Disassembly Of Fuel Distribution Pipe And Fuel Injector Assembly

    X25 2015 Engine 10.3 Disassembly of Fuel Distribution Pipe and Fuel Injector Assembly Removal 1. Unclamp the fuel injector clamp -1- along the direction -Arrow A- and take it out along the direction -Arrow B-. 2. Remove the fuel injector-2-. Tips ...

  • Page 435: Check On Fuel Injector

    X25 2015 Engine 10.4 Check on Fuel Injector 1. Set the multimeter to ohm mode and use the multimeter to measure the coil resistance of the injector -1-. Rated resistance of the fuel injector coil at 20℃: 11.4～12.6 Ω Tips ...

  • Page 436: Charging, Starting And Ignition System

    X25 2015 Engine 23 Charging, Starting and Ignition System 1 Overview Charging System The generator is the major power source for the vehicle, whose job is to provide power supply to all the electrical equipment (excluding the starter) when engine is running at a normal speed (above the idling speed) and charge the battery at the same time.

  • Page 437: Check And Diagnosis

    X25 2015 Engine 2 Check and Diagnosis 2.1 Common Fault Checking and Eliminating 2.1.1 Generator Output Fault Check procedures Check results Preliminary check Normal There's a fault Operation method Check whether there is a Remove the belt, clean screeching sound from The belt is aged, loose off the grease on the Proceed to Step 1.

  • Page 438: Spark Plug: Spark Failure

    X25 2015 Engine Check procedures Check results The coil resistance of the starter Check whether the coil is abnormal; the coil is burnt Proceed to Step Replace the starter resistance of the starter is out, leading to broken circuit; or assembly normal the carbon brush has poor...
  • Page 439 X25 2015 Engine Check procedures Check results Operate the front electric windows and check Find the cause from End of check Faults still exist whether fault occurs after other symptoms. repairs Repair Group 23 - Charging, Starting and Ignition System...

  • Page 440: Technical Parameters

    X25 2015 Engine 3 Technical Parameters Torque Description Specification Grade Tools 14mm Hexagon Generator fixing bolt (M10) M10× 1.25× 90 42～52 Sleeve 12mm Hexagon Generator fixing bolt (M8) M8× 1.25× 40 19～25 Sleeve 12mm Hexagon Adjusting bolt of the generator assembly M8×...

  • Page 441: Charging System

    X25 2015 Engine 4 Charging System 4.1 Removal and Installation of Engine Assembly Removal 1. Disconnect the battery negative cable=>Electrical Equipment: Repair Group: 60; Disconnection and Connection of Battery Negative Cable. 2. Remove the engine trim panel -1-. 3. Disconnect the connecting plug -Arrow A- of the generator and lift up the generator terminal guard -Arrow C-.
  • Page 442 X25 2015 Engine Adjustment bolt -Arrow A- specification:M8× 1.25× 80 Adjustment bolt -Arrow A-tightening torque : 4～6 Nm Adjustment bolt -Arrow A -tool: 12mm hexagon sleeve Tips Just disconnect the belt -1- and the generator assembly, but do not remove the belt. 7.

  • Page 443: Check On Generator

    X25 2015 Engine 4.2 Check on Generator Visual inspection.  Check whether the connecting harness of the generator is in good condition.  Check the generator appearance for cracks, deformation, etc. Check on the Charging Indicator  Turn on the ignition switch and check whether the charging indicator on the instrument cluster lights up. ...

  • Page 444: Starter System

    X25 2015 Engine 5 Starter System 5.1 Removal and Installation of Starter Assembly Removal 1. Disconnect the battery negative cable=>Electrical Equipment: Repair Group: 60; Disconnection and Connection of Battery Negative Cable. 2. Disconnect the power control wiring harness connector -Arrow A- of the starter and disengage the guard -Arrow B- of power supply wiring harness.
  • Page 445 X25 2015 Engine 1. Connect the negative terminal of the battery to the grounding on the housing of the starter assembly. 2. Connect the positive terminal of the battery to the post -Arrow A- of the solenoid switch, via the serial connection of the ammeter. 3.

  • Page 446: Ignition System

    X25 2015 Engine 6 Ignition System 6.1 Ignition Coil 6.1.1 Overview Within the engine ignition system of the vehicle, the ignition coil is the actuating part that provides ignition energy to air and fuel mixture for ignition of the engine cylinder. It mainly functions based on the principle of electromagnetic induction to receive ECU commands through the electronic controller and turn off and turn on the primary current circuit of the ignition coil.

  • Page 447: Check On Ignition Coil

    X25 2015 Engine 3. Remove the engine trim panel -1-. 4. Disconnect the connecting plug -Arrow-B of the ignition coil -1-. 5. Unscrew the fixing bolt -Arrow-A on the ignition coil-1-, and pull out the ignition coil-1- upwardly. Bolt - Arrow - Specifications：M6× 1.0× 18 Bolt -Arrow B- tightening torque: 8~10 Nm Bolt -Arrow- tool: 10mm hexagon sleeve Installation...
  • Page 448 X25 2015 Engine 1. Disconnect the connecting plug -1- of the injector. 2.. Remove the ignition coil=>Refer to Page 436 3. Install a well-functioning spark plug onto the ignition coil. 4. Engage the connecting plug of the ignition coil. 5. Ground the side pole of the spark plug, and then start the engine. 6.

  • Page 449: Spark Plug

    X25 2015 Engine 6.2 Spark Plug 6.2.1 Removal and Installation of Spark Plug Removal Tips These instructions are for the removal and installation of the spark plug of Cylinder 1 but may be used as reference for the removal and installation of spark plugs of other cylinders. 1.

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