Common Malfunction Diagnosis Flow of Geely Automobile.pdf
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Common Malfunction Diagnosis Flow of Geely Automobile
GEELY INTERNATIONAL CORPORATION
JUN.
2008
Common Malfunction Diagnosis Flow of Geely Automobile
Common Malfunction Diagnosis Flow Content of Geely Automobile Engine ....................................................................................................................................... 1 No.001
Engine shuts off abnormally when driving..................................................................... 1
No.002 Engine surging .............................................................................................................. 3 No.003
Over idle speed when warm-up .................................................................................... 5
No.004
Idle speed fluctuation .................................................................................................... 7
No.005
Idle speed unstable or engine shut-off when opening AC or steering ........................... 9
No.006
Engine shuts off intermittently ..................................................................................... 11
No.007
Poor accelerating performance in cold condition ........................................................ 13
No.008
Spark plug non-sparking ............................................................................................. 15
No.009
Low idle speed during engine heating in cold condition .............................................. 17
No.010 Canister oil leaking...................................................................................................... 19 No.011 Fuel smells in vehicle .................................................................................................. 20 No.012
Engine vibration when operating................................................................................. 22
No.013
Engine noise over normal level ................................................................................... 24
No.014
Water temperature over normal value after AC activated............................................ 26
No.015 Oil pan leak ................................................................................................................. 27 No.016
Distributor oil leaking................................................................................................... 29
No.017
JL376/378 engine shut-off when sliding at neutral gear.............................................. 30
No.018 High idle speed when sliding at neutral gear, MK ....................................................... 32 No.019 Engine vibration .......................................................................................................... 33 No.020
Exhaust pipe pours black smoke ................................................................................ 34
No.021
Engine idle speed decreases when activating head beam or fan ............................... 36
No.022
Exhaust pipe blows water ........................................................................................... 38
No.023
Engine shuts off when accelerating ............................................................................ 39
No.024 Oil indicator is always on ............................................................................................ 41 No.025
Water temperature is over normal value when engine running with large load ........... 42
No.026
Canister electromagnetic valve sounds abnormal....................................................... 44
No.027
Engine fails to start ..................................................................................................... 45
No.028
Hard to start in cold condition...................................................................................... 47
No.029
Hard to stard engine when heating ............................................................................. 49
No.030
Idle speed unstable..................................................................................................... 51
Common Malfunction Diagnosis Flow of Geely Automobile
No.031 Non-idle speed............................................................................................................ 54 No.032
Idle speed over normal value ...................................................................................... 56
No.033
Engine accelerates abnormal...................................................................................... 58
No.034
Water temperature over normal value......................................................................... 60
No.035
Oil existing in the water tank ....................................................................................... 62
No.036 There is water in the oil............................................................................................... 64 No.037
Abnormal sound of crankshaft bearing ....................................................................... 65
No.038
Abnormal sound of connecting rod bush..................................................................... 67
No.039
Camshaft with abnormal sound................................................................................... 69
No.040
Camshaft driving gear with abnormal sound ............................................................... 70
No.041
Cylinder knocking sound............................................................................................. 71
No.042 Oil pump with abnormal sound.................................................................................... 73 No.043
Crankshaft thrust piece with abnormal sound ............................................................. 74
No.044 Valve with abnormal sound ......................................................................................... 75 No.045
Engine with insufficient power.....................................................................................76
No.046 Oil consumption too large ........................................................................................... 78 No.047
Intake tempering ......................................................................................................... 83
No.048
Exhaust pipe bombs ................................................................................................... 85
No.049 Engine knocking.......................................................................................................... 86 No.050 Engine burning oil ....................................................................................................... 88 No.051
Cooling water unusually consumed ............................................................................ 89
No.052 Low engine oil pressure .............................................................................................. 90 No.053 Quick diagnosis for ECU............................................................................................. 91 No.054
Quick diagnosis for idling-speed governor EWD......................................................... 93
No.055
Quick diagnosis for knocking sensor........................................................................... 94
No.056
Quick diagnosis for stepper motor .............................................................................. 96
No.057
Quick diagnosis for ignition coil................................................................................. 100
No.058
Quick diagnosis for throttle valve position sensor ..................................................... 102
No.059
Quick diagnosis for inlet pressure temperature sensor ............................................. 104
No.060
Quick diagnosis for water temperature sensor.......................................................... 107
No.061
Quick diagnosis for canister solenoid valve .............................................................. 109
No.062
Fuel injector EV......................................................................................................... 111
No.063
Quick diagnosis for Hall sensor................................................................................. 113
Common Malfunction Diagnosis Flow of Geely Automobile
No.064
Electric fuel pump EKP ............................................................................................. 115
No.065
Fuel pressure regulator DR....................................................................................... 117
No.066
Oxygen sensor LSH.................................................................................................. 119
No.067 JL376/378QE engine’s electric control system check ............................................... 121 No.068
Diagnosis and solution of common malfunctions of JL376/378QE engine’s electric control system.......................................................................................................... 129
No.069
Flashing code list of M1.5.4 series............................................................................ 130
No.070
Malfunction code: P0107 "voltage of intake pressure sensor circuit too low"............ 132
No.071
Malfunction code: P0108
No.072
Malfunction code: P0112 "temperature indicated by intake temperature sensor too low" .......................................................................................................................... 133
No.073
Malfunction code: P0113 "temperature indicated by intake temperature sensor too high"......................................................................................................................... 134
No.074
Malfunction code: P0117 "temperature indicated by cooling liquid temperature sensor too low" .................................................................................................................... 134
No.075
Malfunction code: P0118 "temperature indicated by cooling liquid temperature sensor too high"...................................................................................................................135
No.076
Malfunction code: P0122 "voltage of throttle valve position sensor circuit too low"... 135
No.077
Malfunction code: P0123 "voltage of throttle valve position sensor circuit too high" . 136
No.078
Malfunction code: P0130 "signal circuit of upstream oxygen sensor malfunction" .... 137
No.079
Malfunction code: P0132 "voltage of upstream oxygen sensor circuit too high" ....... 137
No.080
Malfunction code: P0134 "upstream oxygen sensor signal malfunction" .................. 137
No.081
Malfunction code: P0135 "heating circuit of upstream oxygen sensor malfunction".. 138
No.082
Malfunction code: P0171 “self-adapting of closed-loop control of air fuel ratio shall exceed upper part”................................................................................................... 138
No.083
Malfunction code: P0172 “self-adapting of closed-loop control of air fuel ratio shall exceed lower part” ................................................................................................... 139
No.084
Malfunction code: P0201 "one-cylinder oil injector circuit malfunction"..................... 140
No.085
Malfunction code: P0202 "two-cylinder oil injector circuit malfunction" ..................... 140
No.086
Malfunction code: P0203 "three-cylinder oil injector circuit malfunction"................... 141
No.087
Malfunction code: P0204 "four-cylinder oil injector circuit malfunction"..................... 141
No.088
Malfunction code: P0230 "oil pump control circuit malfunction" ................................ 142
No.089
Malfunction code: P0325 "knock sensor circuit malfunction" .................................... 142
No.090
Malfunction code: P0335 “crankshaft position sensor signal malfunction” ................ 143
"voltage of intake pressure sensor circuit too high"........ 133
Common Malfunction Diagnosis Flow of Geely Automobile
No.091
Malfunction code: P0336 “crankshaft position sensor signal with unreasonable malfunction” ............................................................................................................. 143
No.092
Malfunction code: P0340 “Phase sensor signal malfunction”.................................... 144
No.093
Malfunction code: P0342 “circuit voltage of phase sensor too low”........................... 144
No.094
Malfunction code: P0343 “circuit voltage of phase sensor too high” ......................... 145
No.095
Malfunction code: P0443 "Malfunction of control circuit of driver stage of canister control valve" ...........................................................................................................146
No.096
Malfunction code: P0444 "voltage of control circuit of driver stage of canister control valve too low" ........................................................................................................... 146
No.097
Malfunction code: P0445 "voltage of control circuit of driver stage of canister control valve too high" .........................................................................................................147
No.098
Malfunction code: P0480 "malfunction control circuit of cooling fan relay of AC condenser"............................................................................................................... 148
No.099
Malfunction code: P0500 "unreasonable malfunction of speed signal" ..................... 148
No.100
Malfunction code: P0506 "idling speed lower than target speed value" .................... 149
No.101
Malfunction code: P0507 "idling speed higher than target speed value"................... 149
No.102 Malfunction code: P0508 "voltage of control circuit of idling speed governor too low" ................................................................................................................................. 149 No.103
Malfunction code: P0509 "voltage of control circuit of idling speed governor too high" ................................................................................................................................. 150
No.104
Malfunction code: P0511 "malfunction control circuit of idling speed governor"........ 150
No.105
Malfunction code: P0560 "unreasonable system voltage signal" .............................. 150
No.106
Malfunction code: P0562 "system voltage too low" ................................................... 151
No.107
Malfunction code: P0563 "system voltage too high" ................................................. 151
No.108
Malfunction code: P0601 "error of check code of electronic control unit".................. 152
No.109 Malfunction code: P0602 "error of identification code of diagnosis data of electronic control unit" .............................................................................................................. 152 No.110
Malfunction code: P0645 "malfunction of relay control circuit of AC compressor"..... 152
No.111 Malfunction code: P0646 "voltage of relay control circuit of AC compressor too low" 153 No.112 Malfunction code: P0647 "voltage of relay control circuit of AC compressor too high" ................................................................................................................................. 154 No.113
Malfunction code: P1508 "voltage of control circuit of idling speed governor too high" ................................................................................................................................. 155
No.114
Malfunction code: P1651 "malfunction of control circuit of engine malfunction lamp (SVS)" ...................................................................................................................... 155
Common Malfunction Diagnosis Flow of Geely Automobile
No.115
Engine not running or slowly running while startup ................................................... 157
No.116
While startup, engine running, but unable to start ..................................................... 158
No.117
Difficult to start for hot startup.................................................................................... 159
No.118
Difficult to start for cold startup .................................................................................. 160
No.119
Difficulty startup at any time though with normal speed ............................................ 161
No.120 Normal startup with instable idling speed at any time ............................................... 162 No.121 Normal startup, with instable idling speed during warming up .................................. 163 No.122 Normal startup, with instable idling speed after warming up ..................................... 164 No.123 Normal startup, idling speed is instable or the vehicle will flame out when partially loaded (such as: when air conditioner is on) ............................................................ 165 No.124
Normal startup, the idling speed is too high .............................................................. 166
No.125
Unable to rotating speed or flameout while accelerating........................................... 167
No.126
Slow reaction while accelerating ............................................................................... 168
No.127
Weak with poor performance while accelerating....................................................... 169
No.128 Malfunction code with EOBD system ........................................................................ 170 No.129 Malfunction code without EOBD system ................................................................... 174
Transmission ..................................................................................................... 176 No.130
Transmission hard to put into gear............................................................................ 176
No.131 Park position fails...................................................................................................... 177 No.132 Gear indicator lamp off sometimes ........................................................................... 178 No.133
Auto transmission with abnormal sound ................................................................... 179
No.134
Transmission shaking during driving ......................................................................... 181
No.135
Auto transmission case oil temperature rises, reverse gear fails .............................. 183
No.136
Auto transmission upshifts too late............................................................................ 184
No.137
Auto transmission unable to upshift .......................................................................... 186
No.138
Auto transmission unable to force downshift............................................................. 187
No.139 Engine shuts down after putting into gear ................................................................. 188 No.140
No forward gear ........................................................................................................ 189
No.141 Transmission oil easily deteriorate ............................................................................ 190 No.142
Auto transmission oil easily deteriorate..................................................................... 191
No.143
No reversing gear ..................................................................................................... 192
No.144
Trip stop of fourth gear of transmission case ............................................................ 193
Common Malfunction Diagnosis Flow of Geely Automobile
No.145
Transmission with abnormal sound........................................................................... 195
No.146
Gear shifting lever swinging, hard to shift ................................................................. 197
No.147
Sounding when releasing throttle of third, fourth gears and decelerating ................. 198
No.148
Fifth gear not easily shifted up .................................................................................. 199
No.149 Fifth gear, first gear blocks, relieved only when the vehicle stops............................. 200 No.150
Hiss sound when put into gear during driving ........................................................... 201
No.151
Transmission gear runout ......................................................................................... 203
No.152 Hiss sound when second, third, fourth gear upshift .................................................. 204 No.153 Chug sound in transmission case at idling speed ..................................................... 205 No.154
Da-da sound in transmission at idling speed ............................................................ 206
No.155 Buzz sound during driving at high speed .................................................................. 208 No.156
Transmission with abnormal sound while shifting ..................................................... 210
No.157
Transmission gear disorder....................................................................................... 211
No.158 Shaking startup ......................................................................................................... 213
Chassis ................................................................................................................................. 215 No.159 Shaking startup ......................................................................................................... 215 No.160
Clutch slipping........................................................................................................... 217
No.161 Heavy clutch ............................................................................................................. 218 No.162
Not fully separated ....................................................................................................219
No.163 Clutch with abnormal sound...................................................................................... 221 No.164
Shock absorber with abnormal sound....................................................................... 223
No.165 Front wheel with abnormal sound when turning........................................................ 225 No.166 Heavy steering .......................................................................................................... 227 No.167
Steering wheel not well back to original position ....................................................... 229
No.170
Steering power insufficient (hydraulic) ...................................................................... 232
No.171
Power-assisted pump with abnormal sound ............................................................. 233
No.172
Direction running out................................................................................................. 235
No.173
Steering wander during normal driving...................................................................... 237
No.174
Front wheel tire abnormally worn .............................................................................. 239
No.175
Normally when driving straightly, but with abnormal sound while turning.................. 241
No.176 Braking wandering .................................................................................................... 242 No.177
Braking dragging.......................................................................................................244
No.178 Braking with abnormal sound.................................................................................... 246
Common Malfunction Diagnosis Flow of Geely Automobile
No.179
Braking sideslipping, swerving .................................................................................. 248
No.180
Braking intermittently stiffening ............................................................................... 249
No.181 Braking ineffective..................................................................................................... 251 No.182
Brake fails ................................................................................................................. 253
No.183
Steering wheel with too large free stroke .................................................................. 255
No.184
Buzzing noise at rear wheel while driving at high speed........................................... 257
No.185
Braking force of brake master cylinder insufficient.................................................... 258
No.186
Stepping on pedal too heavily ................................................................................... 259
No.187
Common malfunction diagnosis and Solution for Geely automobile tire ................... 260
No.188
Causes analysis for common manufacturing defects of Geely automobile tire ......... 262
Electrics ...............................................................................................................................263 No.189
CD-player disk boot malfunction (without MP3) ........................................................ 263
No.190
CD-player fails to work when activating .................................................................... 265
No.191
CD-player keeps soundless under all modes............................................................ 265
No.192
CD-player/radio gains no power................................................................................ 267
No.193
A loudspeaker of CD-player/radio is soundless......................................................... 268
No.194 Onboard hand-free phone has no sound output (MK)............................................... 269 No.195 CD-player/radio button out of control ........................................................................ 271 No.196
CD-player/radio button indicator malfunction ............................................................ 271
No.197
CD-player/radio memory function malfunction .......................................................... 273
No.198
CD-player/radio no signal ......................................................................................... 273
No.199 CD-player/radio sound distortion at large volume ..................................................... 274 No.200
CD-player/radio tuner can’t stop ............................................................................... 275
No.201 CD-player/radio has noise when receiving signal ..................................................... 276 No.202
CD-player fails to insert disk ..................................................................................... 277
No.203
CD-player fails to popup disk .................................................................................... 279
No.204
CD-player with poor vibration resistance performance ............................................. 280
No.205 USB interface of CD –player malfunction (U-disk) (MK) ........................................... 281 No.206
CD-player burns out when connecting power source................................................ 283
No.207
CD-player consists back drop ................................................................................... 284
No.208
Cassette stuck or failed to popup.............................................................................. 286
No.209
Cassette speed abnormal, turned over automatically and chewed ........................... 287
No.210
Poor timbre, low volume or noise jump when playing CD ......................................... 289
Common Malfunction Diagnosis Flow of Geely Automobile
No.211 Low loudspeaker volume........................................................................................... 291 No.212 Large loudspeaker noise........................................................................................... 293 No.213
Loudspeaker susurrates when pressing horn ........................................................... 295
No.214
Speedometer non-display ......................................................................................... 297
No.215 Freedom ship speedometer malfunction, indicates automatically when pressing horn ................................................................................................................................................. 299 No.216
Incorrect indication of speedometer .......................................................................... 301
No.217 Kilometrage on LCD of odometer will accumulate automatically after the engine starts ................................................................................................................................................. 303 No.218
Automatic movement of odometer pointer after start-up of engine ........................... 305
No.219
Incorrect indication or no indication of engine tachometer ........................................ 307
No.220
Incorrect indication (or no indication) of fuel gauge................................................... 309
No.221
No indication of water temperature gauge ................................................................ 311
No.222
Electric mirror can’t work........................................................................................... 313
No.223
Always-On or failure of water temperature alarm indicator ....................................... 314
No.224
Safety & alarm indicator is always on or not on ........................................................ 315
No.225
Brake fluid level alarm indicator is always on or can’t alarm..................................... 316
No.226 Oil alarm indicator is always on................................................................................. 317 No.227
Headlight is always on or not on ............................................................................... 318
No.228
Weak running of starter............................................................................................. 319
No.229
Starter can’t work ...................................................................................................... 320
No.230 Idling of starter .......................................................................................................... 322 No.231 Abnormal sound during start-up of starter................................................................. 323 No.232
Over-high or over-low recharging voltage from generator......................................... 324
No.233
Generator can’t work................................................................................................. 326
No.234
Charging indicator of generator is always on or not on ............................................. 328
No.235 Flashing of charging indicator of generator ............................................................... 329 No.236 Abnormal sound of generator.................................................................................... 331 No.237
Failure of battery storage .......................................................................................... 332
No.238
Weak running of blower ............................................................................................ 333
No.239
Blower can’t work......................................................................................................334
No.240 Abnormal sound of blower ........................................................................................ 335 No.241
Continuous running of cooling fan............................................................................. 336
No.242
Cooling fan can’t work............................................................................................... 337
No.243
Weak running of cooling fan...................................................................................... 338
Common Malfunction Diagnosis Flow of Geely Automobile
No.244
Wiper can’t work .......................................................................................................339
No.245
Wipe doesn’t work at intermitting position ................................................................. 340
No.246
Electric fuel pump can’t work .................................................................................... 341
No.247
Insufficient pressure of electric fuel pump ................................................................. 342
No.248
Positive pressure of fuel tank too high ...................................................................... 343
No.249
Failure of remote controller ....................................................................................... 344
No.250
Door lock is not self-locked after driving 30 feet........................................................ 346
No.251
Failure of central control locking while driving........................................................... 347
No.252 Flashing CGQ alarm indicator for speedometer........................................................ 348 No.253
Window lifter can’t work ............................................................................................ 349
No.254 Blocking Door lock .................................................................................................... 350 No.255
Failure of door lock ................................................................................................... 351
No.256
If four doors of vehicle are not closed, the anti-theft alarm will be activated automatically and central control will be locked automatically ................................. 352
No.257
Reversing radar can’t work while reversing .............................................................. 353
No.258
Wrong information from the reversing radar.............................................................. 354
No.259 Sunroof can’t move, including malfunction of automatic closing and anti-nip ........... 355 No.260 Abnormal sound and vibration of sunroof while operating ........................................ 356 No.261
Leaking of sunroof (water on internal decoration of roof).......................................... 357
No.262
Air-conditioner can’t work.......................................................................................... 358
No.263 Normal suction pressure and too high exhaust pressure for AC compressor ........... 361 No.264 Too high suction pressure and exhaust pressure for AC compressor ....................... 362 No.265 Too high suction pressure and normal exhaust pressure for AC compressor ........... 363 No.266
Too low suction pressure and exhaust pressure for AC compressor......................... 364
No.267
Air conditioning has abnormal sound ........................................................................ 365
No.268
The air conditioning has no heating supply or the heating air is not warm................ 366
No.269
A/C compressor fails to start ..................................................................................... 368
No.270 The A/C control mechanism is hard to operate ......................................................... 370 No.271 The A/C evaporator is frosting................................................................................... 370 No.272
Constant malfunction and solution of A/C components ............................................. 372
No.273
Vehicle temperature sensor is in poor condition (code display 01)......................... 376
No.274
The vehicle exterior temperature sensor is in poor condition; (code display 02)....... 376
No.275
The evaporator temperature sensor is in poor condition.
No.276
The temperature adjustment performer is in poor condition; (code display 04) ........ 377
(code display 03) ........... 377
Common Malfunction Diagnosis Flow of Geely Automobile
No.277 The sun sensor is in poor condition.(code display 05) .............................................. 378 No.278
The fan governing module is in poor condition;
(code display 06).......................... 378
No.279
The high speed relay is in poor condition; (code display 07) .................................... 379
No.280
The rear defrosting function is invalid ....................................................................... 379
No.281
The display screen has no display ............................................................................ 380
No.282
The internal and external circulation regulation is invalid.......................................... 380
No.283 The wind direction adjustment is abnormal ............................................................... 381 No.284
The blower is in poor operation................................................................................. 381
No.285
Vehicle interior air conditioning is in poor condition................................................... 382
No.286
Vehicle interior central heating is in poor condition ................................................... 383
No.287
Night light regulation function of the a/c controller is invalid...................................... 383
No.288
The compressor is out of service .............................................................................. 384
No.289
Effect of the air conditioning is in poor condition (check it per the content in the following table) .........................................................................................................384
No.290 Installation and Commissioning of the Air Conditioning ............................................ 386 No.291 Line inspection of "EPS" indicating lamp (the "EPS" indicator does not light up when the ignition switch is opened) ................................................................................... 397 No.292
Inspection to "EPS" indicator line ("EPS" indicator does not light up or keep on lighting up when the cross-line connection is made between the diagnoses switch terminal and the ground terminal)................................................................................................. 398
No.293 Main line of DTC11 torque sensor (the main line is broken or short circuit) .............. 398 No.294 DTC13 torque sensor (there is big difference between the auxiliary line outputs of the main line and the torque sensor).............................................................................. 398 No.295
DTC14 torque sensor (power supply voltage of the torque sensor is too high or too low) ................................................................................................................................. 399
No.296 Auxiliary line of DTC15 torque sensor (the auxiliary line is disconnected or short circuit) ................................................................................................................................................. 399 No.297 DTC22 engine speed signal (no engine signal input)................................................ 399 No.298
Vss line(Vss line is disconnected or short circuit) ........................................................................401
No.299
DTC41 motor (the motor voltage is too high or too low)............................................ 401
No.300
DTC51 clutch line (the clutch line is disconnected or short)...................................... 401
No.301
Power circuit of DTC54 control module (low voltage of the battery) ....................... 402
No.302 DTC52 and DTC55 control modules (failure of control module)................................ 402 No.303 Voltage inspection.....................................................................................................402
Common Malfunction Diagnosis Flow of Geely Automobile
No.304
Introduction of mechanical assembly ........................................................................ 403
No.305
Diagnoses to the ABS system failure ........................................................................ 405
No.306
Quick index list of malfunction clearance .................................................................. 406
No.307
Index of malfunction code free malfunction check list ............................................... 406
No.308
Malfunction check list of malfunction code................................................................ 407
No.309 The malfunction codes are 00283, 00285, 00290 and 00287 (mechanical malfunction) ................................................................................................................................................. 408 No.310
Malfunction codes: 00283, 00285, 00290 and 00287 ............................................... 409
No.311 Malfunction codes are 00283, 00285, 00290 and 00287
(electric failure) .............. 410
No.312
Malfunction code: 01044........................................................................................... 411
No.313
Malfunction code: 00668........................................................................................... 411
No.314 Malfunction code: 01130 ........................................................................................... 412 No.315
Malfunction check list of malfunction free code......................................................... 413
No.316
The ABS alarm lamp is normally open after the engine starts................................... 414
No.317 ABS is in abnormal operation.................................................................................... 414 No.318 The brake pedal stroke is too long ............................................................................ 416 No.319
Large force is required to stamp the pedal................................................................ 417
No.320 There is no diagnostic code output ........................................................................... 417 No.321 ABS system inspection ............................................................................................. 419 No.322
ECU code ................................................................................................................. 422
No.323 Fluid filling and air exhaust ....................................................................................... 423
Common Malfunction Diagnosis Flow of Geely Automobile
Engine No. 001 Engine shuts off abnormally when driving Malfunction
Cause
Low fuel pressure or injector blockage
Improper ignition timing, engine shuts off sometimes
Valve clearance too small or throttle body too dirty
Check the injection volume and the atomization of the injector, whether they are normal, clean or replace the injector when necessary. Check fuel pressure. When idling the value shall correspond to 265~304 kPa, when accelerating the value shall increase approximately 50 kPa. If fuel pressure is too low, check fuel pressure controller, electric fuel pump and fuel filter etc. Check engine ignition timing. When idling, the ignition advance angle shall be 10~12°. Otherwise, shall adjust engine initial advance angle. When accelerating, the ignition advance angle shall over 20~30°, automatically adjusted. Otherwise, shall replace ECU or maintain ignition controlling system. Check valve clearance, whether it is too small. When heating, the clearance of air intake and exhaust valve shall be 0.20±0.05mm, otherwise, adjust it to prescribed value according to maintenance manual. Check throttle body, whether it is too dirty. Clean throttle body and idle speed controller when necessary.
Fuel quality problem
When applying poor quality fuel, the fuel pipe must be cleaned then replace standard gasoline, 93# or above.
Spark plug malfunction
Check spark plug resistance, whether the value is 5~8KΩ, as well as the clearance, whether the value is 0.8~1.0mm. Otherwise, shall adjust or replace them.
Ignition coil malfunction
Check ignition coil, the initial winding shall be 0.4~0.6Ω, and the 2nd winding shall be 11~15Ω. Otherwise, shall replace ignition coil.
Spark plug wire Engine shuts off in normal driving, such as geared driving or cornering
Solution
If there is short or open circuit in spark plug wire, then shall replace it.
Idle speed control valve or stepper motor malfunction
When stuck, shall clean or replace it.
Fuel pump relay burnt
Check the relay by multimeter, whether it is connected, as well as the coil resistance, whether the value is 75~90Ω. Replace when necessary.
Valve gumming
Determine whether it is valve gumming, according to local and gasoline using condition. Generally, the malfunction appears in cold condition, and will disappear after vehicle heated. It is recommended that driver shall clean engine without components removing, meanwhile, replace qualified gasoline.
ECU harness pin poor contact
Check ECU, whether it is poor contact, which results signal deviation when idling, as well as abnormal shut-off. Fasten wire connector again, when necessary.
Three way catalytic converter damaged or blocked
Check three way catalytic converter, whether it is free-flowing, as well as the housing, whether there is collision mark. Replace the converter assembly when necessary.
Pressure temperature sensor malfunction
Temperature sensor part (pin disconnected) pin 1# and 2#: the rated resistance at 20℃ is 2.5KΩ±5%, and the value shall decrease when temperature raising. Pressure sensor part (pin connected): black pen connects to earth; red pen connects with pin 3# and 4# respectively. In idle condition, the reference voltage on pin 3# shall be 5V, and the voltage on pin 4# shall be approximately 1.3V (determined by vehicle). If the value abnormal, then the pressure temperature sensor is damaged and shall be replaced.
Poor ECU signal
Check main ECU wire harness connectors, whether they are fixed, as well as poor connecting caused by rust and oxidation. Clean and fix it when necessary. Load data stream by K61 detector, and check the display value of ECU, whether it coordinates to the standard. Replace ECU when necessary.
Insufficient engine cylinder pressure
Check engine compression ratio and pressure, whether they are corresponding with the standard value: 479Q 9.3: 1/1250kpa/250r/min; 479QA 9.8: 1/1440kpa/250r/min; 481Q9.4: 1/1360kpa/250r/min; JI376QE9.5: 1/1225kpa/350r/min; JL378QE 9.5: 1 / 1225kpa/350r/min; audit and maintain engine when necessary.
1
Common Malfunction Diagnosis Flow of Geely Automobile
Engine shuts off abnormally when driving
Abnormal Spark plug, ignition coil, spark plug wire malfunction
Normal
Replace
Improper Adjust
Improper ignition timing
Normal Abnormal Valve clearance too small or throttle body too dirty
Adjust and clean
Normal Abnormal Fuel quality problem
Normal
Replace
Abnormal
Three way catalytic converter damaged or blocked Normal
Replace
Burnt
Fuel pump relay burnt
Normal
Replace
Abnormal
Pressure temperature sensor failure
Normal
Replace
Abnormal Replace
Poor ECU signal Normal Abnormal
Mainatain
Valve gumming Normal
Abnormal
Idle speed control valve or stepper motor malfunction
Normal
Clean or replace
Too low or bocked
Low fuel pressure or injector blockage Normal
Check or replace Abnormal Check engine
Inssuficient engine cylinder pressure
2
Common Malfunction Diagnosis Flow of Geely Automobile
No. 002 Engine surging Malfunction
Cause Fuel fliter blockage
Tachometer large vibrates when engine surging
Solution Check fuel filter, whether it is blocked, and replace it when necessary.
Charcoal canister
Check charcoal canister, whether it contains gasoline, replace it if gasoline contains.
Fuel injector blockage or poor atomized
Check the injection volume and atomization of injector, if they are abnormal, then shall clean and replace injector assembly.
Low fuel pressure
Check fuel pressure, when idling, the pressure shall be in accordance with regular value, 265~304kPa, and shall increase about 50kPa when accelerating. If fuel pressure is too low, shall check fuel pressure controller, electric fuel pump and etc.
Air intake system leakage
Test the actual pressure of manifold, whether it is in accordance with standard. Check intake manifold gasket whether it is damaged, as well as the gasket between intake manifold and throttle. Check the cylinder gasket, whether it is bent and damaged. Check all hoses whether they are ageing and broken.
Poor ignition
Check spark plug applying condition, whether it operates well. Check cylinder wire, whether there is short or open circuit. Check the operating condition of ignition coil and distributor. Check the connecting condition between ignition control and ECU.
Idle motor malfunction
Check idle motor, whether it is too dirty or stuck, clean or replace it when necessary. Load data stream to confirm idle operation parameter status.
Small valve clearance
Check valve clearance: on 4-cylinder engine, the clearance of intake valve shall be 0.20±0.05 mm, exhaust valve 0.30±0.05mm. On 3-cylinder engine, the clearance of intake / exhaust valve shall be 0.20±0.05mm when heating, 0.12±0.04mm in cold condition. Otherwise, shall adjust it.
Improper ignition time
Check ignition advance angle, whether it is normal. In idle condition: on 4-cylinder engine, the advance angle shall be 10°~12° before top dead center. on 3-cylinder engine, the advance angle shall be 12°±3.75° before top dead center. Otherwise, shall adjust it.
Engine mechanical parts
Check exhaust system, whether it is blocked or damaged. Check timing, whether it is misaligned. Check valve spring, whether it is damaged. Check camshaft, cylinder head and piston, whether they are malfunction. Check cylinder pressure, whether it is in normal condition.
3
Common Malfunction Diagnosis Flow of Geely Automobile
Engine surging
Fuel fliter blockage
Blocked Clean or replace
Normal Poor Check the injector whether it is blocked or poor atomized
Clean or replace
Normal Low Low fuel pressure
Maintain
Normal Intake system leaking
Leak Maintain
Normal Poor Poor ignition
Maintain or replace
Normal Abnormal Charcoal canister
Replace
Normal Abnormal Adjust
Engine valve clearance
Normal Engine ignition timing
Abnormal Adjust
Normal Abnormal Clean or replace
Idle motor
Normal Abnormal Engine mechanical parts
Check
4
Common Malfunction Diagnosis Flow of Geely Automobile
No. 003 Over idle speed when warm-up Malfunction
Idle speed raised when warm-up
Cause
Solution
Improper ignition time
Adjust ignition time
Incorrect fuel pressure
Check fuel pressure, whether the value is 265~304kPa. If it is abnormal, shall check fuel pump and pressure controller, as well as the balance fuel injection volume of each injector.
Throttle cable or inner damper fails to return origin position
If throttle cable or inner damper fails to return origin position, sc. opening degree remains, shall check throttle cable and throttle.
Idle speed control valve or stepping motor stuck
Check idle controller, whether there is over carbonization. Implement clean and self-adaption value adjust when necessary.
Intake system leak
Check intake system, whether it is leaking. Maintain or replace when necessary.
The sensitive resistance temperature coefficient of water temperature sensor indicates inaccurately
Check water temperature sensor, at each temperature, whether the operation resistance is in regulated range. For example, at 20℃± 1 ℃ (temperature tolerance), the resistance shall be 2.27~2.73kΩ. Replace when necessary.
Exhaust gas oxygen sensor malfunction
Check heater resistance of heated oxygen sensor (UAES 1~6Ω, Delphi 12Ω, Polarsun 13.2±10%) , heater voltage (12V) and signal voltage (0.1~0.9V), whether they are normal. Check oxygen sensor, whether it is polluted or poisoned. When oxygen senor outputs low voltage or signal error, then ECU will send thick injection order, otherwise, replace the sensor.
A/C control signal error
Check A/C controlling system, whether it is normal. Check pressure switch current, whether it is normal. Check AC system pressure, whether it is normal.
ECU inner data unmatching
Check ECU, whether it is damaged. Replace ECU assembly when necessary.
5
Common Malfunction Diagnosis Flow of Geely Automobile
Over idle speed when warm-up
Abnormal Water temperature sensor malfunction
Replace
Normal Oxygen sensor malfunction
Abnormal
Replace
Normal Abnormal Intake system leaking
Check
Normal Stuck Idle speed control valve or stepping motor stuck Clean or replace
Normal Abnormal Incorrect fuel pressure
Check
Normal A/C control signal error
Abnormal Check
Normal
Improper ignition time (too early)
Abnormal Adjust
Normal Abnormal Maintain
Throttle cable or damper malfunction
Normal Abnormal Replace
ECU inner malfunction
6
Common Malfunction Diagnosis Flow of Geely Automobile
No. 004 Idle speed fluctuation Malfunction
Cause Throttle is stuck and dirty
Ignition maladjustment
Voltage unstable
Sensor and executive unit malfunction
Solution Clean and check throttle sealing condition. Check spark plug, whether it is dirty, cracked or tracking; Check wire of each cylinder, whether they are ageing, tracking, short or open circuit; Check ignition timing, whether it is maladjustment. (ignition timing shall position at 10~12° before top dead center when idling. Adjust ignition timing advance angle if necessary, when accelerating, the angle shall increase 20~30°) Check battery voltage, whether the value is 12~14.5V; Check generator, whether it operates normally; Check body earth lead, whether it is fastened. Check cooling temperature sensor, whether the resistance is according with the standard in different temperatures. Check intake temperature sensor, and replace it when necessary. Check idle speed control valve or stepping motor, whether it is stuck or damaged, clean or replace it when necessary. Check throttle position sensor, whether the bolts are over raised, and adjust them when necessary. Check oxygen sensor, whether it waves between 0.1V and 0.9V. If injector sealing leaking, then replace injector assembly. If spark plug operates poorly, then replace the plug.
Exhaust system malfunction
Check canister, whether it is polluted and blocked. Check exhaust pipe, whether it is deformed and damaged. Check 3-way catalytic converter, whether it is damaged or blocked.
Poor tachometer sensitivity
Check instrument connector, whether it is poor contact. Fix it again when necessary. If it conducts normally, then replace the instrument panel.
ECU malfunction
Test the voltage between each 2 terminals of ECU, whether the value is in normal range. Check the connecting condition between ECU and wire. Load data stream according to origin data.
Engine mechanical malfunction
Check the pressure difference between each cylinder, whether they are over normal range. Check the sealing condition of each cylinder.
7
Common Malfunction Diagnosis Flow of Geely Automobile Idle speed fluctuation
Stuck, dirty Clean
Throttle is stuck and dirty Normal
Abnormal Adjust
Ignition maladjustment Normal
Abnormal
Exhaust system malfunction
Check or replace
Normal Abnormal Voltage unstable Normal
Check or replace Abnormal
Sensor and executive unit malfunction Replace Normal
Abnormal
ECU malfunction
Replace
Normal Abnormal Engine mechanical malfunction
Check
8
Common Malfunction Diagnosis Flow of Geely Automobile
No. 005 Idle speed unstable or engine shut-off when opening AC or steering Malfunction
Idle speed unstable or engine shut-off when openinig AC or steering
Cause
Solution
Compressor or booster pump malfunction
AC compressor over load (for example, coolant over filling, tube blocked, condenser is dirty, and etc.), belt over tensioned, compressor inner stuck, as well as booster pump inner rotor stuck and results over load.
Intake system abnormal
When intake manifold leaking, repair or replace relevant component. When valve clearance disalignment, adjust it. When air filter blocking, replace it.
Oil line pressure abnormal
Replace oil pump, when it operates abnormally. Fuel filter blocked, replace it. Fuel pressure controller operates abnormally, replace it. Oil pump relay poor contact, maintain or replace it.
AC switch or booster pump oil pressure sensor malfunction
When opening AC or steering, ECU doesn't receive loading signal, which results low idle speed and engine shut-off. Maintain or replace it.
Idle speed controller or stepping mortor malfunction
Check stepping motor, whether it is stuck or dirty. Clean or replace it when necessary.
Injector malfunction
When injector blocked or poor atomized, shall clean the injector, and replace it if necessary.
Improper ignition timing or weak jump-spark power
Check ignition timing, coil, wire and spark plug etc. and each connecting part, whether they are damaged. Maintain or replace them.
ECU malfunction
Check ECU and each connecting part, whether there are damage.
Low engine pressure
cylinder
Disassemble and maintain the engine.
9
Common Malfunction Diagnosis Flow of Geely Automobile Idle speed unstable or engine shut-off when openinig AC or steering
Abnormal Compressor or booster pump failure Normal
Check or replace Abnormal
Intake system abnormal
Check
Normal Abnormal Check or replace
Oil line pressure abnormal Normal Abnormal AC switch or booster pump oil pressure sensor malfunction Normal
Replace
Abnormal Clean or replace
Idle speed controller or stepping mortor malfunction Normal
Abnormal
Injector malfunction Normal
Clean or replace
Abnormal
Improper ignition timing or weak jump-spark power
Normal
Adjust or replace
Abnormal
ECU malfunction Normal
Replace Abnormal
Insufficient engine cylinder pressure
Check
10
Common Malfunction Diagnosis Flow of Geely Automobile
No. 006 Engine shuts off intermittently Malfunction
Cause
Solution
Spark plug clearance abnormal or tracking
Engine shuts off intermittently when running at idle speed
is
Adjust spark plug clearance: on 4-cylinder engine, 0.8~1.0mm. On 3-cylinder engine, 1.0~1.1mm. Replace the plug when there is current leaking.
Ignition wire tracking, short or open circuit
Replace ignition wire.
Fuel pump relay conducting point burnt
Check relay conducting point, whether it is burnt. Replace it when necessary.
Improper fuel pressure
Check oil pressure and the atomization of each injector, whether they are normal. Check oil pump, oil pressure controller and fuel filter when necessary. As well as clean and replace the injector.
Fuel pollution
Check oil, whether it is polluted or mixed with water.
Ignition coil malfunction
Check ignition coil, whether it is over heat or short circuit. Measure primary winding, the resistance shall be 0.4~0.6Ω, and secondary winding, the resistance shall be 11~15kΩ. Otherwise, shall replace ignition coil.
Canister oil leaking
Check canister, whether it contains gasoline or it is blocked. Replace it when necessary.
Distributor malfunction
Replace distributor assembly.
Exhaust system blocked
Check 3-way catalytic converter or exhaust pipe, whether it is bent or blocked. Replace it when necessary.
Improper valve adjustment
Check the valve clearance of each cylinder, whether the value is too small. Adjust it to standard value when necessary. For 4-cylinder engine, the intake valve clearance shall be 0.20±0.05mm, the exhaust valve clearance shall be 0.30±0.05mm. For 3-cylinder engine, the intake / exhaust valve clearance shall be 0.20±0.05mm when heating, and 0.12±0.04mm when in cold condition. Otherwise, shall adjust the clearance.
Crankcase malfunction
clearance
venting
device
Check PCV valve, whether it is blocked or stuck. Maintain or replace it when necessary.
Fuel tank inner vacuum
Check fuel tank, whether it contains inner vacuum. Replace tank cover or canister electromagnetic valve when necessary.
Oxygen sensor malfunction
Check oxygen sensor, whether it is polluted or poisoned. Replace it when necessary.
Idle speed control valve or stepping motor operates abnormal
Check idle speed control valve or stepping motor, whether it is stuck or operating abnormal. Clean or replace idle speed control valve or stepping motor when necessary.
ECU and connecting circuit malfunction
Check ECU body, whether the heat condition and operating condition are in according with manufacturer requirements. Replace ECU assembly when necessary. Check engine computer wire harness connector, whether it is loose, fix it again when necessary.
11
Common Malfunction Diagnosis Flow of Geely Automobile Engine shuts off intermittently
Abnormal Improper fuel pressure
Maintain or replace
Normal Burnt Fuel pump relay conducting point burnt
Normal
Replace
Abnormal
Idle speed control valve or stepping motor is dirty or stuck
Normal
Check or replace
Abnormal
Fuel pollution
Replace
Normal Abnormal Ignition coil malfunction
Replace
Normal Abnormal Canister oil leaking
Check or replace
Normal Blocked Exhaust system blocked
Check or replace
Normal Abnormal Oxygen sensor malfunction
Replace
Normal Abnormal Improper valve clearance
Adjust
Normal Abnormal Crankcase venting device malfunction
Check
Normal Abnormal Fuel tank inner vacuum Normal
Check Abnormal Replace
Spark plug and ignition wire malfunction Normal
Abnormal
ECU and connecting circuit malfunction
Check or replace
12
Common Malfunction Diagnosis Flow of Geely Automobile
No. 007 Poor accelerating performance in cold condition Malfunction
Poor accelerating performance in cold condition, particularly in low speed and middle speed.
Cause
Solution
Improper gasoline quality
Clean fuel pipe and replace clean gasoline, 93# or above.
Low gasoline pressure
Check filter, whether it is blocked. As well as fuel pressure controller, whether it operates normally, replace it when necessary. Check gasoline pump pressure whether the value is normal, maintain or replace it when necessary.
Air filter blocked
Check air filter, whether it is blocked, clean or replace it when necessary.
Low cylinder pressure
Check cylinder pressure, whether there is carbon deposit at intake valve, as well as valve leaking and cylinder wearing malfunction. Maintain or replace then according to the malfunction.
Idle speed controlling valve or stepping motor operates abnormal
Clean or replace idle speed control valve or stepping motor
Throttle malfunction
Check throttle body, whether it is stuck, clean or replace it when necessary.
Ignition system malfunction
Check ignition coil, wire and spark plug, whether they are malfunction, replace them when necessary.
Intake temperature pressure sensor
Pressure sensor malfunction. Check the resistance and voltage, whether the value is in normal range. Replace the sensor when necessary.
Oxygen sensor malfunction
Check oxygen sensor, whether the heating function is normal. As well as the voltage signal, whether it varies between 0.1V and 0.9V.
Intake manifold leaking
Check the vacuum, whether the value is in normal range. Check the connecting condition of each vacuum hose, as well as intake/exhaust manifold gasket, whether it is damaged.
Ignition timing maladjustment
Check tachometer sensor signal and ignition datum, whether they are normal.
ECU and malfunction
connecting
circuit
Check ECU, whether it is malfunction. Check connecting wire, whether it is of poor contact. Maintain or replace it when necessary.
13
Common Malfunction Diagnosis Flow of Geely Automobile Poor accelerating performance in cold condition
Lack Improper gasoline quality or low gasoline
Check or replace
pressure Normal Blocked Air filter blockage
Clean
Normal Low Low cylinder pressure
Check
Normal Stuck Idle speed valve or throttle malfunction
Check
Normal Abnormal Ignition system malfunction
Check or replace
Normal Abnormal Intake temperature pressure sensor
Replace
Normal Oxygen sensor malfunction
Abnormal Replace
Normal Abnormal Intake manifold leaking
Check
Normal Abnormal Ignition timing maladjustment
Check and adjust
Normal Abnormal ECU and connecting wire malfunction
Check or replace
14
Common Malfunction Diagnosis Flow of Geely Automobile
No. 008 Spark plug non-sparking Malfunction
Engine has no start symptom and spark plug non-sparking
Cause
Solution
Ignition coil malfunction
Measure the primary winding, the resistance shall be 0.4~0.6Ω, and the secondary winding, the resistance shall be 11~15kΩ. Otherwise shall replace ignition coil. Check the coil, whether there is short or open circuit. Replace it when necessary.
Spark plug malfunction
Check spark plug, whether it is leaking current, as well as the clearance of electrode.
Distributor cover or distributor arm malfunction
Check cover or distributor arm, whether there is current leaking, dielectric puncture or damage. Replace it when necessary.
Ignition wire malfunction
Check ignition wire, whether it is leaking current or open circuit. Replace it when necessary.
Tachometer sensor malfunction or the Hall sensor in distributor malfunction
Measure sensor resistance (UAES 4-cylinder engine tacho sensor resistance shall be 770~950Ω, Delphi 540Ω, Polarsun 530±50Ω), as well as the signal output and ECU wire, whether they are operating normally. Maintain it when necessary.
EFI fuse and relay malfunction
Check EFI fuse, whether it is burnt or poor contact. Check main relay, whether it is burnt. Check the circuit, whether it is poor contact. Maintain them when necessary.
ECU malfunction
Check terminal input and output signal, whether they are normal.
Ignition control system circuit malfunction
Check all connecting wires, whether they are poor contact or open circuit. Maintain it when necessary.
Engine anti-thief system malfunction
Check anti-thief controller and all connecting wires, whether they are normal connected, as well as the anti-thief status activated.
control
15
Common Malfunction Diagnosis Flow of Geely Automobile Spark plug non-sparking
Abnormal Ignition coil malfunction
Replace
Normal Abnormal Spark plug malfunction
Adjust or replace
Normal
Abnormal
Distributor cover or distributor arm malfunction
Replace
Normal
Abnormal
Ignition wire malfunction
Replace
Normal
Abnormal
Tachometer sensor failure or the Hall sensor in distributor malfunction
Replace
Normal Abnormal ECU malfunction
Replace
Normal Abnormal Ignition control system circuit malfunction
Check
Normal Abnormal Engine anti-thief control system malfunction
Replace
16
Common Malfunction Diagnosis Flow of Geely Automobile
No. 009 Low idle speed during engine heating in cold condition Malfunction
Cause
Solution
Weak ignition spark
Check ignition coil, wire and spark plug, whether they are normal. Adjust or replace them when necessary.
Crankcase device fails
Check PCV valve, whether it is normal. Replace crankcase venting device when necessary.
venting
Intake system leaking
Measure vacuum, check the connecting condition of manifold gasket, throttle gasket, and all vacuum pipes.
Thermostat malfunction
Check thermostat, whether it is leaking, which results warm-up period over normal value. Replace thermostat when necessary.
Idle speed (steeping maladjustment
Measure the resistance (UAES idle speed valve 17.6Ω, Delphi motor 53Ω, Polarsun motor 48±2.4Ω) and voltage of idle motor, whether they are normal. Check idle speed motor, whether it is dirty and stuck. Maintain and replace it when necessary.
valve motor)
Improper clearance
Low idle speed during engine heating in cold condition
valve
Adjust valve clearance: on 4-cylinder engine, the intake valve clearance shall be 0.20±0.05 mm, the exhaust valve clearance shall be 0.30±0.05mm. On 3-cylinder engine, the intake/exhaust valve clearance shall be 0.20±0.05mm when warming-up, and 0.12±0.04mm in cold condition.
Low cylinder pressure
Check engine compression ratio and pressure, whether they are in accordance with standard value. 479Q 9.3: 1/1250kpa/250r/min; 479QA 9.8: 1/1440kpa/250r/min; 481Q 9.4: 1/1360kpa/250r/min; JI376QE 9.5: 1/1225kpa/350r/min; JL378QE 9.5: 1 / 1225kpa/350r/min; Inspemction the cause, whether valve leaking or piston ring and cylinder wearing. Disassembly and maintain the engine when necessary.
Water temperature sensor damaged
Check the resistance of water temperature sensor in cold condition (UAES 2.5kΩ, at 20℃; Delphi 3.56~2.26kΩ, at 20~30℃; Polarsun 2.5kΩ, at 20℃), whether they are in accordance with standard. Or measure the temperature of cold vehicle by scanner, whether it is in accordance with actual engine temperature. Replace coolant fluid temperature sensor when necessary.
Injector malfunction
Check injector, whether it is blocked or stuck. Check atomization and implement leak test. Clean or replace injector.
Oxygen malfunction
Check heat-type oxygen sensor heater resistance (UAES 1~6Ω, Delphi 12Ω, Polarsun 13.2Ω±10%), as well as heater voltage, 12V, and signal voltage, 0.1~0.9V, whether they are in normal range. Check sensor surface, whether it is dirty and results voltage over normal value, as well as the fuel-air mixture is too thin.
Ignition maladjustment ECU malfunction
sensor
timing
Check ignition time and calibrate ignition timing, in idle condition: on 4-cylinder engine, the ignition advance angle shall be 10°~12° before top dead center. On 3-cylinder engine, the value shall be 12°±3.75° before top dead center. Check connecting conditions of ECU and all wires.
17
Common Malfunction Diagnosis Flow of Geely Automobile Low idle speed during engine heating in cold condition
Abnormal Check and replace
Weak ignition spark
Normal
Abnormal
Crankcase venting device failure
Normal
Check
Damaged Replace
Water temperature sensor damaged Normal
Abnormal Replace
Thermostat failure Normal
Abnormal
Improper valve clearance
Adjust
Normal Abnormal Check
Intake system leaking Normal Abnormal Ignition timing maladjustment
Normal
Check Low Check
Low cylinder pressure Normal
Abnormal
Idle speed valve (steeping motor)
Clean and replace
maladjustment Normal
Abnormal Clean and replace
Injector failure
Normal Abnormal Oxygen sensor malfunction Normal
Replace Abnormal Replace
ECU malfunction
18
Common Malfunction Diagnosis Flow of Geely Automobile
No. 010 Canister oil leaking Malfunction
Cause
There is fuel under vehichle when parking, and the engine speed is unstable when idling.
Solution
Check valve damage, on fuel tank
Check the single check valve on fuel tank, whether it is damaged. Replace fuel tank assembly when necessary.
Fuel tank cover damage
Check the single check valve of fuel tank cover, whether it can open. Replace fuel tank cover when necessary.
Canister venting (air) pipe blocked
Check the white venting pipe, to air, at the bottom of canister, whether it is blocked by silt and result oil leaking. Unplug or replace it when necessary.
Controlling canister malfunction
Check controlling canister inner charcoal and pipe export, whether they are blocked. Replace them when necessary. Check canister, whether the mounting position is too low. Adjust the mounting height when necessary.
Vacuum pipe blocked, on top of canister
Raise engine speed to 2000r/min, if vacuum pipe suction is low, then shall check vacuum pipe system.
Canister control valve malfunction
Check canister controlling valve resistance, which shall be 22~30Ω at 20℃. Check controlling wire and valve element, whether they are in normal condition. Maintain and replace them when stuck.
ECU malfunction
Check ECU and canister electromagnetic valve controlling circuit, whether they are in normal condition.
Canister oil leaking
Damaged Check valve damage, on fuel tank
Replace
Normal Damaged Fuel tank cover damage
Replace
Normal Damaged Controlling canister malfunction
Replace
Normal Pipe blocked, on top of canister
Blocked Check
Normal Damaged Canister control valve malfunction
Replace
Normal Abnormal ECU malfunction
Replace
19
Common Malfunction Diagnosis Flow of Geely Automobile
No. 011 Fuel smells in vehicle Malfunction
Cause
Solution
Gas station man-made malfunction
Fuel smells in vehicle, when opening window, it smells even worse
When filling, fuel dropped around tank filling port and cover, then flows into vehicle. Clean vehicle.
Fuel tank filling port and port cover leaking
Check or replace fuel tank filling port and cover.
Fuel pipe leak
Check or replace leaking fuel pipe.
Fuel tank cracked and leaking
Check fuel tank, whether it is leaking. Replace it when necessary.
Canister leak
Check canister controlling system and venting system.
Fuel tank inner pressure abnormal
Replace fuel tank, check valve and fuel filling port cover etc.
Controlling canister pipe malfunction
Check canister pipe, whether it is dropped.
Canister malfunction
Check canister controlling valve, whether it is blocked, as well as the suction capacity, whether it is poor or fails to open.
controlling
valve
Fuel pump and fuel sensor mounting Check or replace fuel pump and fuel sensor mounting sealing. gasket leaking Ignition timing maladjustment
Maintain ignition timing, whether it is delayed.
Injector leak
Check sealing of injector and pipe.
Engine operates abnormal
Check engine operation, whether there is unavailable cylinder.
Oxygen sensor
Measure the voltage of sensor, whether it is too low, as well as the fuel-air ratio, whether it is over normal value.
20
Common Malfunction Diagnosis Flow of Geely Automobile Fuel smelling strong in vehicle
Leak Fuel pipe leakage Normal
Check Leak
Fuel tank leakage Normal
Replace Leak, blocked Replace or check
Canister leak or block Normal
Abnormal
Fuel tank inner pressure abnormal Normal
Check Leak
Injector leak
Check Normal
Abnormal
Engine oprates abnormal Normal
Check
Abnormal Check
Ignition timing maladjustment Normal
Abnormal
Canister controlling valve malfunction Normal
Replace Abnormal
Canister pipe malfunction Normal
Replace Abnormal Replace
Oxygen sensor
21
Common Malfunction Diagnosis Flow of Geely Automobile
No. 012 Engine vibration when operating Malfunction
Engine operates unstably and vibrations, when running in idle and low speed, there is tu-tu-tu sound in exhaust pipe.
Cause
Solution
Engine operates with unavailable cylinder
Check cylinder pressure, spark plug, ignition wire and valve etc., whether they are abnormal. Replace the malfunction part when necessary.
Incorrect ignition timing
Adjust ignition time
Fuel pressure abnormal
Check electric fuel pump, fuel pressure controller and pipes
Engine fuel grade doesn't in accordance with standard Injector malfunction
Replace qualified fuel Check injector fuel atomization and pulse width
Engine shock pad malfunction or mounting bracket deformed Cylinder gasket damage
Adjust or replace relevant components Replace cylinder gasket
Clutch operates abnormal
Maintain or replace relevant components
Gearbox or vehicle transmission accessories damage
Adjust or replace relevant components According to components
Crank link mechanism malfunction
22
sound
position,
maintain
relevant
Common Malfunction Diagnosis Flow of Geely Automobile Engine vibration when operating
Unavailable cylinder Engine operates with unavailable cylinder
Normal
Check Abnormal
Incorrect ignition timing
Normal
Check
Abnormal Check
Fuel pressure abnormal Normal
Abnormal
Injector failure Normal
Check Abnormal Check
Cylinder gasket damage Normal
Abnormal
Engine fuel grade doesn't in accordance with standard Normal
Replace
Abnormal
Engine mounting bracket deformed Normal
Check Abnormal Check
Crank link mechanism malfunction Normal
Abnormal
Clutch operates abnormal
Check
Normal Abnormal Gearbox or vehicle transmission accessories
Check
damaged
23
Common Malfunction Diagnosis Flow of Geely Automobile
No. 013 Engine noise over normal level Malfunction Engine noise over normal level, and vibration when idling
Cause
Solution
Exhaust system leaking or block
Maintain leaking components, as well as replace blocking parts.
Poor fuel quality, which results engine operating abnormal
Replace qualified fuel that match Geely vehicle requirement.
Engine operates abnormal
When engine operating with unavailable cylinder, the malfunction shall be excluded. When camshaft assembly and gear sound abnormally, shall adjust or replace them. As well as the crankshaft and piston link mechanism.
Generator water pump, booster pump etc. sound abnormally
Replace generator, water pump and booster pump assembly.
Water tank fan and AC fan sound abnormally
Replace relevant components.
Water temperature over normal value
Maintain fan and cooling system, whether they operate normally.
Ignition timing maladjustment
Maintain or adjust ignition timing.
Compressing ratio over normal value
Maintain cylinder capacity, combustion chamber volume, as well as the end surface of cylinder block and cylinder head, whether they are normal.
Detonation sensor malfunction
Maintain mounting condition of sensor and correct the voltage.
Poor lubrication
Check oil pressure and quality.
Engine interferences accessories
with
Intake system leak or block
relevant
Maintain and exclude the malfunction. Replace relevant components when leaking. Unplug or replace them when blocked.
24
Common Malfunction Diagnosis Flow of Geely Automobile Engine noise over normal level
Leaking or block Exhaust system leaking or block
Normal
Check and replace
Abnormal
Engine operates abnormal Normal
Check
Abnormal sound
Generator water pump, booster pump etc. sound abnormally Normal
Check and replace
Abnormal sound
Water tank fan and AC fan sound abnormally Normal
Check and replace
Abnormal
Water temperature over normal value Normal
Interferen
Engine interferences with relevant accessories
Normal
Check Over normal value Check
Compressing ratio over normal value Normal
Check
Leak or block
Intake system leak or block
Check
25
Common Malfunction Diagnosis Flow of Geely Automobile
No. 014 Water temperature over normal value after AC activated Malfunction
Cause
Radiator over heated after AC activated when driving
Solution
Insufficient coolant fluid
Fill coolant according to requirements.
Radiator fan operates abnormal
Radiator fan blade deformed and stuck. Replace radiator fan assembly when the fan speed is low.
Too much refrigerant
Check refrigerant, whether it is too much, which increases engine load and high water temperature. The refrigerant shall be filled to standard level.
Condenser fan malfunction
Maintain fan wire and motor.
AC system pressure over normal value
Adjust system pressure to normal value.
The cooling and cycling performance of cooling system lower than normal level
Too much furring contains in engine water pipe, which results poor water cycling and cooling, and shall be cleaned. Clean or replace the radiator, when it is dirty and blocked.
Generator belt loose
Adjust belt tightness according to requirement.
Water pump operates abnormal and results poor cooling water recycles.
Maintain or replace pump assembly
Thermostat fails to open
Replace thermostat assembly
ECU malfunction
Maintain ECU and all wire terminals
Engine operates abnormally
Disassemble and maintain engine
Water temperature over normal value after AC activated Lack Insufficient coolant fluid Normal
Add
Poor
Radiator fan operates abnormal Normal
Check and replace
Over normal value
Too much refrigerant
Drain
Normal
Failure
Condenser fan malfunction Normal
Check and replace Over normal value
AC system pressure over normal value
Check
Normal The cooling and cycling performance of cooling system lower than normal level Normal
Not smooth Check
Poor
Poor cooling water recycles Normal
Check Abnormal
ECU failure
Replace Normal
Abnormal
Engine operates abnormally
Check
26
Common Malfunction Diagnosis Flow of Geely Automobile
No. 015 Oil pan leak Malfunction
Oil leak at rear end of oil pan after vehicle parked.
Cause
Solution
Too much oil
Fill oil according to standard. For 4-cylinder engine, dry, 3.5L; wet, 3.0L. For 4G18 engine, with oil filter, 4.0L; without oil filter, 3.8L. For 3-cylinder engine, 3.0L.
Oil pan gasket damage
Replace oil pan gasket; tighten the bolts after sealant coated.
Rear end cover gasket leak
Replace rear end cover gasket and coat with sealant.
Rear oil pipe capping leak
Replace or maintain rear main oil pipe capping.
There is blow hole on rear end
Maintain the blow hole on rear end.
Oil pan bolt loose
Tighten oil pan retaining bolt or replace damaged bolt.
Oil pan damaged or deformed
Maintain or replace oil pan.
Irregular assembly procedure
Inner engine pressure over normal value Crankshaft rear oil seal ageing or damage
Oil pan retaining bolt adjust to 4.9NM, evenly. Coat sealant with proper quantity, otherwise, the gasket may slid and move. Unplug or replace gas exhaust system (PCV valve) Engine cylinder, piston ring and piston worn out. Maintain or replace relevant component when necessary. Replace crankshaft rear oil seal.
27
Common Malfunction Diagnosis Flow of Geely Automobile Oil pan leaking Too much Fill oil according to standard
Too much oil Normal
Damage
Oil pan gasket damage
Replace
Normal Irregular assembly procedure
Irregular Remount
Normal Oil pan damaged
Damage Replace
Normal Rear end panel deformed or seal gasket failure
Normal
Abnormal Check and replace
Blocked
Rear oil pipe capping leaking
Check and replace
Normal Oil pan bolt loose
Loose Tighten
Normal Over normal value Inner engine pressure over normal value
Normal
Check
Abnormal Replace
Cranksahfe rear oil seal ageing or damage
28
Common Malfunction Diagnosis Flow of Geely Automobile
No. 016 Distributor oil leaking Malfunction
Cause
Engine stands stil after activated. There is visible oil leaking at distributor
Solution
Too much oil
Drain spare oil
Poor crankcase venting
Check crankcase intake pipe, whether it is blocked. Clean and unplug intake pipe to exclude the malfunction.
Distributor seal ring ageing and damage
Check distributor seal ring, whether it is ageing or damaged. Replace O-ring when necessary.
High inner engine pressure
Check exhaust pipe and single check valve, whether they are blocked. Unplug or replace them when necessary.
Distributor rotating shaft loose
Check distributor rotating shaft, whether the loose volume is in accordance with standard. Replace distributor assembly when necessary.
Distributor rotor gear wearing
Check distributor gear, whether it is worn out. Replace distributor assembly when necessary.
Blow hole or crack on distributor
Check oil leak of distributor sear and further determine the processing accuracy of distributor. If there is blow hole or crack, then shall replace distributor seat.
Distributor oil leaking Y Drain spare oil
Too much oil N
Damage
Poor crankcase venting
Normal
Check
Loose Check
High inner engine pressure
Normal
Loose
Distributor seal ring ageing and damage
Replace
Normal Wearing Distributor rotating shaft loose
Replace
Normal Over normal value Distributor rotor gear wearing
Normal
Replace
Poor
Blow hole or crack on distributor
Replace
29
Common Malfunction Diagnosis Flow of Geely Automobile
No. 017 JL376/378 engine shut-off when sliding at neutral gear Malfunction
Engine operates well when accelerating normally, while shut-off when sliding at neutral gear or steering.
Cause
Solution
Improper spark plag electrode clearance or spark plug current leak and non-resistance
Adjust or replace spark plug (spark plug clearance is 1.0~1.1mm)
Improper adjustment
Adjust valve clearance, 0.20±0.05mm in hot condition, 0.12±0.05mm in cold condition
valve
clearance
Distributor malfunction
Maintain and replace distributor assembly
Intake system leaking
Maintain or replace relevant component；
Idle speed controller motor) malfunction Crankcase pressure
generates
(stepping negative
Check stepping motor controlling wire, resistance and blocked. Clean and replace then when necessary. Check exhaust single check valve
Fuel circuit stuck (when steering)
Maintain fuel tank, whether there is impurity in it.
Fuel pressure abnormal
When fuel pipe is leaking, replace it When air filter is blocked, replace it. When fuel pump or fuel pressure controller, which value shall between 264kPa and 305kPa, is damaged, replace it.
Fuel contains in canister
Maintain and replace canister
Fuel contains in vacuum pipe
Maintain oil pressure controller
Throttle shaft run-out
Replace throttle body assembly
Wire malfunction
Check wire circuit, whether it is poor contact.
Low cylinder pressure
Check cylinder pressure, whether the valve is leaking, as well as the wearing condition of piston ring and cylinder.
30
Common Malfunction Diagnosis Flow of Geely Automobile JL376/378 engine shut-off when sliding at neutral gear Improper Improper spark plug and valve clearance adjustment Normal
Adjust
Stuck
Fuel circuit stuck (when steering) Normal
Check
Abnormal
Idle speed controller (stepping motor) Normal
Clean and replace Abnormal
Fuel pressure abnormal
Check
Normal Distributor failure
Abnormal Replace
Normal Intake system leaking
Leak Maintain
Normal Fuel contains Fuel contains in vaccum pipe Normal
Maintain
Low
Low cylinder pressure
Check
31
Common Malfunction Diagnosis Flow of Geely Automobile
No. 018 High idle speed when sliding at neutral gear, MK Malfunction
Cause
Solution
Improper ignition timing
Adjust ignition timing
Throttle body or cable fails to return
Clean throttle, adjust or replace throttle cable
Intake system leaking
Maintain or replace relevant component
Improper valve clearance High idle speed when sliding at neutral gear, MK
Adjust valve clearance
Improper fuel pressure
Normal pressure: between 250kPa and 300kPa. When fuel pump, fuel filter and fuel pressure controller operating abnormally, shall replace relevant component.
Electric injection unit operates poorly
Stepping motor stuck, clean it. Throttle position sensor sensitive poorly, adjust or replace it. Fuel injector leaking, replace it. Intake temperature pressure sensor malfunction, replace it. (see the table above for details of check method)
ECU software malfunction or inner damage
Software malfunction, update it or check ECU, whether it is damaged. Replace ECU when necessary.
High idle speed when sliding at neutral gear, MK
Fails to return Throttle body or cable fails to return
Check and replace
Normal Improper ignition timing
Abnormal Check and adjust
Normal Intake system leaking
Leak Check
Normal
Improper valve clearance
Normal
Abnormal Adjust
Operates poorly
Electric injection unit operates poorly
Normal ECU software failure or inner damage
Check and replace
Abnormal Replace
32
Common Malfunction Diagnosis Flow of Geely Automobile
No. 019 Engine vibration Malfunction
Cause
Engine operating unstably, starting slowly, with surge and vibration
Solution
Engine bracket or vehicle body deformed
Replace engine bracket or correct vehicle body.
Low fuel pressure
Check supply pressure of fuel system, whether it is too low, while the normal value is between 250kPa and 300kPa. Replace fuel pressure controller, fuel filter or electric fuel pump and other relevant damaged components.
Clutch system malfunction
Generally, the malfunction is caused by unbalance fly wheel or press plate etc. Replace relevant components.
Engine operating with unavailable cylinder
Spark plug, cylinder cable, valve, valve clearance, injector and cylinder sleeve worn out, and results unavailable cylinder. Exclude the malfunction. Check idle speed stepping motor, whether it is too much carbon deposit. Clean or replace it when necessary.
Electric injection unit malfunction
Check throttle opening degree, clean or replace throttle sensor when necessary. Check ECU integrated circuit, whether it is damaged. Replace it when necessary.
ECU damaged
Engine vibration
Check Engine oprating with unavailable cylinder
Normal
Check
Low
Low fuel pressure
Check
Normal Deform Engine bracket or vehicle body deformed
Normal
Check and replace
Abnormal
Clutch system malfunction
Normal
Check and replace
Damage
ECU damaged
Replace
33
Common Malfunction Diagnosis Flow of Geely Automobile
No. 020 Exhaust pipe pours black smoke Malfunction Light smoke when idling, heavier when accelerating
Cause
Solution
Air filter blocked
Check and clean/replace air filter
Low fuel quality
Apply unleaded clean fuel, 93# or above, which is in accordance with manufacturer requirements.
Fuel contains in vacuum pipe
Check fuel pressure controller, whether it is damaged and leaking
High oil pressure
Check fuel pump, pumping pressure and controller function.
Improper ignition timing
Check and adjust ignition timing
Unavailable cylinder
Implement cylinder cross firing test respectively, check the performance of wire and spark plug.
Valve leaking
Clean combustion chamber carbon deposit. Replace or grind valve.
Injector leak or atomization abnormal
Clean or replace malfunction injector
Throttle position sensor malfunction
Measure the resistance and voltage of throttle, replace it when necessary.
Oxygen sensor voltage abnormal
Measure sensor voltage and resistance, replace it when necessary.
Cylinder gasket damage
Maintain or replace cylinder gasket.
ECU malfunction
Check ECU and circuit whether they are normal.
Low cylinder pressure
Disassemble and maintain engine.
34
Common Malfunction Diagnosis Flow of Geely Automobile Exhaust pipe pours black smoke
Blocked Clean or replace
Air filter blocked Normal
Abnormal
Low fuel quality
Replace
Normal
Low
High oil pressure
Check and replace
Normal
Abnormal
Unavailable cylinder Normal
Check and replace
Abnormal
Improper ignition timing Normal
Adjust Abnormal
Oxygen sensor voltage abnormal Normal
Check
Leaking
Valve leaking
Check and replace Normal
Abnormal
Cylinder gasket damage Normal
Replace
Abnormal
ECU failure
Replace Normal
Abnormal
Injector leak or atomization abnormal
Clean or replace Abnormal
Normal Low cylinder pressure
Check
35
Common Malfunction Diagnosis Flow of Geely Automobile
No. 021 Engine idle speed decreases when activating head beam or fan Malfunction
Engine speed decreases, with vibration, when activating head beam or fan
Cause
Solution
Fuel quality is not in accordance with requirement
Apply unleaded clean fuel, 93# or above.
Generator belt loose
Adjust belt tension to 50NM, when pressuring downwards, and the deflection shall be 10MM.
Earth lead loose
Check gearbox, body earth lead and instrument earth lead, whether they are loose. Tighten them when necessary.
Generator operates abnormal
Check the electrical energy of generator, whether it is beneath 9V. Replace generator voltage controller when necessary.
Battery open circuit
Check the gravity of battery electrolyte, maintain or replace battery assembly when necessary.
Idle speed controlling valve or stepping motor malfunction
Clean idle speed control valve or stepping motor. Replace it when damaged.
Grouped switch short circuit
Maintain grouped switch and relevant harness.
The power of head beam or the load of fan is over normal value.
Check head beam, whether it applies the bulb requires the power over standard value. Replace standard power bulb when necessary. Replace fan motor or maintain the circuit.
Low generator charging current (75A)
Replace generator assembly, which supplies 90A charging current.
Poor ECU signal
Measure the voltage among terminals and wire connecting condition. Maintain or replace them when necessary.
Engine operates abnormal
Maintain engine
36
Common Malfunction Diagnosis Flow of Geely Automobile Engine idle speed decreases when activating head beam or fan
Loose Generator belt loose
Adjust
Normal Low Earth lead loose
Check
Normal Open circuit Generator operates abnormal
Check or replace
Normal Battery open circuit
Check
Normal Idle speed controlling valve or stepping motor failure Normal
Abnormal Clean and replace
Short circuit
Combined switch short circuit Normal
Check and replace Over load
The power of head beam or the load of fan is over normal value Normal
Replace Poor Replace
Poor ECU signal Normal
Abnormal Check
Engine operates abnormal
37
Common Malfunction Diagnosis Flow of Geely Automobile
No. 022 Exhaust pipe blows water Malfunction
Cause
Solution
Water log in silencer
Check silencer inner water log. The tail water exhaust port of silencer is blocked, and blows large quantity of water when accelerating. Punch a hole on silencer to drain water.
Throttle body water leak Engine vibration when idling, with abnormal noise, and cooling water is always polluted.
Maintain or replace throttle body.
Gasket damaged
Maintain cylinder and cylinder head surface, replace gasket.
Crack or blow hole in cylinder head
Check cylinder head, whether there is crack or blow hole in it, which results coolant flow into cylinder. Remove cylinder head and inspect the crack in it, by magnaflux. Replace cylinder head when necessary.
Crack or blow hole on clinder wall
Check cylinder wall, whether there is crack or blow hole in it, which results coolant flow into cylinder. Remove cylinder wall and inspect the crack in it, by magnaflux. Replace cylinder head when necessary.
Exhaust pipe blows water
Water log Check
Water log in silencer
Normal
Water leak Replace
Throttle body water leak
Normal Damage Gasket damage
Normal
Replace
Crack or blow hole
Crack or blow hole in cylinder head
Normal
Replace
Crack or blow hole Replace
Crack or blow hole on clinder wall
38
Common Malfunction Diagnosis Flow of Geely Automobile
No. 023 Engine shuts off when accelerating Malfunction
Cause Fuel tank lacks of fuel
Engine shut-off when vehicle picking up
Solution Fill fuel
Poor fuel quality
Replace with standard fuel
Air filter blocked
Clean or replace air filter
Low intake vacuum
Vacuum sense port of intake pressure sensor is blocked by carbon deposit. Clean it. Intake vacuum pipe cracked, and results vacuum decreased, mixture gas rarefied, as well as engine shut-off when vehicle picking up.
Exhaust system partly blocked
Check 3-way catalytic converter, whether it is dropped or blocked.
Ignition maladjustment
Check fly wheel signal rim, whether it operates correctly. Check tachospeed sensor, whether it is normal. Check valve timing, whether it is normal. Check ignition system, whether it contains ignition miss.
Positive electrode of oxygen sensor short or open circuit.
Check output voltage of oxygen sensor, in idle condition the value shall be about 4.5V. Otherwise, replace oxygen sensor.
Fuel pressure decrease when accelerating
Normal fuel pressure is between 250kPa and 300kPa. Check fuel pump, fuel filter and fuel pressure controller etc. Replace them when necessary.
Throttle position sensor short or open circuit
Check throttle position sensor, whether there is short or open circuit. Replace it when necessary.
Low cylinder pressure
Check operation of each cylinder, whether it operates normal. Disassemble and maintain engine when necessary.
39
Common Malfunction Diagnosis Flow of Geely Automobile Engine shuts off when accelerating
Lack Fuel tank lacks of fuel
Fill
Normal Poor fuel quality
Poor quality Replace
Normal Air filter blocked
Normal
Blocked Clean or replace
Low
Low intake vaccum Normal
Check Blocked
Exhaust system blocked
Check and replace
Normal Abnormal Ignition maladjustment Normal
Check
Decrease
Fuel pressure decrease when accelerating Normal Positive electrode of oxygen sensor short or open circuit Normal
Replace
Abnormal Replace Abnormal Check
Low cylinder pressure
40
Common Malfunction Diagnosis Flow of Geely Automobile
No. 024 Oil indicator is always on Malfunction Instrument warning lamp is always on after engine started
Cause
Solution
Low oil quantity results low oil pressure
Fill oil to standard level
Low oil viscosity or oil deteriorated
Replace required oil
Oil pressure switch damage
The inner conducting point of oil pressure switch burnt seriously and results short circuit. Replace oil sensing plug.
Oil indicator circuit leads to earth partly
The wire between oil sensing plug and grouped instrument partly leads to earth at front wall, and results oil indicator lightening constantly after circuit lead to earth.
Grouped instrument inner short circuit
Replace grouped instrument
Low oil pressure
Maintain oil pump and oil pipe, whether it is blocked. Unplug it when necessary. Check oil leaking condition and maintain it.
Large engine liner clearance, which results low oil pressure
Large clearance results oil leaking and low oil pressure. Normal value shall be 49kPa. Replace relevant component.
Oil pipe leaking
Maintain or replace relevant component.
Oil indicator is always on
Low Low oil quantity results low oil pressure
Normal
Fill
Deteriorate
Low oil viscocity or oil deteriorated
Replace
Normal Oil pressure switch damage
Normal
Damage Replace
Short circuit
Grouped instrumernt inner short circuit
Replace
Earth lead
Normal Oil indicator circuit leads to earth partly
Normal
Check
Low
Low oil pressure
Check
Normal Large clearance Large engine liner clearance, which results low oil pressure
Check
Normal
Leak Check
Oil pipe leaking
41
Common Malfunction Diagnosis Flow of Geely Automobile
No. 025 Water temperature is over normal value when engine running with large load Malfunction
Cause
Solution
Lack of coolant fluid
Water temperature is over normal value when diving in high speed, and is normal in low speed.
Fill non-standard anti-freeze fluid
Replace standard anti-freeze fluid
Fuel grade against requirement
Apply specified fuel
Low thermostat open travel
Thermostat shall be fully opened when water temperature reaches 82℃, otherwise, replace it.
Water pump belt loose
Adjust tension rate
Radiator is too dirty inside or outside, and results low cooling performance, as well as water temperature increased.
Clean radiator, the dirt and water mark, replace water tank when necessary.
Radiator fun operates abnormal (low speed or fails to work sometimes)
Maintain fan circuit and replace fan.
Improper ignition timing
Adjust timing
Engine water pipe rust
Clean rust
Engine mixed gas is too thick
Engine oxygen sensor damaged and results mixed gas viscosity misadjusted.
Improper piston fit clearance
Low cylinder pressure, maintain it. Low clearance often caused by applying non-standard piston, replace and reassemble with proper piston.
Cylinder bolt loose or cracked
42
Common Malfunction Diagnosis Flow of Geely Automobile Water temperature is over normal value when engine running with large load Poor Low cooling performance of rediator Normal
Check and replace Poor
Fan operates abnormal
Check and replace
Normal Improper piston fit clearance
Abnormal Check
Normal Too thick Engine mixed gas is too thick
Adjust
Normal Low thermostat open travel
Too small Replace
Normal Loose Water pump belt loose
Adjust
Normal Rust Engine water pipe rust Normal
Clean
Against
Fuel grade againsts requiremen
Replace
43
Common Malfunction Diagnosis Flow of Geely Automobile
No. 026 Canister electromagnetic valve sounds abnormal Malfunction
Cause
Electromagnetic valve sounds abnormal when idling
Solution
Canister electromagnetic valve is dirty inside
Clean it with carburetor detergent
Canister electromagnetic valve retaining rubber seat damage
Replace canister electromagnetic valve retaining rubber seat and adjust the position, as far as possible with vehicle body
Serious fuel tank inner vacuum
Replace fuel tank cap
Over adjustment of canister electromagnetic valve inner tube
Adjust canister electromagnetic valve according to standard flow rate
Serious canister electromagnetic valve wearing
Replace canister electromagnetic valve assembly
Canister electromagnetic valve sounds abnormal
Dirt Canister electromagnetic valve is dirty inside
Clean and replace
Normal Damage Canister electromagnetic valve retaining rubber seat
Replace
damage
Normal Vaccum Maintain
Serious fuel tank inner vaccum
Normal Over normal value Over adjustment of canister solenoid valve inner tube
Adjust
Normal Wearing Serious canister solenoid valve wearing
Replace
44
Common Malfunction Diagnosis Flow of Geely Automobile
No. 027 Engine fails to start Malfunction
Cause
Solution
No fuel
Check fuel gauge and fuel level
Low battery voltage
Check battery voltage, whether it is normal, which shall above 11.5V. Charge or replace battery when the value is too low. Check or replace circuit, if battery fails to be charged as normal (check whether there is short circuit in inner/outer circuit, which results current leaking). Check battery circuit and all connections, whether they are well conducted. Check starter, whether it operates normally. Maintain or replace it when necessary.
Starter malfunction
Ignition switch circuit and malfunction
Check starter, whether it operates normally. Check starter circuit, solenoid switch, carbon brush, coil and rotor, whether there is short or open circuit, as well as poor conduction. Check one-way clutch whether it is slipping, as well as one-way clutch and fly wheel tooth, whether they are damaged. Maintain or replace them when necessary.
open wire
Check circuit, fuse, ignition switch by multimeter, set to resistance range, whether they are open circuit. To inspection the malfunction.
Electric control system malfunction
Connect Geely special No. to check whether there is malfunction No.. And inspect again if it shows malfunction No.. Then check relevant component and circuit according to the indication of malfunction No..
Improper ignition timing or weak spark voltage Engine fails to start
Check high voltage spark, if it operates normally, then check engine speed sensor, ignition coil, ECU and relating circuit. Maintain or replace them when necessary. (Connect two pins of primary winding respectively to multimeter, and the resistance shall be 0.4~0.6Ω at 20℃. In same condition, the resistance of secondary winding shall be 11~15kΩ. Connect pin 2 and pin 3 of sensor to multimeter pen respectively, and at 20℃ the rated resistance shall be 860Ω±10%) Check ignition timing, if it is improper, then check flywheel signal plate, whether it is loose and malposition. Maintain or replace it when necessary. Check high voltage spark energy, if it is weak, then check ignition coil, high voltage resistance. Replace it when necessary.
Spark plug malfunction Incorrect valve timing
Check spark plug electrode clearance and carbon deposit condition. Adjust or replace it when abnormal. Check timing belt, whether there is damage. Replace it when necessary. Check timing belt, whether there is damage. Replace it when necessary.
Air filter blocked or intake system leaking
Check air filter, whether it is blocked. Clean or replace it when necessary. Check intake system, particularly intake manifold, injector, vacuum pipe and connector, whether they are leaking. Exclude the malfunction when necessary.
Fuel malfunction
Fuel pressure shall above 260kPa when idling. Otherwise, the fuel pressure is low, and shall check fuel pump, fuel pressure controller and fuel pipe, whether there is malfunction.
system
Engine signal loose or moved Exhaust blocked
plate
system
Check engine signal plate, whether is it loose or moved. When necessary, shall position it (20 teeth after point T for 4-cylinder, 16 teeth after point T for 3-cylinder) first, then weld or replace engine signal plate. Check or replace exhaust system blocking position
Low cylinder pressure
Measure cylinder pressure. Fill a few oil into cylinder to determine whether the cylinder or piston ring worn out, as well as valve sealing leaking. Adjust valve clearance or disassemble engine when cylinder pressure is too low.
Injector malfunction
Check both ends of connector of each injector by oscillograph or multimeter, whether there is pulse signal. If not, shall check parts of controlling circuit or ECU. Otherwise, remove injector and check fuel injection quantity and atomization, whether it is normal. Clean or replace it when necessary.
ECU malfunction
ECU controller fails to input or output signal normally, replace it.
45
Common Malfunction Diagnosis Flow of Geely Automobile Engine fails to start
N No fuel
Fill
Y
Lack
Low battery voltage
Charge
Normal Abnormal Starter failure Normal
Check and replace
Abnormal
Ignition switch open circuit and wire failure
Check and replace
Normal Abnormal Electric control system failure Normal
Check and replace Abnormal
Improper ignition timing or weak spark voltage
Check
Normal Abnormal Spark plug failure
Replace
Normal
Error
Incorrect valve timing
Check
Normal
Blocked
Air filter blocked
Clean
Normal Abnormal Fuel system failure
Maintain
Normal Low pressure Low cylinder pressure Normal
Maintain
Abnormal
Exhaust system blocked Normal
Unplug
Abnormal
Injector failure
Clean and replace
Normal Abnormal Engine signal plate loose or moved Normal
Check or replace Abnormal Replace
ECU inner short circuit
46
Common Malfunction Diagnosis Flow of Geely Automobile
No. 028 Hard to start in cold condition Malfunction
Cause
Solution Check battery voltage whether it is normal. Charge or replace it when necessary.
Low engine speed when driven by starter
Check starter, whether it operates normally. Maintain or replace it when necessary. Check oil condition, whether it is too thick. Replace standard grade oil when the oil is too thick, which results large inner engine friction and further causes low engine speed.
Hard to start in cold condition
Electric controlling system malfunction
Connect Geely special decoder to check whether there is malfunction code.. And inspect again if it shows malfunction code. Then check relevant component and circuit according to the indication of malfunction code.
Cooling fluid temperature sensor malfunction
Water temperature sensor fails to output signal or outputs incorrectly, which will affect fuel injecting adjustment of engine ECU and results improper mixture gas viscosity. And further causes engine fails to start, operates unstably, stop operating or running intermittently. Check cooling fluid temperature sensor. In different temperatures, its resistance shall vary according to specified standard. Replace it when necessary.
Spark plug abnormally
The spark plug clearance shall between 0.8mm and 1.2mm. If there is lots of fuel on spark plug surface, it indicates fuel fouling in cylinder. In this case, shall remove all spark plugs, disconnect injector circuit, full open the throttle, and start engine for several times to exclude the malfunction.
operates
Low fuel pressure
Check fuel pressure, if it is too low, shall check fuel pressure controller, electric fuel pump and fuel filter etc.
Incorrect oil grade, too thick
Since oil grade is improper, which results large oil viscosity and hardly start, the oil shall be replaced according to local temperature. Check valve timing, whether it is correct. Adjust it when necessary.
Improper ignition timing or weak spark energy
Check igniting operation, whether there is high voltage spark. If not, shall check engine speed sensor, ignition coil and related ECU circuit. Maintain or replace them when necessary. Check high voltage spark energy, if it is weak, then check ignition coil, high voltage resistance. Replace it when necessary.
Exhaust system blocked
Unplug blocked exhaust system
Over carbon deposit in intake manifold or valve
Over carbon deposit in intake manifold and valve, will cause low viscosity of mixture gas in cold condition, and results hard to start. Shall clean the carbon deposit.
Air filter blocked or intake system leaking
If the filter element is too dirty and blocked, the engine will be hard to start. Remove the filter element and start engine, if it operates normally, then replace the element. Check intake system, whether it is leaking. Particularly the intake mainfold gasket, vacuum pipe and connector etc. Exclude the malfunction.
Injector blocked or fuel atomized abnormally
Remove injector, check fuel injection quantity and fuel atomization, whether they are normal. Clean or replace it when necessary.
Low cylinder pressure
Measure engine cylinder compressing pressure, if it is low, but will increase after filled a few oil into the cylinder, then the cylinder or piston ring is worn out and need to replace or implement cylinder boring repair. If the pressure remains at low value, then it indicates improper valve clearance, valve burnt or leaking. Shall adjust valve clearance or replace valve.
ECU malfunction
ECU controller fails to input or output signal normally, replace it.
47
Common Malfunction Diagnosis Flow of Geely Automobile Hard to start in cold condition
Abnormal Low engine speed when driven by starter
Check
Normal Electric controlling system short or open circuit
Abnormal Check
Normal Abnormal Cooling fluid temperature sensor failure
Replace
Normal Poor Spark plug operates abnormally
Adjust and replace
Normal Low Low fuel pressure
Check
Normal
Abnormal
Improper ignition timing or weak spark energy
Maintain
Normal Abnormal Injector blocked or fuel atomized abnormally
Clean and replace
Normal Blocked Air filter blocked
Normal
Clean
Over carbon deposit
Over carbon deposit in intake mainfold or valve; exhaust pipe blocked
Normal
Check
Lack
Low cylinder pressure
Check
Normal Abnormal ECU malfunction
Replace
48
Common Malfunction Diagnosis Flow of Geely Automobile
No. 029 Hard to stard engine when heating Malfunction
Cause
Solution Check battery voltage, whether it is normal. If the value is too low, shall charge and check charge circuit, as well as related components.
Low starter speed or sliding
Check starter, and maintain or replace it when starter coil is heated and short circuit. If motor idles, then the starter flywheel gear and motor gear slide when match, which results engine hard to start.
Electric malfunction
controlling
system
Connect Geely special decoder to check whether there is malfunction code. And inspect again if it shows malfunction code. Then check relevant component and circuit according to the indication of malfunction code. Check spark plug electrode clearance and carbon deposit condition. Adjust or replace it when necessary.
Spark plug malfunction
Check heating operation, whether there is high voltage spark. If not, check engine speed sensor, ignition coil, ECU and relating circuit. Maintain or replace them when necessary.
Weak high voltage spark
Check high voltage spark energy. If it is weak, check ignition coil, spark wire resistance. Replace them when abnormal. Cooling fluid malfunction
temperature
sensor
Hard to start engine when heating
Check cooling fluid temperature sensor. In different temperatures, its resistance shall vary according to specified standard. Replace it when necessary.
Injector malfunction
When heating, the expansion difference of valve seat and element may affect injector pin valve and result valve seat and element stuck or leak, which relates with spark plug drown and primary fuel pressure lose and cause hardly to ignite. Check injector, replace it when necessary.
Fuel quality problem
Check fuel, whether it is polluted, or contains other problem. It is recommended that customers shall change the gas station, where they often attend.
Engine cylinder, connect rod, crankshaft and camshaft bearing fit pressure is over normal value
Engine cylinder, connect rod, crankshaft and camshaft bearing fit pressure is over normal value, the expansion when heating will result crankshaft stuck. Maintain relating part.
Speed sensor output signal abnormal
Engine speed sensor resistance or output signal and signal tooth clearance abnormal, which results improper ECU ignition timing, as well as engine hard to start. Shall adjust or replace engine speed sensor.
Air filter blocked
Clean or replace
Low fuel pressure
Check fuel pressure, if it is too low, shall inspect fuel pressure controller, electric fuel pump, fuel filter and pipes.
Intake pressure temperature sensor operates abnormally
Intake pressure temperature sensor is heated, which results signal misalignment.
ECU inner malfunction
The triode in ECU controller is heated, and fails to input or output signal normally. Shall replace ECU.
49
Common Malfunction Diagnosis Flow of Geely Automobile Hard to stard engine when heating
Low Low starter speed or sliding
Normal
Check and replace
Abnormal
Electric controlling system failure
Normal
Check and replace
Abnormal
Spark plug failure
Replace
Normal
Abnormal
Weak high voltage spark
Check
Normal Abnormal Cooling fluid temperature sensor failure
Replace
Normal Abnormal Injector failure
Clean and replace Normal Abnormal
Fuel quality problem
Replace
Normal Over fitted Engine fit pressure is over normal value
Check
Normal Abnormal Speed sensor output signal abnormal Normal
Replace
Blocked
Air filter blocked
Clean
Normal
Lack
Low fuel pressure
Check Normal
Abnormal
Intake pressure temperature sensor operates abnormally Normal
Replace Abnormal Replace
ECU inner malfunction
50
Common Malfunction Diagnosis Flow of Geely Automobile
No. 030 Idle speed unstable Malfunction
Engine idle unstable
Cause
Solution
Improper throttle position sensor adjustment
When idling, the action, such as open AC, operate steering wheel or open front lamp, will increase engine load. ECU will add injection quantity to remain engine running stably, as well as to prevent engine shut-off when engine load increased. Disconnect idle speed conducting point, while engine is not running in idle condition, determined by ECU, and it will remain injection quantity instead of increase it. Therefore, the engine speed remains as before, and ECU will adjust idle speed according to the order of oxygen sensor mixer. The malfunction is indicated by low engine speed when open AC or operate steering wheel in idle condition. When the throttle is closed totally, inspect idle switch of throttle position sensor by Geely special deNo.r, whether it is normal. Adjust or replace it when necessary.
Idle speed by-pass pipe blocked
Check throttle and idle speed by-pass pipe, whether they are blocked. Clean it when necessary to ensure free-flowing air intake.
Idle speed control valve or stepping motor malfunction
According to engine speed, temperature, throttle open degree and AC signal etc., ECU will calculate and adjust idle speed control valve or stepping motor, as well as by-pass pipe, to decrease engine speed. If idle speed control valve delayed or stuck, as well as in the case of throttle malposition etc., ECU will fail to implement idle speed adjusting correctly, which results idle speed unstable. Shall clean or replace relating parts, sc. replace idle speed control valve and implement self-adaption on idle speed control valve or stepping motor by deNo.r, series Geely, when necessary.
Electric controlling malfunction
Connect Geely special decoder to check whether there is malfunction code. And inspect again if it shows malfunction code. Then check relevant component and circuit according to the indication of malfunction code.
speed
system
Individual cylinder fails to work
Check operating condition of each cylinder, whether there is individual cylinder, which operating abnormal. Particularly the spark plug, spark wire, cylinder pressure etc. Maintain or replace then when malfunction cause was found.
51
Common Malfunction Diagnosis Flow of Geely Automobile
Intake pipe leak
Intake pipe leaking and results incorrect flow rate decision on ECU, which will cause unstable idle speed. Check leaking position, particularly intake manifold gasket, injector seal ring, vacuum pipe and connector etc.
It has not implement self-adaption, after engine ECU or battery was replaced.
In case of replacing engine ECU, battery or disconnect battery power for a long time, it shall implement self-adaption according to Geely engine self-adaption procedure.
Generator voltage abnormal
Check running engine, whether the output voltage of generator is in normal value. If it is abnormal and results unstable idle speed, then check generator and relating circuit and parts. Maintain or replace them when necessary.
Injector leak or block
If the injector is leaking or blocked, and fails to inject according to ECU order, which results improper mixure gas viscosity, as well as individual cylinder operating abnormal and unstable idle speed, then shall replace the injector.
Exhaust system blocked
Gum deposit, carbon deposit, broken or such problems in 3-way catalytic converter result partly or random blockage, which will increase the backpressure when exhausting, as well as low vacuum of intake pipe, which results abnormal engine exhaust and intake performance, that relating with cylinder operating performance directly. Replace 3-way catalytic converter.
Improper stepping motor gasket thickness
Often appears on vehicle MR7131A, stepping motor gasket is too thin caused by manufacture process, and results motor operating abnormal. Exclude the malfunction by replacing gasket.
Intake temperature malfunction
sensor
Low fuel pressure Improper spark plug and ignition advance angle, which results unstable idle speed
Check sensor data and voltage, replace it when necessary. Measure fuel pressure, check electric fuel pump, pipes and circuit when it is lower than normal value. Maintain or replace them when necessary. Check spark wire cross firing condition, as well as ignition timing. Adjust or replace it when necessary.
Engine bracket cracked
Check vehicle, whether there is any sign of accident. Engine bracket cracked will cause engine vibration, and unstable idle speed.
Oxygen sensor malfunction
Check oxygen sensor signal, replace it when necessary.
Canister valve malfunction
Check canister control valve, replace it when necessary.
52
Common Malfunction Diagnosis Flow of Geely Automobile Idle speed unstable Improper adjusted Improper throttle position sensor adjustment
Normal
Adjust and replace
Blocked
Idle speed by-pass pipe blocked
Clean
Normal Abnormal Idle speed control valve or stepping motor failure
Normal
Clean and replace
Abnormal
Replace
Electric controlling system failure Normal
Fails to work
Individual cylinder fails to work
Check
Normal Leak Intake pipe leak
Check
Normal Abnormal Voltage abnormal
Check
Normal Abnormal Injector failure
Normal
Clean and replace
Blocked
Exhaust system blocked
Normal
Check and replace
Abnormal Replace
Intake temperature sensor failure
Normal
Low
Low fuel pressure
Normal
Check
Cracked
Engine bracket cracked
Normal
Replace
Abnormal
Oxygen sensor failure
Normal
Replace
Fail
Canister valve failure
Replace
53
Common Malfunction Diagnosis Flow of Geely Automobile
No. 031 Non-idle speed Malfunction
Cause
Solution
Idle speed air pipe blocked
Check throttle and idle speed air pipe, whether they are blocked. Clean them if there is too much carbon deposit to ensure free-flowing intake.
Ilde speed stepping motor malfunction
Check idle speed stepping motor, whether it operates normally and flexibly. Clean it if there is too much carbon deposit. Replace motor when necessary.
Improper throttle cable or thorttle position sensor adjustment
Non-idle speed, engine shut-off when pressing throttle pedal
Loose throttle pedal and check throttle cable condition, adjust it if the clearance is improper. When throttle is closed totally, inspect throttle position sensor idle speed switch, by Geely special decoder, whether it operates normally. Adjust or replace it when necessary.
Electric controlling system malfunction
Connect Geely special decoder to check whether there is malfunction code. And inspect again if it shows malfunction code. Then check relevant component and circuit according to the indication of malfunction code.
Cooling fluid temperature sensor malfunction
Check cooling fluid temperature sensor. In different temperatures, the resistance of coolant temperature sensor shall vary according to regulated standard. Otherwise, replace it.
Indicidual cylinder fails to work
Check operating condition of each cylinder, whether individual cylinder operates abnormally, particularly inspect the spark plug, spark wire and cylinder pressure etc. Maintain or replace relating parts when malfunction cause was found.
Engine voltage abnormal
Check running engine, whether the output voltage of generator is in normal value. If it is abnormal and results unstable idle speed, then check generator and relating circuit and parts. Maintain or replace them when necessary.
Intake system leaking
According to idle speed operating principle, vacuum pipe leaking will result non-idle speed. Shall replace vacuum pipe.
Incorrect timing
engine
valve
Timing belt loose and cause gear malposition, as well as similar condition with non-idle speed. Shall adjust ignition timing.
Circuit malfunction
Part of idle speed controlling circuit is ageing or affected by water, may result non-idle speed. Shall maintain circuit.
Engine ECU malfunction
Pull out ECU engine connector, measure the resistance between each terminal by multimeter, whether the value is corresponding to technical requirements. Replace engine ECU when abnormal.
54
Common Malfunction Diagnosis Flow of Geely Automobile Non-idle speed
Blocked Idle speed air pipe blocked
Normal
Clean
Abnormal
Ilde speed stepping motor failure
Clean and replace
Normal Improper throttle cable or thorttle position sensor adjustment
Normal
Abnormal
Clean and replace
Abnormal
Electric controlling system failure
Check
Normal Abnormal Cooling fluid temperature sensor failure
Replace
Normal Fails to work Indicidual cylinder fails to work
Check
Normal Abnormal Engine voltage abnormal
Check
Normal Leak Intake system leaking
Normal
Check
Error Check and adjust
Incorrect engine valve timing
Normal Abnormal Circuit failure
Check
Normal Abnormal Engine ECU failure
Replace
55
Common Malfunction Diagnosis Flow of Geely Automobile
No. 032 Idle speed over normal value Malfunction
Idle speed normal value
Cause
Solution
Improper throttle cable or throttle position sensor adjustment
Loose throttle pedal and check throttle cable condition. Adjust it when the clearance is improper.
Throttle contains too much carbon deposit, sc. it is stuck, which results the throttle fails to close normally.
Check throttle, if there is too much carbon deposit, which results throttle fails to close as normal, then shall clean it.
Idle speed stepping motor malfunction
Check idle speed stepping motor, whether it operates flexibly. If it is stuck, caused by carbon deposit, and then shall clean it. Replace stepping motor when necessary.
Intake system leaking
Intake pipe leaking, result incorrect decision to air flow rate on ECU, and causes improper control, which leads to over idle speed. Check leaking position, particularly the intake manifold gasket, fuel injector seal ring, vacuum pipe and connector etc.
Electric controlling system malfunction
Connect Geely special decoder to check whether there is malfunction code. And inspect again if it shows malfunction code. Then check relevant component and circuit according to the indication of malfunction code.
Cooling fluid temperature sensor malfunction
Check water temperature sensor, whether it can send temperature signal to ECU correctly. In normal condition, the coolant temperature is applied to adjust fuel injecting quantity, sc. mixture gas viscosity. In low temperature, ECU controls injector to inject more fuel to increase mixture gas viscosity, as well as idle speed. Check water temperature sensor, if it fails to measure temperature as normal. In different temperatures, the resistance of cooling temperature sensor shall vary according to regulated standard. Otherwise, replace coolant temperature sensor.
Intake pressure sensor malfunction
Check intake manifold pressure temperature sensor, replace it when abnormal.
Oxygen sensor malfunction
Measure oxygen sensor, if the voltage is low, beneath 0.5V, then will cause incorrect ECU order, which results mixture gas viscosity increase, as well as idle speed. Replace oxygen sensor when necessary.
Engine ECU malfunction
Pull out engine ECU pin and measure the resistance between each terminal of ECU, whether the value is accordance with technical requirements. Replace engine ECU when abnormal.
over
56
Common Malfunction Diagnosis Flow of Geely Automobile Idle speed over normal value
Improper Improper throttle cable or thorttle position sensor adjustment
Normal
Adjust
Over normal value
Throttle contains too much carbon deposit
Clean
Normal Abnormal Idle speed stepping motor failure
Clean and replace
Normal Leak Intake system leaking
Check
Normal Abnormal Electric controlling system failure
Check
Normal Abnormal Temperature sensor failure
Normal
Replace
Abnormal
Intake pressure sensor failure
Replace
Normal Abnormal Oxygen sensor failure
Replace
Normal Abnormal Engine ECU failure
Replace
57
Common Malfunction Diagnosis Flow of Geely Automobile
No. 033 Engine accelerates abnormal Malfunction
Cause
Solution Check air filter, whether it is blocked. Clean or replace when necessary.
Air filter blocked
Check intake system, whether it is leaking. Measure intake manifold vacuum, the value shall above 30kPa when idling. Otherwise, the intake system is leaking. Shall check connectors and all hoses and vacuum pipes carefully.
Improper adjustment of throttle cable or throttle position sensor, which results throttle fail to fully open.
Press accelerate pedal fully, and check whether the throttle fully opens. Adjust throttle cable or pedal, if it fails to open fully.
Improper ignition timing or weak spark energy.
Check ignition timing. When idling, the ignition advance angle shall be 10º~12º. Otherwise, shall adjust the primary ignition advance angle. When accelerating, the angle shall increase to 20º~30º automatically. When abnormal, shall check ignition controlling system, including ignition coil, spark wire and spark plug etc., alternative replace ECU.
Low fuel pressure
Check fuel pressure. When idling, fuel pressure shall in accordance with regulation, 265~304kPa. When accelerating, fuel pressure shall increase about 50kPa. If fuel pressure is too low, then shall check fuel pressure controller, electric fuel pump, fuel filter and etc.
Injector blocked poor atomization
Engine accelerates abnormal
Check throttle position sensor. During throttle varies from full close to full open, the resistance between signal terminal and earth terminal shall increase constantly, without interruption. Adjust or replace the sensor according to regulation, when abnormal.
or
Remove injector and check injecting quantity and atomization quality, whether they are normal. When abnormal, clean or replace the injector.
Low battery voltage
Check battery voltage, whether it is normal. If the value is too low, when will cause fuel injecting quantity decrease, which results low engine power, as well as accelerating delay. In this case, shall check charging system or replace battery.
Coolant temperature sensor malfunction
Check coolant temperature sensor. In different temperatures, the resistance of the sensor shall vary in accordance with regulated standard. Otherwise, shall replace the sensor.
Intake pressure sensor malfunction
Check intake manifold pressure temperature sensor. Replace it when abnormal.
Clutch sliding
Replace driven plate of clutch.
Low engine cylinder pressure
Measure the compressing pressure of engine cylinder. If it is too low, then shall adjust valve clearance, or disassemble and inspect engine.
Poor flywheel signal
In case of low power and accelerating performance, caused by poor flywheel and signal wheel signal, shall replace flywheel assembly.
Crankshaft position sensor malfunction
In case of ECU order delay and low accelerating performance, caused by the sensor fails to indicate crankshaft position correctly, shall replace the sensor.
Incorrect engine valve timing
Check engine valve timing, whether it is correct. Adjust it when incorrect.
Individual fails to work
cylinder
Exhaust blocked
system
Oxygen malfunction
sensor
Check the operating condition of each cylinder, such as individual cylinder operating, whether it is abnormal. Particularly the spark plug, spark wire and cylinder pressure etc. Determine the malfunction cause and maintain or replace relating parts. Check 3 way catalytic converter, whether it is blocked. The reverse interfere caused by blockage will result poor engine accelerating performance. In this case, replace 3-way catalytic converter. It results indiscernible mixture gas rate, as well as low power.
58
Common Malfunction Diagnosis Flow of Geely Automobile Engine accelerates abnormal
Blocked Air filter blocked Normal
Clean Improper adjusted
Improper adjustment of throttle cable or throttle position sensor
Adjust
Normal
Abnormal
Improper ignition timing or weak spark energy
Check
Normal
Low
Low fuel pressure
Check
Normal Blocked Injector blocked
Clean and replace
Normal
Low
Low battery voltage Normal
Charge Abnormal
Cooling fluid temperature sensor failure Normal
Replace Abnormal
Intake pressure sensor failure
Normal
Normal
Sliding
Clutch sliding
Replace Normal
Low
Low engine cylinder pressure
Check
Normal Poor Poor flywheel signal
Check
Normal Abnormal Crankshaft position sensor failure Normal
Replace
Error
Incorrect engine valve timing Normal
Check and adjust
Fails to work
Individual cylinder fails to work
Check
Normal
Blocked
Exhaust system blocked
Check and replace
Normal Abnormal Oxygen sensor failure
Replace
59
Common Malfunction Diagnosis Flow of Geely Automobile
No. 034 Water temperature over normal value Malfunction
Cause
Solution
Lack of coolant
Check cooling system, whether there is enough coolant. Add coolant if it is lack of coolant, which will affect cooling performance.
Water temperature meter and sensor malfunction
Water temperature over normal value, virtually. Replace relating components.
Radiator leaking
Check radiator cap and radiator, maintain or replace leaking part.
Thermostat fails to open as normal
Check upper and lower pipe temperature of radiator, if there is high value difference, then shall remove thermostat and measure the activating temperature. Replace thermostat if it fails to open normally.
Water pipe leaking
Check water pipe, maintain leaking position and fasten loose clip Check water pump driving belt, whether it is loose or damaged. Adjust or replace when necessary. Open radiator cap and start engine, to inspect coolant flowing condition and determine whether the water pump is working. If the coolant keeps still, then remove and check water pump. Replace it when blade wheel is damaged.
Water pump malfunction Water temperature over normal value, when engine operating
Heater radiator leaking
Check heater radiator, maintain or replace it. Check radiator cooling fan motor and fan blade, whether they are damaged. Maintain or replace them when necessary.
Radiator cooling fan fails to operate normally
Check coolant temperature sensor. In different temperatures, the resistance of coolant temperature sensor shall vary in accordance with regulated standard. Otherwise, shall replace the sensor. Check engine ECU and radiator cooling fan motor controlling circuit. Maintain or replace them when necessary. Check radiator, whether there are bubbles nearby. Replace cylinder head gasket, may exclude the malfunction.
Cylinder head gasket damage
Poor radiator cooling performance
Check radiator, whether it is blocked by mud or other impurity. Clean or replace it, when cooling performance is affected by blockage. Check furring condition in radiator. Clean or replace it, when cooling performance is affected.
Part blockage in engine inner water cycling pipe
60
Unplug or replace cylinder block
Common Malfunction Diagnosis Flow of Geely Automobile Water overheat
Insufficient Insufficient coolant
Fill
Normal Failure Water temperature gauge and sensor fails
Replace
Normal Abnormal
Thermostat can not open normally
Replace
Normal Water leaking Check
Water leakage in water tank Normal Abnormal Water pump trouble
Replace
Normal Water leaking Water leakage in water pipe
Replace
Normal Water leaking Replace it
Water leakage in water tank of fan heater Normal Radiator cooling fan can not run normally
Overhaul and replace it
Normal Cylinder head gasket damaged
Replace it
Normal Poor heat radiating of the radiator
Check and replace
Normal Partial clogging in engine’s internal circulating water pipe
Check and replace
61
Common Malfunction Diagnosis Flow of Geely Automobile
No.035 Oil existing in the water tank Malfunction
Oil appears in the water tank during engine operation
Cause
Solution
Man-made malfunction
Oil enters cooling system during engine repair, and oil enters water tank along with coolant after the engine operates to normal water temperature. This malfunction can be eliminated through replacing coolant for several times;
Malfunction of cylinder head gasket
Cylinder head gasket is slightly damaged or not pressed tightly, after the engine starts, oil appears in the water tank due to oil pressure higher than the pressure of cooling system which causes oil entering into cooling system along the damage of cylinder head gasket. In case of this malfunction , disassemble the engine to check cylinder head and its gasket, cylinder block surface, repair or replace it and then tighten it in accordance with standard torque;
Cylinder head or cylinder block deforming
Check whether cylinder head or cylinder block is deformed, if any, repair or replace it;
There is crack on the cylinder head
There is crack inside oil way of cylinder head, and the crack is enlarged once heated, therefore oil enters into cooling system through it. In this case, check carefully that there is any crank on the cylinder head, use instrument if necessary, if any, replace it;
There is crack on the cylinder block
There is crack inside oil way of cylinder block, and the crack is enlarged once heated, therefore oil enters into cooling system through it. In this case, check carefully that there is any crank on the cylinder block, use instrument if necessary, if any, replace it;
In case of this malfunction , the pipeline must be Automatic transmission fluid and radiating treated timely, the malfunction exists in automatic pipe connect and oil enters transmission type Geely Vehicle;
62
Common Malfunction Diagnosis Flow of Geely Automobile Oil existing in the water tank
Man-made trouble
Replace
Malfunction of cylinder head
Replace
Cylinder head or cylinder block deforming
There is crack cylinder head
on
Replace
the
Replace
There is crack on the cylinder block
Replace
Automatic transmission fluid and radiating pipe connect and oil enters
Replace
63
Common Malfunction Diagnosis Flow of Geely Automobile
No. 036 There is water in the oil Malfunction
Cause
Man-made malfunction
Solution During engine repairing, there is water mixed into crankcase, oil mixes with water and color changes after the engine operates to normal water temperature. This malfunction can be eliminated by changing oil;
Cylinder head gasket is slightly damaged or not pressed tightly, after the engine starts, water enters into crankcase through cylinder head gasket. In case of this Malfunction of malfunction , disassemble the engine to check cylinder head and its gasket, cylinder cylinder head gasket block surface, repair or replace it and then tighten it in accordance with standard torque; There is water in the engine oil There is crack on cylinder head, and the crack is enlarged once heated, therefore There is crack on the water enters into crankcase through it. In this case, check carefully that there is any cylinder head crank on the cylinder head, use instrument if necessary, if any, replace it;
There is crack on cylinder block, and the crack is enlarged once heated, therefore There is crack on the water enters into crankcase through it. In this case, check carefully that there is any cylinder block crank on the cylinder block, use instrument if necessary, if any, replace it; There is water in the oil
Incorrect
Man-made trouble
Check
Normal Malfunction of cylinder head gasket
Damaged
Replace
Normal There is crack on the cylinder head
Crack
Replace
Crack
Replace
Normal There is crack cylinder block
on
the
64
Common Malfunction Diagnosis Flow of Geely Automobile
No. 037 Abnormal sound of crankshaft bearing Malfunction
Cause
Solution
Oil filter blocked
Replace the oil filter
Poor oil quality
Change oil
Engine water temperature high
Eliminate it in accordance with malfunction of high water temperature;
Abnormal pressure of oil pump
Check oil pressure, abnormality will also cause abnormal sound, if necessary, change oil pump;
Check the matching clearance between main bearing shell and main bearing There is abnormal sound in journal, the value is 0.020mm-0.059mm, if crankshaft bearing, sound is Matching clearance between main bearing shell and the clearance exceeds limit 0.1mm, it is heavy in crankcase with necessary to select main bearing shell main bearing journal too large toneless “plump”; the faster again according to measured diameter of the engine speed, the louder main bearing journal and technical the noise, and the noise is requirements (empirical value); obvious particularly when accelerating suddenly. When serious, engine block Measure thrust clearance of crankshaft at vibrates, lubricant pressure thrust washer, the value is reduces; the noise does not Thrust clearance between thrust washers too large 0.087mm-0.177mm, if the value exceeds change when engine limit 0.300mm, the thrust washer should be temperature changes. changed; (empirical value)
Crankshaft bending
Check crankshaft camber, if the camber exceeds limit 0.1mm, the crankshaft should be corrected or changed (empirical value);
Main bearing shell is ablated and worn seriously
Check that there is any peeling, ablation or other abnormality on the surface of bearing shell, if the bearing shell fails, it should be changed;
Bolt on the cover of main bearing shell is loose
If main bearing shell is just loose, tighten the bolt on the cover of main bearing shell by torque specified;
65
Common Malfunction Diagnosis Flow of Geely Automobile Abnormal sound of crankshaft bearing
Poor
Poor oil quality
Replace
Normal Blocked
Oil filter blocked
Replace
Normal Water temperature high
Engine water temperature high
Check
Normal Bend
Crankshaft bending
Replace
Normal Wearing Replace
Main bearing shell is ablated and worn seriously
Normal Abnormal
Abnormal pressure of oil pump
Check
Normal Thrust clearance washers too large
between
Too large
thrust
Check
Normal Too large
Matching clearance between main bearing shell and main bearing journal too large
Check
Normal Loose
Bolt on the cover of main bearing shell is loose
66
Check
Common Malfunction Diagnosis Flow of Geely Automobile
No. 038 Abnormal sound of connecting rod bush Malfunction
When engine accelerates suddenly, obvious clear and short knocking is produced and becomes louder as the loading increases; creaking can be heard by shaking throttle slightly; the noise does not change obviously when engine temperature changes.
Cause
Solution
Poor oil quality
Change oil
Oil filter clogged
Replace the oil filter
Oil too diluents
Change oil
Abnormal pressure of oil Check oil pressure, abnormality will also cause abnormal sound, if pump necessary, replace oil pump;
Shell clearance too large
Check the clearance between connecting rod bearing shells, the value is 0.020mm-0.063mm, if the clearance exceeds limit 0.1mm, it is necessary to select connecting rod bearing shell again according to measured connecting rod bearing diameter and technical requirements. (empirical value);
Check that there is any peeling, wearing, ablation or other Shell wearing excessively, abnormality on the surface of connecting rod bearing shell, if the loosing or breaking etc. bearing shell fails, it should be changed;
Connecting rod bolt is loose
If connecting rod bearing shell is just loose, tighten the bolt by torque specified;
67
Common Malfunction Diagnosis Flow of Geely Automobile Abnormal sound of connecting rod bush
Poor oil quality
Replace
Normal Oil too diluent
Replace
Normal Oil filter blocked
Replace
Normal Abnormal pressure of oil pump
Check
Normal Halfshell clearance too large
Adjust it
Normal Connecting rod bolt loose
Overhaul
Normal Halfshell wearing loosing or breaking
excessively,
Replace it
68
Common Malfunction Diagnosis Flow of Geely Automobile
No. 039 Camshaft with abnormal sound Malfunction
Causes
When the engine is normal, sound similar as resonance appears; when severe, irregular noise appears.
Solution
Engine with high water temperature
Eliminate malfunction based on high water temperature;
Engine oil with poor quality
Replace engine oil;
Oil filter blocked
Replace filter;
Camshaft cam is worn, causing Check camshaft; repair or replace; abnormal sound Fit clearance between camshaft and Check fit clearance; if necessary, repair engine or replace camshaft bearing too large concerned malfunction parts; Camshaft seat burnt and damaged
Check it is burnt and damaged; repair the engine;
Hardness of internal spring of the Replace the spring or assembly; gear not enough Pressure of oil pump abnormal
Check oil pressure, which will cause abnormal sound if abnormal; if necessary, replace oil pump;
Camshaft with abnormal sound
Worn
Engine with high water temperature
Repair
Normal Not good
Engine oil with poor quality
Replace
Normal blocked
Oil filter blocked
Normal
Burnt
Camshaft seat burnt and damaged
Replace
Normal
Abnormal
Pressure of oil pump abnormal
Normal
Repair
Stiffness
Hardness of internal spring of the gear not enough
Normal
Replace
Repair
Too large
Fit clearance between camshaft and wall
Replace
Normal Cam worn
Abnormal
69
Replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 040 Camshaft driving gear with abnormal sound Malfunction
Causes
Solution
Lubricating oil with poor quality
Replace lubricating oil
Fit clearance not matched
Strained clearance of driving gear not matched, causing abnormal sound;
Improper assembling
Check driving gear of admission camshaft and that of exhaust camshaft are correctly assembled; if not, reassemble;
Matching angle under stress not even
Adjust angle of driving gear; if necessary, replace it;
Camshaft driving Hardness of internal spring of the gear not Replace the spring or assembly; gear with enough abnormal sound Check inlet filter screen of oil pump is blocked; if so, clean or replace; Check clearance between drive gear and driven gear of oil pump. And check relief valve is blocked; if so, repair or replace;
Engine oil pressure too low
Check lubricating system is leaking, and mainly check clearance of connecting rod tile; if leaking, eliminate it; check driving gear is with obvious metal damaging traces, causing noises; if so, replace it;
Driving gear worn Camshfat driving gear with abnormal sound
Improper
Improper assembling
Reassemble
Normal Lubricating quality
oil
with
Poor
poor
Replace
Normal Unusual Matching angle under stress not even
Replace
Normal Not matching
Fit clearance of gears not matching Normal
Repair
Stiffness insufficient
Hardness of internal spring of the gear not enough
Replace
Normal Too low Repair
Engine oil pressure too low
Normal
Worn Replace
Driving gear worn
70
Common Malfunction Diagnosis Flow of Geely Automobile
No. 041 Cylinder knocking sound Malfunction
Causes
Solution Put screwdriver at filler port, and put your ear against the screwdriver lever, and carefully observe and listen; Flame out for cylinders gradually; if sound of this cylinder weakens or disappears, then it is confirmed that this cylinder has abnormal sound;
Piston and cylinder wall severely To differentiate from other abnormal sound, fill in some lubricating worn, with too large clearance oil at spark plug hole of this cylinder; if the sound weakens or disappears, then it is confirmed as piston knocking sound;
When knocking sound is very severe and filler port is smoking externally, it is because that clearance between piston and cylinder wall is too large; When the engine operates at idling speed, upper of cylinder body generates clear and rhythmical metal knocking sound “Dang”. When cooling, the sound becomes obvious. With rising engine temperature and speed, the sound becomes smaller or disappears.
Fuel grade too low, with poor Check fuel quality, and confirm its grade; if not reaching specified quality requirements, replace it;
Ignition time too early
Check ignition timing. When the engine is at idling speed, ignition advance angle is 10°--12°; if not correct, adjust advance angle of initial ignition of the engine. When accelerating, ignition advance angle could automatically be increased to 20°--30°. If unusual, check ignition control system or replace ECU;
Engine oil filter blocked
Replace engine oil filter;
Knock sensor malfunction
Check knock sensor; if piston knocking is caused due to damaged knock sensor, replace it;
Carbon deposit cylinder too many
within
the Check carbon deposit within the cylinder; if too many causing glowing ignition and piston knocking, clean it;
Clearance of connecting rod tile Check and repair the engine; too large Piston ring blocked
Check operations of piston ring; if blocked, repair or replace it;
Compression ratio too large
Check cylinder cover is grinding; if grinding too large causing combustion chamber smaller, and compression ratio too large causing piston knocking, replace cylinder cover;
Clearance of piston ring too Check piston ring; if necessary, replace it; large
71
Common Malfunction Diagnosis Flow of Geely Automobile Cylinder sound
knocking
Piston and cylinder wall severely worn its clearance
Worn
Repair
Normal Fuel grade too low, with poor quality
Poor quality
Replace
Normal Ignition time too early
Too early
Adjust
Normal Knock sensor malfunction
Abnormal
Replace
Normal Carbon deposit within the cylinder too many
Too many
Repair
Normal Clearance of connecting rod tile too large
Large clearance Repair
Normal Piston ring blocked
Blocked
Replace
Normal Filter element blocked
Blocked
Replace
Too large
Replace
Normal Clearance of piston too large
72
Common Malfunction Diagnosis Flow of Geely Automobile
No. 042 Oil pump with abnormal sound Malfunction
Engine with clattering
bottom regular
Causes
Solution
Engine oil not sufficient
Check oil level within crankcase; if too low, fill up to standard height;
Engine oil with poor quality
Replace engine oil;
Filter screen blocked
Check filter screen is blocked; if so, clean or replace;
Clearance of driving gear of oil pump too large
Check clearance; if necessary, replace it;
Oil pump sounding
When at idling speed, probably oil pan position appearing with clear clattering; if necessary, replace oil pump;
Valve blocked
Check and clean;
Driving gear of oil pump sounding
Fit clearance between driving gear of oil pump and driving gear of camshaft changes, thus damaging driving gear of oil pump;
JL376/378 driving chain sounding
Replace driving chain;
Oil pump with abnormal sound
Insufficient Engine oil not sufficient
Add
Normal Engine oil with poor quality
Poor
Replace
Normal Filter screen blocked
Blocked
Clean
Normal Clearance of driving gear of oil pump too large
Large clearance
Replace
Normal Sounding
Oil pump sounding
Replace
Normal blocked
Valve blocked
Clean Normal
Driving gear of oil pump sounding
Sounding Repair
Normal Driving sounding
chain
Sounding
73
Replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 043 Crankshaft thrust piece with abnormal sound Malfunction
Causes
Solution
Engine oil not sufficient
Check oil level within crankcase; if too low, fill up to standard height;
Engine oil with poor quality
Replace engine oil; ②Check filter screen is blocked; if so, clean or replace;
Engine oil with too low pressure
③Check clearance between drive gear and driven gear of oil pump. Crankshaft thrust And check relief valve is blocked; if so, repair or replace; piece with Crankshaft and thrust piece severely Crankshaft and thrust piece severely worn, causing too large axial abnormal sound worn play, and abnormal sound; disassemble the engine and repair; Thrust piece burnt and damaged
Check it is burnt and damaged; if necessary, replace thrust piece;
Thrust clearance too large
Measure thrust clearance at thrust piece, with standard value as 0.087mm-0.177mm; if exceeding limit value 0.300mm, replace thrust piece. (empirical value)
Crankshaft thrust unusual noise
piece
with
Insufficient
Engine oil not sufficient
Add
Normal Poor
Engine oil with poor quality
Replace
Normal Engine oil with too low pressure
Too large
Repair
Normal Crankshaft and thrust piece severely worn
Worn
Replace
Normal Thrust piece damaged
burnt
and
Burnt and damaged
Replace
Normal Thrust large
clearance
too
Large clearance
74
Repair
Common Malfunction Diagnosis Flow of Geely Automobile
No. 044 Valve with abnormal sound Malfunction
Causes
Continuous, regular and clear “da-da” sound is heard at one side of valve chamber. When the engine is at idling, medium speed, the sound becomes obvious; when high speed, the sound is in disorder. This sound is not affected by engine temperature and flameout.
Solution
Valve clearance too large
Remove valve chamber cover, and make the engine run at idling speed; listen to the sound and observe splashing of lubricating oil, and make preliminary judgment; insert feeler gage to suspected valve clearance; if the sound weakens or disappears, then it is this valve that is sounding; with the engine under cold state, adjust valve clearance; when clearance of intake valve is 0.12mm~0.15mm, corresponding exhaust valve clearance is 0.20mm~0.25mm. when adjusting, make the valve closed;
Engine oil not sufficient
Check oil level within crankcase; if too low, fill up to standard height;
Cylinder cover deformed
Replace cylinder cover; Check oil screen is blocked; if so, clean or replace;
Engine oil with too low Check clearance between drive gear and driven gear of oil pump. And pressure, poor lubrication check relief valve is blocked; if so, repair or replace; causing abnormal sound Check clearance between crankshaft and connecting rod tile is too large causing oil leaking too much and oil pressure too low; Camshaft worn
If abnormal sound still exists after adjustment of valve clearance, check and measure cam lobe is damaged or severely worn; if exceeding limit value 0.300mm, replace it. (empirical value)
Valve with abnormal sound
Valve clearance too large
Too large
Adjust
Normal Engine oil sufficient
not
Insufficient
Add
Normal Cylinder deformed
cover
Deformed
Replace
Normal Poor
Engine oil with too low pressure, poor lubrication causing unusual noise
Repair
Normal Camshaft worn
Worn
Replace
75
Common Malfunction Diagnosis Flow of Geely Automobile
No. 045 Engine with insufficient power Malfunction
Causes
Solution ① Check air filter is blocked; if so, clean or replace;
① Air filter blocked
② Check intake system is leaking. Measure degree of vacuum of intake manifold. When at idling speed, degree of vacuum shall be larger than 30KPA; if too small, it indicates that intake system is leaking; carefully check connection and each hose, vacuum pipe; ③ Step on accelerator pedal to the bottom, and check throttle valve is fully opened; if not, adjust its dragline or pedal;
② Throttle valve tie-line or throttle valve ③ Check throttle valve position sensor. When throttle valve is position sensor improperly adjusted, and changed from fully closed to fully opened, resistance of its could be fully opened signal terminal and earthing terminal shall be increased The engine is continuously, without interruption; if unusual, adjust or replace it basically running accordingly; normally without load; but ⑤Check ignition timing. When the engine is at idling speed, accelerating slowly ignition advance angle is 10°--12°; if not correct, adjust advance ③ Improper ignition timing or weak and hard to grade angle of initial ignition of the engine. When accelerating, ignition high-pressure spark up with load; when advance angle could automatically be increased to 20°--30°. If stepping on unusual, check ignition control system or replace ECU; accelerator pedal ⑥ Check fuel pressure. When at idling speed, fuel pressure to the bottom, still shall conform to specified value 265~304kpa. When feels that power is accelerating, fuel pressure shall increase about 50kpa. If too not enough, ④Fuel pressure too low low, check fuel pressure adjuster, electric fuel pump, gasoline rotating speed filter, etc; could not be increased, and ⑤ Oil injector blocked or with poor ⑦ Remove oil injector; check ejecting amounts and atomization unable to reach atomization are normal; if not, clean or replace oil injector; maximum speed. ⑧ Check battery voltage is normal; if too low, it will cause reduced ejecting amounts, causing insufficient dynamic force, ⑥ Battery voltage too low and slow acceleration; if too low, check charging system or replace battery; ⑨ Check cooling liquid temperature sensor. Resistance of this ⑦ Cooling liquid temperature sensor sensor could be changed according to specified standard under malfunction different temperatures; if not, replace this sensor; ⑧
Inlet pressure sensor malfunction
⑨Engine cylinder pressure too low
⑩ Check intake manifold pressure temperature sensor; if unusual, replace it; ⑾ Measure compression pressure of engine cylinder; if too low, adjust valve clearance or remove the engine;
76
Common Malfunction Diagnosis Flow of Geely Automobile Engine with insufficient power
Blocked
Air filter blocked
Clean or replace Normal Leaking
Intake system leaking
Repair leaks
Normal Throttle valve opening abnormal
Unusual
Adjust
Normal Throttle valve position sensor malfunction
Unusual
Adjust or replace
Normal Improper ignition timing
Abnormal
Adjust advance angle of initial ignition
Too low
Repair
Normal Fuel pressure too low Normal Remove, ejector
clean
Abnormal
oil
Replace oil injector
Normal Battery low
voltage
Abnormal
too
Check charging battery
system
or
Normal Cooling liquid temperature sensor malfunction
Abnormal
Replace cooling temperature sensor
liquid
Normal Intake manifold pressure sensor malfunction
temperature
Unusual
Replace intake manifold pressure
Normal Replace ECU contrast test
Changes
Replace ECU
No changes Compression pressure of cylinder too low
Unusual
Remove and repair engine
77
replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 046 Oil consumption too large Malfunction
Causes
Solution
Driving habit problem
Also the most common problem. The counselor shall explain to the customer patiently and nicely, using euphemism;
Oxygen sensor malfunction
Check oxygen sensor could correctly identify concentration of gas mixture; if not, it will cause high oil consumption;
Clearance of spark plug too Clearance of spark plug is too large, causing poor ignition, which is one of large reasons causing high oil consumption; Check ignition timing; when the engine is at idling speed, ignition advance angle shall be 10º~12º; if not correct, it may cause rising oil consumption; adjust ignition advance angle of the engine;
Improper ignition timing
Oil injector blocked or poor Remove oil injector; check ejecting amounts and sealing are normal; if not, sealing clean or replace oil injector; Check cylinder pressure, valve, etc. If individual cylinders are not working, repair it accordingly; replace or adjust parts causing unusual working;
Cylinder poorly operating
Check cooling liquid temperature sensor. Resistance of this sensor could be Cooling liquid temperature changed according to specified standard under different temperatures; if sensor malfunction not, replace this sensor; Air filter blocked
During using, oil consumption of the engine is a lot Poor fuel quality higher than Tire obviously worn or standard value pressure severely insufficient
Check air filter is blocked; if so, it may cause poor intake and large oil consumption; clean or repair it; Fuel with poor quality may cause this malfunction; recommend the customer to replace it at filling station that he often uses; Tire will cause increased friction force, balancing out partial engine power, causing increased oil consumption; With sudden acceleration, speed counter of the engine is quickly increased, but the vehicle speed is very slowly increased, which could be judged that the clutch is slipping, causing idle running and increased oil consumption; replace clutch pressure plate and driven disk;
Clutch slipping
For carburetor vehicle in old Geely model, the following malfunctions may Temperature control system occur: temperature control switch and thermostat are damaged, causing malfunction causing large oil increased oil consumption as these damages will cause reduced water consumption temperature, and carburetor cold not work normally, causing poor gasoline atomization and obviously increased oil consumption; replace it; Fuel pipe leaking
Check fuel pipe; replace leaking pipe;
Braking seizing
Adjust front and rear braking; if necessary, burnish brake disk;
Oil tank cover not well sealed
Poor sealing causes fuel evaporation;
Canister control valve damaged
Replace it;
non-return
Intake quantity not conforming to standard values, causing error control, Inlet pressure and and high oil consumption when the vehicle is driving; check it with computer temperature sensor damaged diagnosis instrument; if necessary, replace inlet pressure sensor; Throttle valve position sensor Unable to identify opening; replace sensor; with broken circuit Three-way catalyzer blocked
Cementing within three-way catalyze blocked, with poor exhaust, causing high oil consumption; replace it;
Inlet pipe leaking
Replace inlet pipe;
Individual working
cylinders
not
Check operations of each cylinder; if individual cylinders are poorly operating, mainly check spark plug, high tension line, cylinder pressure, etc. Confirm causes and repair or replace;
Incorrect valve timing of the Check valve timing is correct; if not, adjust it; engine Cylinder pressure too low
Measure compression pressure of engine cylinder; if too low, check valve clearance or remove and repair engine;
Idling speed too large or too Eliminate one by one according to idling speed-related malfunction 78
Common Malfunction Diagnosis Flow of Geely Automobile small
template, making idling speed reach normal state;
Water temperature abnormal
Eliminate one by one according to water temperature-related malfunction template, making water temperature reach normal state;
79
Common Malfunction Diagnosis Flow of Geely Automobile Oil consumption too high
Driving habit problem
Habit problem
Drive correctly
Normal Abnormal Oxygen malfunction
sensor
Normal
Replac e
Too large Adjust
Clearance of spark plug too large
Normal
Improper
Improper ignition timing
Check and adjust
Normal Poor sealing Oil ejector obstructed or poor sealing
Clean
Normal Cylinder poorly operating
Repair
Repair
80
Common Malfunction Diagnosis Flow of Geely Automobile
Normal Abnormal Cooling liquid malfunction
temperature
Replace
sensor
Normal blocked
Air filter blocked
Clean
Normal Poor
Poor fuel quality
Replace
Normal Unusual
Tire obviously worn or pressure severely insufficient
Repair or replace
Normal Slipping Clutch slipping
Replace
Normal Abnormal Repair
Temperature control system malfunction causing large oil consumption
Normal Leaking Fuel pipe leaking
Repair
Normal Seizing
Braking seizing
Replace
Normal Oil tank sealed
cover
not
Not well sealed
well
Replace
Normal Canister control damaged
non-return
valve
Damaged
Replace
Normal Abnormal
Inlet pressure and temperature sensor damaged
Replace
Normal Throttle valve position sensor with open circuit
Open circuit
81
Replace
Common Malfunction Diagnosis Flow of Geely Automobile
Three-way catalyzer blocked
Blocked Replace
Normal Not working Individual working
cylinders
Repair
not
Normal Incorrect valve timing of the engine
Normal
Incorrect
Repair
Too low
Cylinder pressure too low
Repair
Normal Idling speed too large or too small
Abnormal Repair
Normal Water temperature abnormal l
Abnormal
Repair
82
Common Malfunction Diagnosis Flow of Geely Automobile
No. 047 Intake tempering Malfunction
Causes
Solution
Improper ignition timing
Check ignition timing. When the engine is at idling speed, ignition advance angle is 10°--12°; if not correct, adjust advance angle of initial ignition of the engine. When accelerating, ignition advance angle could automatically be increased to 20°--30°. If unusual, check ignition control system or replace ECU;
Valve not well closed
Check valve clearance is normal; if not, adjust it; if the valve is burnt and deformed and not well closed, replace the valve and re-furbish;
Oil injector blocked or with Remove oil injector; check ejecting amounts and atomization are normal; if not, poor atomization clean or replace oil injector; Inlet pressure sensor Check intake manifold pressure temperature sensor; if unusual, replace it; malfunction Intake manifold with Check throttle valve position sensor. When throttle valve is changed from fully tempering Throttle valve position sensor closed to fully opened, resistance of its signal terminal and earthing terminal shall malfunction be increased continuously, without interruption; if unusual, adjust or replace it accordingly; Gas mixture too thin
Oil duct malfunction is caused by too low oil ejected, which is caused mainly as: oil pressure is too low; oil injector blocked. Malfunction of intake system is caused as intake amounts are too many, which is caused mainly as: sensor controlling intake amounts are invalid; intake manifold leaking;
Engine valve timing error
Check valve timing is correct; if not, adjust it;
Oil injection control program Replace engine’s Electronically Controlled Unit (ECU); malfunction within ECU
83
Common Malfunction Diagnosis Flow of Geely Automobile Intake tempering
Improper ignition timing
Improper Check and adjust
Normal Not well closed Valve not well closed
Repair
Normal Poor atomization Oil ejector blocked or with poor atomization
Clean
Normal Abnormal Inlet pressure sensor malfunction
Replace
Normal Unusual Throttle valve position sensor malfunction
Replace
Normal Gas mixture too thin
Too thin
Repair
Normal Error Engine valve timing error
Repair
Normal Malfunction of oil injection control program within ECU
Abnormal Replace
84
Common Malfunction Diagnosis Flow of Geely Automobile
No. 048 Exhaust pipe bombs Malfunction
Exhaust bombs
Causes
Solution
①Improper ignition timing
①Check ignition timing. When the engine is at idling speed, ignition advance angle is 10°--12°; if not correct, adjust advance angle of initial ignition of the engine. When accelerating, ignition advance angle could automatically be increased to 20°--30°. If unusual, check ignition control system or replace ECU;
pipe
②Oil injector leaking, causing gas mixture ②Check oil injector is leaking; if so, replace it; too thick ③Engine valve timing error
③Check valve timing is correct; if not, adjust it;
④Oil injection control program malfunction ④Replace engine’s Electronically Controlled Unit (ECU); within ECU
Exhaust pipe bombs
Improper Improper ignition timing
Repair
Normal Leaking Oil injector leaking
Clean
Normal Engine valve timing error
Error
Repair
Normal Oil ejection control program malfunction
Unusual Replace
85
Common Malfunction Diagnosis Flow of Geely Automobile
No. 049 Engine knocking Malfunction
Causes
Solution
Fuel with low grade and poor quality
Check fuel quality and confirm fuel grade; if not reaching specified requirements, replace it;
Ignition time too early
Check ignition timing. When the engine is at idling speed, ignition advance angle is 10°--12°; if not correct, adjust advance angle of initial ignition of the engine. When accelerating, ignition advance angle could automatically be increased to 20°--30°. If unusual, check ignition control system or replace ECU;
Cooling system malfunction
Engine overheating may cause this problem; check cooling system; Put screwdriver at filler port, and put your ear against the screwdriver lever, and carefully observe and listen; Flame out for cylinders gradually; if sound of this cylinder weakens or disappears, then it is confirmed that this cylinder has abnormal sound;
To differentiate from other abnormal sound, fill in some Piston and cylinder wall severely worn, lubricating oil at spark plug hole of this cylinder; if the sound weakens or disappears, then it is confirmed as piston knocking with too large clearance sound; When knocking sound is very severe and filler port is smoking externally, it is because that clearance between piston and cylinder wall is too large;
Metal knocking sound occurs when the engine increases the load or grades up
After confirming knocking sound, check cylinder diameter and piston dimension; repair according to technical requirements or replace it; Intake manifold leaking
Causing too many intake amounts, and thin gas mixture causes engine knocking; check pipes; if abnormal, repair or replace;
Oil pressure too low
Oil pressure too low, causing too few ejecting amounts, and thin gas mixture causes engine knocking; check fuel pump and pipe; if necessary, replace it;
Oil injector blocked
Oil injector blocked, causing too few ejecting amounts, and thin gas mixture causes engine knocking; check and clean the oil injector; if necessary, replace it;
Carbon deposit within the cylinder too Check carbon deposit within the cylinder; if too many causing many glowing ignition and knocking, clean it; Compression rate too large
Check cylinder cover is grinding; if grinding too large causing combustion chamber smaller, and compression ratio too large causing piston knocking, replace cylinder cover;
Individual cylinders not working
Eliminate it one by one
Causing too many intake amounts, and thin gas mixture Intake manifold pressure temperature causing engine knocking; check electrical signal of sensor; if sensor invalid abnormal, replace it; Program malfunction within ECU
Replace ECU assembly;
86
Common Malfunction Diagnosis Flow of Geely Automobile Engine knocking
Poor quality
Fuel with low grade and poor quality
Replace
Normal Worn
Piston and cylinder wall severely worn, with too large clearance
Repair
Normal Too early
Ignition time too early
Repair
Normal Too low
Repair
Oil pressure too low
Normal blocked
Oil ejector blocked
Clean
Normal Carbon deposit within the cylinder too many
Too much
Repair
Normal Compression rate too large
Too large
Repair
Normal Individual working
cylinders
not
Not working
Repair
Normal Abnormal
Replace
Intake manifold pressure temperature sensor invalid Normal Leaking
Repair
Intake manifold leaking
Normal Abnormal Cooling malfunction
Repair
system
Normal Program malfunction within ECU
Abnormal
87
Replace
Common Malfunction Diagnosis Flow of Geely Automobile
No. 050 Engine burning oil Malfunction
Causes
Solution
PCV valve invalid
Check one-way throughout of PCV valve at upper of valve chamber hood; if not, it will cause exhaust gas pressure too high within the engine, thus burning engine oil; otherwise replace it;
Engine oil too much
Reduce oil amounts;
Engine oil with poor quality
Replace engine oil;
Oil consumption too much, tail gas Valve oil seal malfunction in blue
Check valve oil seal is aged, without sealing, engine oil enters to combustion chamber through valve stem. Replace valve oil seal; Check clearance between valve stem and valve guide; if too large caused by abrasion, replace it;
Valve oil seal malfunction
Check piston ring is broken and elasticity and end clearance, side clearance, back clearance conform to requirements; if not, replace;
Piston and cylinder severely worn
Check clearance between piston and cylinder bushing conforms to requirements; if not, repair the engine;
Engine burning oil
Invalid
PCV valve invalid
Replace
Normal Abnormal
Valve oil seal malfunction
Repair
Normal Too much Engine oil too much
Discharge
Normal Engine oil poor quality
Poor
with
Replace
Normal Piston ring, piston cylinder malfunction
and
Abnormal Repair
88
Common Malfunction Diagnosis Flow of Geely Automobile
No. 051 Cooling water unusually consumed Malfunction
Causes
Solution
Cooling system leaking
Check water tank, water bottle, pipe, radiator, radiator cap, warm-wind radiator are water leaking; repair or replace. (pay attention to unusual consumption of cooling water caused by deformed assembling of rubber ring of radiator cap)
Cylinder ring malfunction
Cylinder ring is damaged or not pressed out. After startup of engine, water enters to crankcase or combustion chamber through cylinder ring; combustion chamber is through with water duct; if there is bubble out or water column spraying out of cooling water, it will cause unusual cooling water; observe engine oil is emulsified; if so, replace cylinder ring;
Cooling water of the engine consumed too Water without anti-freezing This malfunction is rare in higher temperature area, but still with possibility; in much during efficiency, causing icing after case of this situation, replace anti-freezing liquid conforming to requirements; parking in winter using Cylinder cover with cracks, which will be increased under heating, and water will enter to crankcase or combustion chamber through cracks. Under this Cylinder cover with cracks situation, check carefully cylinder cover is with cracks; if necessary, use special instruments; in case of cracks, replace it; Cylinder body with cracks
Consumption cooling water
Cylinder body with cracks, which will be increased under heating, and water will enter to crankcase or combustion chamber through cracks. Under this situation, check carefully cylinder body is with cracks; if necessary, use special instruments; in case of cracks, replace it;
of
Leaking Cooling system leaking
Repair replace
Normal Cylinder malfunction
Abnormal Replace
ring
Normal
Icing Replace
Water without antifreezing efficiency, causing icing after parking in winter
Normal
Cracks
Cylinder cover with cracks
Replace
Normal Cylinder body with cracks
Cracks
89
Replace
or
Common Malfunction Diagnosis Flow of Geely Automobile
No. 052 Low engine oil pressure Malfunction
Causes
Solution
Insufficient lubricating oil
Check engine oil; if necessary, replace or add lubricating oil;
Oil viscosity too small
Use engine oil with correct grade; at least above SG of summer SAE10W-40/winter 5W-30 Check oil screen is blocked; if so, clean or replace;
Oil pump malfunction Clearance of connecting rod tile Engine oil with too too large, causing oil leaking low pressure when Clearance of crankshaft tile too engine is working large, causing oil leaking Main oil duct blocked or leaking
Check clearance between drive gear and driven gear of oil pump. And check relief valve is blocked; if so, repair or replace; Check clearance of connecting rod tile is too large, causing oil leaking; if so, repair or replace; Check clearance of crankshaft tile is too large, causing oil leaking; if so, repair or replace; Analyze causes and repair accordingly;
Oil pressure sensor or indicator Check electrical signal of sensor and oil indicator lamp; if abnormal, lamp damaged replace it; Oil induction plug leaking
Replace induction plug
High water temperature
Eliminate malfunction one by one according to relevant template, making water temperature normal;
Low engine oil pressure
Insufficient Insufficient lubricating oil
Add
Normal Too small
Oil viscosity too small
Replace
Normal Damaged Oil pressure damaged
sensor
or
indicator
Repair
lamp
Normal Too large
Clearance of connecting rod tile too large, causing oil leaking
Normal
Too large
Clearance of crankshaft tile too large, causing oil leaking
Repair
Replace
Normal Main oil duct blocked or leaking
Blocked or leaking
90
Repair replace
or
Common Malfunction Diagnosis Flow of Geely Automobile
Quick diagnosis for M1.5.4 Electrical injection system components of MR479 engine No.053 Quick diagnosis for ECU Power source: Power supplied by the battery continuously via 18# pin; Power supplied while main relay is turned on via 37# pin; power supplied while ignition switch is turned on via 27# pin. Earthing: 2#, 10#, 14#, 19#, 24#, 30#, 48# pin. Malfunction diagnosis interface: 55# pin, engine data K line. Call out malfunction information records within ECU via K line, or manually input some instructions, such as clear malfunction information records, make idle speed actuator self-learning, etc; General causes: 1. Invalid caused by burnt and damaged parts and components within ECU due to electrical overload of externally connected device; 2. ECU entered with water causing circuit board rusty, etc; Maintenance precautions: 1. Before removing ECU, remove battery cell firstly; 2. For welding on the vehicles, cut off ECU power source; 3. Close ignition switch firstly while startup with externally connected power source or as externally connected power source; 4. Radio speaker could not approach the controller; Simple measuring method: 1 (connect the connector) Read engine malfunction records via engine data K line, and make comparison based on engine system data and normal vehicle data, find out differences and continue in-depth inquiry; 2 (Remove the connector) check ECU connections are complete, and mainly check ECU power supply, earthing lines are normal; 3. Check external sensor is working normally, output signal is reliable, and its lines are complete; 4. Recommend the ECU replaced to be assembled in the normal vehicle, and simulate malfunction malfunction, and further confirm the malfunction;
91
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart for voltage of M1.5.4 electrical injection system
92
Common Malfunction Diagnosis Flow of Geely Automobile Y
1. Switch on diagnosis instrument, and display voltage value of battery cell; when the engine is running under normal operating temperature, check voltage is higher than 15V? N 2. When the engine is running under normal operating temperature, check voltage displayed on the instrument is lower than 15V?.
N
N
3. Check voltage value of battery anode and earthing is higher than 15V?.
N
Y
Y 4. Check when the engine is running at 20001Vm, and switch on head lamp, air conditioner, voltage value of battery cell is higher than 15V?.
N
Till malfunction elimination instructions
Y 5. Repair or replace the engine; confirm it is repairable.
No.054 Quick diagnosis for idling-speed governor EWD Function: provide idling-speed bypass air route, and control air quantity by changing cross-section of the route, realizing closed-loop control over rotating speed while the engine is under idling-speed condition; principle: one permanent magnet rotating freely on the shaft within idling-speed governor is rigidly connected with one rotating slide block, and could rotating driven by the coil, making slide block also rotating. Angular position of slide block determines opening of bypass duct, and thus adjusting bypass air quantity. Angular position of slide block is controlled by duty ratio of electrical pulse output by electronic controller;
Idle speed actuator
93
Common Malfunction Diagnosis Flow of Geely Automobile
Definition of EWD3 pin: #4# EWD3-1# pin; 2#26# EWD3-2# pin;
Simple measuring method:
1. (Remove the connector) place digital multimeter to ohm position, and two pens are respectively connected to 1#, 2# pins of governor; rated resistance is 17.6Ω±0.6Ω under 20℃; otherwise, replace it; 2. (Connect the connector) Start the engine, and make it rotate under idling speed; carefully put the hands against EWD3, and you feel slight vibration (recommend oscillograph); 3. When the engine is rotating under idling speed, take off harness connector of idling-speed governor, and rotating speed of the engine shall be changed, which indicates that idling-speed governor is working normally; 4. Take out harness connector of idling-speed governor, and measure its terminal voltage via multimeter or oscillograph. When the engine is rotating, terminal of harness connector of idling-speed governor shall be output with impulse voltage, which indicates that control system lines of ECU and idlings-peed governor are faul-free; if idling speed is still not stable at this point, with large deviations from specified value, check idling-speed governor. If output without impulse voltage, open the air conditioner and test again; if still not, it means that control system lines of ECU and idlings-peed governor are malfunction. If after installation of governor, too low idling speed, idling-speed-free appears, replace for the pad with 0.3-0.5mm thick, and screw down bolt twice, with the first torque as 2N·M, and 7N·M for the second, and maximum torque no larger than 7N·M. If the torque is too large, it will cause EWD casing deformed, and internal slide block and valve body blocked with above-mentioned malfunctions;
No.055 Quick diagnosis for knocking sensor Function: this sensor is for providing engine knocking information to electronic controller ECU for knocking control. Principle: knocking sensor is a vibration acceleration sensor, which is installed at engine cylinder body. Only one or several sensors installed is ok. Its sensitive element is a piezoelectric crystal, to which vibration of cylinder body is transferred via mass block within the sensor, and which will generate voltage at two pole faces due to pressure generated from vibration of mass block, and transforms vibration signal into voltage signal;
94
Common Malfunction Diagnosis Flow of Geely Automobile
95
Common Malfunction Diagnosis Flow of Geely Automobile
Definition of sensor pin: 1#11#
Knocking signal output;
2#30#
Earthing;
3#19#
Earthing (shielded)
Simple measuring method: 1. (Remove the connector) place digital multimeter to ohm position, and two pens are respectively connected to 1#, 2# and 1#, 3# pins of sensor; resistance under normal temperature shall be larger than 1MΩ; 2. Place digital multimeter to MV position, and knock at knocking sensor slightly with a small hammer; at this point, voltage signal shall be output; Note: please check 3# shielded line is well earthed. 3. Communicate diagnosis instrument specified by complete vehicle plant with electrical injection ECU, and read malfunction data within ECU, thus making judgment over throttle valve position sensor;
No.056 Quick diagnosis for stepper motor Function: provide idling-speed bypass air route, and control air quantity by changing cross-section of the route, realizing closed-loop control over rotating speed while the engine is under idling-speed condition; Principle: stepper motor is actuall a miniature motor, and its stator is polyphase coil winding and rotor is permanent magnet, through which one spiral axis is threaded, and these two are contacted with thread. When stator coil is switched with current, the rotor will rotate towards corresponding directions. As rotor and spiral axis are contacted with thread, angular displacement of rotor is transformed into linear displacement of spiral axis. Bypass cross-section could be changed by front and rear moving of spiral axis. If the rotor rotates fixed angle each time, spiral axis will move a certain displacement, i.e. one step. Electronic controller could control moving steps of stepper motor by changing coil energization phase to obtain corresponding bypass air flow.
96
Common Malfunction Diagnosis Flow of Geely Automobile
Idle speed actuator step motor
97
Common Malfunction Diagnosis Flow of Geely Automobile
Maintenance precautions: 1. Do not apply any forces axially to press down or take out the axle; Before idle speed governor with stepper motor is installed within throttle valve body, the axle must be at completely holdback position; 3. Pay attention to cleaning of bypass air route; 4. After removing battery cell, manually trigger self-learning function of stepper motor duly by using K line for malfunction diagnosis for earthing with three times, and earthing time equaling to and larger than 2.5s each time, or self-learning by using diagnosis instrument; Simple measuring method: 1. (Remove the connector) place digital multimeter to ohm position, and two pens are respectively connected into AD, BC pins of regovernor, and rated resistance under 25℃ is 53±5.3Ω; otherwise, replace it; 2. (Connect the connector) Start the engine, and make it rotate under idling speed; put hands slightly against stepper motor, and you feel slight vibration at this point; 3. Read amount of step of idle speed stepper motor out of engine parameter with diagnosis instrument, and start the air conditioner, and amount of step will increase. If rotating speed of the engine is kept at 3000rpm for a certain time, check amount of step will continue to rise, till to maximum opening value, which indicates that stepper motor is working normally; 4. If you cannot make judgment, recommend malfunction recurrence testing on malfunction-free vehicle;
98
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart of idling speed stepper motor 1. Switch on diagnosis instrument, and start the engine, and observe its idling speed is stable? Observe stepper motor is within normal working range through idling speed status of diagnosis instrument?
Y
N N
2. Check bypass opening is clean and not obstructed?
Y 3. Check control lines of stepper motor are with the following conditions? Socket connector is tightly inserted or loosening; open circuited; shorted to ground or shorted to voltage source; joint of stepper motor falls out.
Y Repair
N N
4. Check resistance of stepper motor coil is within 35-95ohm? Note: this value is related to temperature.
Y N
5. Check resistance between terminal B and D, and A and C of idling speed stepper motor is infinitely large?
Y Y
6. Check joint terminal and earthing resistance is larger than 10000ohm?
7. Clean idling speed bypass opening with compressed air gun; drive stepper motor with idling-speed initialization function of diagnosis instrument, making valve stem slide to clean pollutants with compressed air; confirm repairs are completed.
8. Replace idling-speed control stepper motor; confirm repairs are completed?
9. Replace ECU, and confirm repairs are completed?
99
N
Y
Common Malfunction Diagnosis Flow of Geely Automobile
No.057 Quick diagnosis for ignition coil Function: transform low-voltage direct current of the battery into high-voltage, and generate spark through discharging of spark plug, causing gas mixture within the cylinder. Principle: when earthing channel of primary winding is switched on, this winding is charged. If circuits of primary winding are cut off by ECU, then charging is terminated, and meanwhile, high voltage is inducted from secondary winding, making spark plug discharge. What is different from ignition coil with distributor is that, secondary winding of ignition coil ZSK2 2 has spark plug each connected to its two terminals, and these two plugs will ignite at the same time. ignition coil
Ignition switch #90
Ignition coil ZSK-ROV has two pins at its low-voltage sides: Pin with “+” is connected with the battery, and pin with “-” with ECU1#; High voltage side: connected to center of distributor Double-spark ignition coil
Ignition switch #90
100
Common Malfunction Diagnosis Flow of Geely Automobile
Low-voltage side: 1# connected with ECU20# earthing channel of No. 1 coil primary winding; 2# connected with ECU1# earthing channel of No. 2 coil primary winding; 3# and 4# connected both to power source (+); High-voltage side: 1, 2, 3, 4 respectively connected with spark plug of engine cylinder of same numbering; Simple measuring method: 1. (Remove the connector) place digital multimeter to ohm position, and two pens are respectively connected to two pins of primary winding, resistance is 0.41-0.53Ω for Type ROV, and 0.42-0.58Ω for Type 2X2 under 20℃; and for secondary winding, resistance is 7-9kΩ for Type ROV, and 11.2-14.8kΩ for Type 2X2; 2. Take out spark plug within the engine, and connect with high voltage line, and make its casing earthed; start the starting motor and observe flashover of spark plug; Diagnosis flowchart for ignition coil 1. Check and confirm connection between ignition coil and ECU is loosening,
Y
and terminal damaged? N 2. Check ignition switch to terminal 1 is open circuited or shorted to ground? Check support of ignition coil is earthed?
Y
N 3. Ignition switch closed; remove joint of ECU and ignition coil; and check ECU
Y
and ignition coil is shorted circuited to voltage source?
N 4. Check ignition coil terminal 2 to ECU terminal 1 is shorted to earth?
5. Check ignition coil terminal 2 to ECU terminal 1 is open circuited?
N 6. Replace ignition coil; confirm malfunction still exists after replacement?
Y 7. Replace ECU
Y Completed
101
Y
Y
Repair
Common Malfunction Diagnosis Flow of Geely Automobile
No.058 Quick diagnosis for throttle valve position sensor Function: this sensor is for providing information about outer corner of throttle valve to ECU, based on which, ECU could obtain information related to engine load, condition (such as startup, idling speed, dragging, partial load, full load) and acceleration and deceleration. Principle: this sensor is actually corner potentiometer with linear output characteristics. Rocker arm of potentiometer is installed with throttle valve at the same axis; when throttle valve rotates, it will make rocker arm slide to certain position; potentiometer will output voltage signal proportional to throttle valve position.
Definition of sensor pin: 1#30# earthing; 2#12# connected to 5V reference voltage; 3#53# sensor signal output Simple measuring method: 1. (Remove the connector) place digital multimeter to ohm position, and two pens are respectively connected to 1#, 2# pins of sensor, with its resistance as 2kΩ±20% under normal temperature; 2. Two pens are respectively connected to 1#, 3# pins; rotate throttle valve, and its resistance will increase as opening of throttle valve, and for 2#, 3# pins, the opposite condition will occur; Note: while observing changes of resistance value, observe it jumps largely; if so, it indicates that the signal has break point; then replace it; 3. (Connect the connector) Open ignition switch and do not start the engine, then place digital multimeter to direct current voltage position, with black pen for earthing, and red pen for 2# pin; which shall have 5V reference voltage at this point; connect 3# pin and measure signal output; when throttle valve is fully closed, its voltage value is about 0.3V (specific value related to vehicle model); when throttle valve is fully opened, its voltage value is about 3V (specific value related to vehicle model).
102
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart for throttle valve position sensor 1. Switch on ignition switch, the engine not started Change opening of throttle valve, and check it is indicated as C degree to
N
about 34 degree with diagnosis instrument? Y Y
2. Close ignition switch; take out sensor joint; ignition switch switched on.
Y
Opening of throttle valve is indicated as 10 degree? N N
3. Check signal circuit of the sensor (53-3) is shorted circuited or shorted to
Y
earth with B+? N 4. Check reference voltage circuit of the sensor (12-1) is open circuited,
Y
shorted to earth or shorted to B+? N 5. Check signal circuit of the sensor (53-3) is open circuited, shorted to earth
Y
or shorted to B+? N Y 6. Check earth circuit of the sensor (30-2) is open circuited, shorted to earth or shorted to B+? N 7. Ignition switch closed; signal terminal 3 of sensor is shorted circuit to N
reference voltage terminal 12 of ECU; ignition switch turned on, opening of throttle valve is fully opened 84 degree (about 5V)? Y
N
8. Ignition switch turned on; measure voltage between earth circuit (terminal 2) and reference voltage (terminal 1) is 5V with the voltmeter?
Repairs
Y Completed
9. Replace throttle position sensor
10. Replace ECU
103
Common Malfunction Diagnosis Flow of Geely Automobile
No.059 Quick diagnosis for inlet pressure temperature sensor Function: this sensor is for measuring absolute pressure and inlet temperature of intake manifold, and providing information related to engine load and inlet temperature. Principle: piezoelectric transducer is for measuring inlet pressure, and will provide "load signal" to the controller according to difference between atmospheric pressure and intake manifold pressure; provide 5V via controller and feed 0-5V to the controller according to difference of inlet pressure. Type NTC (negative temperature coefficient) sensor is for measuring inlet temperature, and resistance changes by inlet temperature, and this sensor will transfer one voltage indicating changes of inlet temperature to the controller.
air intake manifold absolute pressure and air intake temperature sensor
Definition of sensor pin: #30# earthing; 2#44# temperature signal output; 3#12# connecting 5V reference voltage; 4#7# pressure signal output; Simple measuring method: 1. Read malfunction code via engine diagnosis instrument and check malfunction information by referencing parameter of inlet temperature and inlet pressure. When the vehicle is not started, inlet pressure is close to the local atmosphere pressure, generally as one atmosphere pressure; after startup, pressure is reduced to 300～400kpa, and inlet temperature is ambient temperature at that time; 2. For temperature sensor, (remove the connector) place digital multimeter to ohm position, and two pens are respectively connected to 1#, 2# pins of sensor, and rated resistance is 2.5kΩ±5% under 20℃, and other corresponding resistance values could be measured from characteristic curve above. When measuring, use simulation method, specifically, supply air to the sensor via air blower (do not approach too closely), and observe changes of sensor resistance, which shall be reduced at this point; 3. For pressure sensor, (connect the connector) place digital multimeter to DC voltage position, with black pen for earthing and red pen respectively connecting with 3#, 4# pins. At idling speed, 3# pin shall have 5V reference voltage, and voltage of 4# pin is about 1.3V (specific value related to vehicle model); under empty load, slowly open throttle valve, and voltage of 4# pin is not greatly changed; quickly open throttle valve, and voltage of 4# pin could reach about 4V 104
Common Malfunction Diagnosis Flow of Geely Automobile
immediately (specific value related to vehicle model), and then reduced to about 1.5V (specific value related to vehicle model). Diagnosis flowchart for inlet pressure temperature sensor (inlet temperature sensor) 1. Ignition switch closed; remove ECU joint and check earth circuit (30-1) of sensor Y
is open circuited or shorted to B+?
N
2. Check signal circuit (44-2) of sensor is open circuited, shorted to earth or shorted Y
to B+?
Y N
3. Plug in ECU joint, and take out sensor plug, ignition turned on. Check socket N
connector terminal (2-1) has reference voltage of 5V? Repairs
Y
4. Replace intake temperature sensor
5. Replace ECU
Completed
105
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart for inlet pressure temperature sensor (inlet pressure sensor) 1. Any following conditions occur? ---Vacuum booster or fuel pressure-regulating valve hose loosening or Y
damaged --- Intake manifold vacuum leaking and throttle valve leaking N Y
2. Disconnect sensor joint, and connect diagnosis instrument, and ignition turned on. Observe absolute pressure displayed on diagnosis instrument is N
N
3. Check lines between ECU terminal 7 of signal circuit of sensor and sensor
Y
terminal 4 is shorted circuited to B+?
4. Check lines between ECU terminal 7 of signal circuit of sensor and
Y
sensor terminal 4 is open circuited or shorted to earth? N 5. Check lines between ECU terminal 12 of 5V reference voltage and sensor
Y
terminal 3 is open circuited or shorted to earth or to power source?
N N
6. Check absolute pressure displayed on diagnosis instrument is 1013hpa after the following operations? Ignition switch closed; ECU terminal 7 shorted circuit to ECU terminal 3; ignition switch turned on Y 7. Check lines between ECU terminal 30 of earth circuit of sensor and
Y
sensor terminal 3 are open circuited, shorted to earth or to power source?
N N
8. With ignition switch turned on, check voltage between earth circuit (terminal 1) and reference voltage (terminal 3) is about 5V
Repairs
N 9. Replace manifold intake pressure sensor
10. Replace ECU
Completed
106
Common Malfunction Diagnosis Flow of Geely Automobile
No.060 Quick diagnosis for water temperature sensor Function: this sensor is for providing information about engine cooling liquid temperature, so that the controller could correct oil injection and ignition accordingly. Principle: this sensor is a heat variable resistor of negative temperature coefficient (NTC), with its resistance value reduced as the temperature rises, but not as linear relationship. This resistor is installed within copper heat guiding sleeve.
Definition of sensor pin: 1#45# temperature signal output; 2#30# earthing. Simple measuring method: 1. (remove the connector) place digital multimeter to ohm position, and two pens are respectively connected to 1#, 2# pins of sensor, and rated resistance is 2.5kΩ±5% under 20℃, and other corresponding resistance values could be measured from characteristic curve above. When measuring, use simulation method, specifically, put working area of the sensor into boiling water (soak time shall be sufficient), and observe changes of sensor resistance, which shall be reduced to 300Ω-400Ω (specific value up to temperature of boiling water); 2. Check water temperature parameter of engine diagnosis instrument is close to water temperature at the time, also with obvious changes; make judgment according to value displayed; Serial No.
Resistance Temperature tolerance Min.
Temperature Temperature tolerance
Max.
Min.
107
Max.
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart for cooling liquid temperature sensor 1. Ignition switch closed: take out ECU joint and check earth circuit of sensor (2 pin – 30 pin) Y Y
is open circuited or shorted to B+?
N
2. Check signal circuit of sensor (1-45) is open circuited, shorted to B+ or shorted to ground?
Y
N
3. Plug in ECU joint, turn on ignition and check there is 5V reference voltage between two N
terminals of sensor joint?
Repairs
Y
4. Replace cooling liquid temperature sensor of the engine
5. Replace ECU
Completed
108
Common Malfunction Diagnosis Flow of Geely Automobile
No.061 Quick diagnosis for canister solenoid valve Function: for controlling flow of regenerated air flow of fuel evaporation control system. Principle: canister of fuel evaporation control system could absorb oil vapor of oil tank, till saturation. After canister control valve by electronic controller is opened, fresh air and fuel vapor saturated in the canister will form regenerated air flow, and reintroduce to engine inlet pipe. And electronic controller will change duty ratio of impulse signal transferred to magnet coil of canister control valve according to engine’s different conditions, thus controlling over flow of regenerated air flow. In addition, this flow is affected by pressure difference at two s ides.
Definitino of TEV pin: 1# TEV driver stage pin; 2#5# TEV control pin; Maintenance precautions: 1. When installing, airflow direction shall conform to specifications; 2. In case control valve becomes invalid due to black particle within valve body, and needed to be replaced, check canister; 3. During maintenance, avoid liquid such as water, oil from entering to valve; 4. To avoid transfer of solid borne noise, recommend to hang up canister control valve and install it at hose. Simple measuring method: 1. (remove the connector) place digital multimeter to ohm position, and two pens are respectively connected to two pins of canister control valve; rated resistance is 26Ω under 20℃; 2. Remove canister control valve, and absorb the air inside and check; canister control valve shall be stuffy; then apply battery voltage of 12V to two connecting terminals, and absorb the air to control valve, and the valve shall be airing. If upon check, status of canister control valve is not consistent with above check results, it indicates that it is malfunction, and replace it;
109
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart for canister control valve Y
1. Ignition switch closed: remove joint of canister control valve, and turn on ignition switch, but unable to start the engine. Measure there is 12V voltage to ground at one terminal of socket connector?
N Y
2. Check lines between main relay terminal 87 and canister control valve are open circuited, shorted to ground or to power source?
Y N 3. Check resistance of canister control valve is 5-50Ω?
N
N
4. Ignition switch closed: remove ECU joint: check lines between ECU and canister control valve are open circuited, shorted to ground or to power source? Y
5. Replace canister control valve
6. Replace ECU, and confirm repairs are completed.
Repairs
110
Y Repairs
Common Malfunction Diagnosis Flow of Geely Automobile
No.062 Fuel injector EV
1.
O ring
2.
Filter screen
3.
Ejector body with electric plug
4.
Coil
5.
Spring
6.
Valve needle with coil
• Function: fuel injector ejects fuel within specified time according to instructions of ECU, and provides fuel to the engine and make it atomized. • Principle: ECU supplies power to coil of fuel injector, forming magnetic field force; when this force increases enough to overcome resultant of pressure of release spring, gravity of needle valve and friction force, needle valve starts to rise, and fuel injection starts. When injection impulse stops, pressure of release spring will make needle valve re-closed. • Mounting position: Intake manifold close to inlet valve. Malfunction: Poor idling speed, poor acceleration, unable to startup (difficult startup), etc. General causes: Colloid deposit within fuel injector due to lack of maintenance, causing it ineffective. Maintenance precautions: 1. There are many types of fuel injectors, and those with the same appearance and which could be installed may not be the proper one. Part number for injector during repairs must be the same with that of original injector. Do not mix up; 2. To ensure convenient installation, apply clean silicon-free oil at surface of upper O ring connected with fuel distribution pipe. Do not pollute inner of oil injector and jet orifice; 3. When removing and reassembling fuel injector, replace O ring; do not damage sealing surface of fuel injector; 4. If fuel injector has two slots, make it correct when installing clamps by referencing mounting position of original parts; 5. Do not remove, and clean or replace filter screen without permission; 6. After removing, make sure fuel injector seat is clean. Avoid foreign substances entering to the cylinder.
111
Common Malfunction Diagnosis Flow of Geely Automobile
Simple measuring method: (remove the connector) Place digital multimeter to ohm position, and two pens are respectively connected to two pins of oil injector, and rated resistance is 11-17Ω under 20℃. Suggestions: thoroughly clean oil injector with special cleaning analyzer for each 20000kM. Diagnosis flowchart for oil injector Y
1. Close ignition switch and disconnect joint of oil ejector; connect voltmeter to No. 1 terminal of the first cylinder ejector and earth between; switch on ignition switch, and observe voltage of No. 1 terminal of oil ejector is 12V instantaneously? For other oil ejectors, same steps.
N
2. Repair earthing, short circuit and open circuit between main relay, oil
Y
pump relay, oil ejector
3. Check lines between oil ejector and ECU terminal (17-2) are open circuited, shorted to ground or to power source?
N
N
4. Close ignition switch, and remove joint of oil ejector: measure resistance of each oil ejector is lower than 15.95Ω one by one with ohmmeter?
Y Y
5. Connect oil ejector joint of each cylinder and ground with ohmmeter; measure resistance between each oil ejector and ground is larger than 1MΩ?
N 6. Replace oil ejector
7. Replace ECU
Completed
112
Y Repairs
Common Malfunction Diagnosis Flow of Geely Automobile
No.063 Quick diagnosis for Hall sensor
Principle of hall sensor
Hall effect
When the current IS passes through semiconductor slice, hall voltage UH will occur at right-handed rotation direction, which is proportion to magnetic field induction B (vertical to current IS) and current. Hall voltage is affected by induction strength B. Hall element at (ON) status
Low level
UV
Hall element status
High level
UV UA output voltage UV input voltage
113
at
(LOCKED)
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart for Hall sensor (ignition distributor) 1. Remove hall sensor, and measure resistance between terminal C of sensor joint and ground is between 0-2Ω?
N
Y 2. Ignition switch turned on, but unable to start the engine: measure voltage between terminal 3 and ground is between 1.0-1.5V?
N
Y N
3. Close ignition switch and remove ECU joint; measure resistance between terminal 1 of sensor joint and lines terminal 48 of ECU joint is between 0-2Ω? Y
N
4. Measure resistance between terminal 1 of sensor joint and ground is infinitely large? Y 5. Connect all joints, and clear malfunction code; as road testing, malfunction code is displayed? Y
Y
6. Replace hall sensor, and confirm malfunction code still exists after repairs are completed?
7. Repair open circuit of lines between sensor and ground, and confirm repairs are completed?
8. Repair problems such as open circuit or shorted to ground of lines between sensor and ECU, and confirm repairs are completed?
9. Repair problems such as open circuit between sensor and ECU, and confirm repairs are completed
10. Replace ECU
114
N
Troubleshooting tip
Common Malfunction Diagnosis Flow of Geely Automobile
No.064 Electric fuel pump EKP
1. Oil pump end cover 2. Armature 3. Oil duct 4. Impeller
• Function: Transfer fuel from oil tank to the engine, and provide sufficient fuel pressure and rich fuel. • Principle: Fuel pump is vane pump driven by DC motor, and placed within oil tank and immerged by fuel, using fuel for heat emission and lubrication. The battery supplies power to electric fuel pump through oil pump relay, which will only switch on lines of electric fuel pump when started and the engine is running. When the engine stops running due to accidents, fuel pump will stop running automatically. • Mounting position: Within fuel tank. Malfunction: Large running noise, poor acceleration, unable to startup (difficulty startup), etc. General causes: Due to uses of poor quality fuel, it will cause: 1. formation of insulating layer due to colloid accumulation; 2. locking of oil pump bushing and armature; 3. corrosion of oil level sensor elements, etc. Maintenance precautions: 1. according to needs of the engine, electric fuel pump is with different flows. Even mountable fuel pump with the same appearance is not proper. For maintenance, number of part of fuel pump shall be consistent with original one; 2. to prevent damages of fuel pump, do not operate it under dry condition for a long time; 3. if fuel pump is to be replaced, clean fuel tank and pipes and replace fuel filter. Simple measuring method: (remove the connector) Place digital multimeter to ohm position, and two pens are respectively connected to two pins of fuel pump, and measure internal resistance, which shall not be zero or infinite (i.e. non-short-circuited, off state). (connect the connector) for oil return system, connect the fuel pressure gauge at oil sucker, and start the engine, making it operate at idling speed status. Fuel pressure of the engine shall be around 260kPa at this time; take out vacuum tube of fuel pressure regulator, and fuel pressure shall be around 300kPa at this time.
115
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart of oil pump circuit Y 1. Check fuse of oil pump relay is open circuited? N 2. Close inigtion and remove fuel pump relay: ignition switched on, and voltage of terminal 85, 30 of relay is larger than 10.7V?
N
Y N
3. Remove ECU joint, and measure resistance of lines between ECU terminal 3 and fuel pump relay is lower than 0.5Ω? Y N 4. Measure resistance between ECU terminal 3 and ground is infinitely large? Y N
5. Measure resistance of relay coil (85-86) is about 80-90Ω?
Y N
6. Check lines between fuel pump and fuse, and oil pump relay are normally connected?
Y
Y
7. Replace ECU and confirm repairs are completed.
Y
8. Repair “shorted to ground” of fuse of fuel pump relay, and confirm repairs are completed?
9. Repair malfunctions such as open circuit, short circuit of relay, fuse, power supply, and confirm repairs are completed?
Y
Y 10. Repair short circuit of lines between relay and ECU, and confirm repairs are completed?
11. Replace oil pump reay, and confirm repairs are completed?
116
Y
Repairs
Common Malfunction Diagnosis Flow of Geely Automobile
No.065 Fuel pressure regulator DR
• Function: For oil return system, fuel pressure regulator is used for regulating fuel pressure of fuel system, making difference with pressure of intake manifold kept at a constant value. • Principle: This pressure regulator is diaphragm type overflow valve. when system fuel pressure is increased, oil pressure within oil inlet exceeds resultant force of pre-tightening force of the spring and air pressure within spring chamber, the diaphragm will be jacked, and valve will be opened. Fuel is returned to fuel tank through oil return port in center of pressure regulator, and fuel pressure dropped, till the valve is closed. • Mounting position: Installed at fuel distribution pipe for oil return system. Malfunction: Fuel pressure too low or too high, difficult to startup, etc. General causes: Due to uses of poor quality fuel, it will cause: 1. blocked filter screen; 2. foreign substances causing large leakage. In addition, manually mechanical damages, etc. Maintenance precautions: during maintenance: 1. do not impact diaphragm element by high pressure gas; 2. do not clean it with strong corrosive liquid; 3. deformation is not allowed due to outside force. Simple measuring method: For oil return system, connect fuel pressure gauge at oil sucker, and start the engine, making it operate at idling speed status. Fuel pressure of the engine shall be around 260kPa at this time; take out vacuum tube of fuel pressure regulator, and fuel pressure shall be around 300kPa at this time.
117
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart of fuel regulation 1. With the engine running at 1200rpm under normal temperature, N
check voltage of oxygen sensor displayed is kept at lower than 0.275V with the diagnosis instrument?
Y
2. Remove joint of oxygen sensor, and check its voltage is between 0.35-0.55V with the engine under idling speed?
N N
3. Check two lines connecting oxygen sensor (10-3; 28-4) are with
Y REPAIR
open circuit, shorted to ground or shorted to voltage source?
4. Check voltage of oxygen sensor displayed is kept larger than 0.75V
N
with the diagnosis instrument?
Y 5. Remove joint of oxygen sensor, and its voltage is lower than 0.35V Y
with the diagnosis instrument?
N
6. Remove oxygen sensor
7. Repair short circuit or open circuit
Completed
118
To troubleshooting tip
Common Malfunction Diagnosis Flow of Geely Automobile
No.066 Oxygen sensor LSH
1 cable conductor， 2 disk washer, 3 insulating bushing, 4 protective sleeve, 5 clamping connector of heating element 6 heating rod, 7 contact gasket 8 sensor seat, 9 ceramic probe, 10 protective tube
•
Function: Measure oxygen contents of engine exhaust, and determine gasoline and air are fully burnt. And electronic controller realizes closed-loop control using excess air coefficient =1 as the goal according to this information, to ensure maximum conversion efficiency of three-way catalytic converter on three pollutants such as HC, CO and Nox from the exhaust.
• Principle: Sensing element is ceramic tube, to exhaust externally and to atmosphere internally. When temperature of sensing ceramic tube reaches 350℃, it is with solid electrolyte. With this feature, convert concentration difference of oxygen to potential difference, reaching output of electrical signal. If mixture gas is too thick, concentration difference of oxygen in and out of ceramic tube is high, and potential difference is also high. And a great amount of oxygen is moved from inner side to outer side, and output voltage is high (close to 900mV); if mixture gas is too thin, concentration difference of oxygen in and out of ceramic tube is low, and potential difference is also low. And only a small amount of oxygen is moved from inner side to outer side, and output voltage is low(close to 100mV). Mounting position: Installed at front of exhaust pipe. Malfunction: poor idling speed, poor acceleration, tail gas exceeding standard, oil consumption too large, etc. Installation torque: 40~60 N•M General causes: 1. wet water vapor enters to inner of sensor, and temperature changes suddenly and probe is broken; 2. oxygen sensor “poisoning”.( Pb, S, Br, Si ). Maintenance precautions: do not use cleaning liquid, oily liquid or volatile solid at oxygen sensor during maintenance. Simple measuring method: (remove the connector) Place digital multimeter to ohm position, and two pens are respectively connected to 1# (white), 2# (white) pins of sensor, and resistance is 1~6Ω under normal temperature. (connect the connector) under idling speed status, when oxygen sensor reaches working temperature of 350℃, place digital multimeter to DC voltage position, and two pens are respectively connected to 3# (grey, 4# (black) pins of sensor, and voltage shall fluctuate quickly between 0.1-0.9V.
119
Common Malfunction Diagnosis Flow of Geely Automobile
Diagnosis flowchart of oxygen sensor
Y
1. Connect the diagnosis instrument, and start the engine to water temperature ＞ 80℃. Observe voltage of sensor signal is between 0.2-0.8? N
N
2. Check two lines connecting oxygen sensor (sensor 4-ECU28, sensor 3-ECU10) are with open circuit, shorted to ground or power source (＞1.098V for shorted to power source, ＜0.092 for shorted to ground)
Y
3. Close ignition, and plug in controller. Connect voltmeter to two white conductors of oxygen sensor, and the engine is started and running at idling speed, and check value displayed at voltmeter is between 12-14V?
N
Y
N
4. Close ignition and remove connection of socket connector of oxygen sensor. Connect two white conductors of oxygen sensor with multimeter, and check resistance is between 0.5-20ohm? Note: this value is related to temperature.
Y
N
5. Close ignition and remove connection of socket connector of oxygen sensor. Measure resistance of signal line (black) and signal cathode conductor (grey) of the sensor is within the following range: ＞30MΩ at -20℃; ＞10MΩ at 350℃; ＞100KΩ at 850℃.
Y 6. Close ignition and take out controller plug. Remove connection of socket connector of oxygen sensor, and connect the multimeter, and check resistance of cathode conductor is ＜0.5Ω?
N
Y 7. Steps same as 6; connect the multimeter to another terminal, andcheck resistance of anode conductor is ＜0.5Ω? Y N
8. Close ignition, plug in controller, and remove connection of socket connector of oxygen sensor. Connect black and central earthing with the voltmeter, with ignition turned on. Observe reading of voltmeter is between 0.4-0.6V?
Replace oxygen sensor, and confirm repairs N Replace ECU
Completed
120
No
Repairs
Common Malfunction Diagnosis Flow of Geely Automobile
No.067 JL376/378QE engine’s electric control system check Testing Testing terminal step
Component, part check
Preparations for testing conditions
Sealing of intake system
Ignition closed, take out plug of controller, and intake pipe in front of throttle valve is sealed with proper materials. Take out connecting pipe of canister control valve of throttle vavle body. No generation of bulb Apply compressed air, and make pressure within intake pipe as about 1-2bar. Check liquid leaking, and check all sealing seams. After check, reassemble connecting pipe of canister
02
Fuel device
Ignition closed, take out plug of controller, and connect pressure gauge at fuel high-tension loop. Take out fuel return pipe of the pressure regulator, and install auxiliary hose on the connector of pressure regulator. And auxiliary hose leads to one proper barrel (with capacity of at least 2 liters). 46 and 3 pins on the controller are earthed at the same time, making oil pmp rotate 30 seconds.
02.1
Oil supply of fuel pump
Carry out same as step 02
700-1000ccm
02.2
Fuel pressure
Carry out same as step 02
2.8—3 bar
02.3
Oil return pipe
Remove auxiliary hose, and connect return pipe to oil tank, and ignition is switched on, and 3 and 46 terminals of controller plug are earthed (with auxiliary cable). Read out pressure of Max. 2.9—3.1 bar pressure gauge, and disconnect earth connection, and ignition is closed.
02.4
pressure maintenance
After about 10 seconds, read pressure of the monograph again, and record dropped value of 0.2-0.3 bar the pressure.
02.5
pressure function
Plug in the controller, and the engine will start and operate at idling speed. Record fuel pressure at idling speed, and increase the throttle, and meanwhile observe pressure gauge, and pressure must be increased
01
02.6
regulator
Rated value
About 2.5 bar, About 2.8 bar
Ignition closed, and take out controller plug, and connect the voltmeter to plug of fuel pump, Power supply of fuel pump and make 3 and 46 terminals of controller plug earthed at the same time (with auxiliary cable). Min. 10.7V And fuel pump must be operating, and read out power supply voltage.
121
Common Malfunction Diagnosis Flow of Geely Automobile
02.7
Voltage drop of anode Same as description of 02.6, but multimeter placed to another terminal. side
Max. 0.5V
02.8
Voltage drop of cathode Same as description of 02.6, but multimeter placed to another terminal. side
Max. 0.5V
02.9
Total value of voltage drop Values calculated based on 02.7 and 02.8.
Max. 0.8V
03.0
Earth connection constant anode controller
of to Ignition closed, take out controller plug and connect multimeter
03.1
18．．．2
Constant anode, earthing Carry out same as step 3.0 terminal 2
About 12V
03.2
18. 14
Constant anode, earthing Carry out same as step 3.0 terminal 14
About 12V
03.3
18． 19
Constant anode, earthing Carry out same as step 3.0 terminal 19
About 12V
03.4
18…24
Constant anode, earthing Carry out same as step 3.0 terminal 24
About 12V
Anode to controller earth connection, voltage drop Ignition closed, take out controller plug, load resistance and voltmeter connection ignition switch
＜0.3V
Voltage drop terminal 18
Load resistance terminal 18 and 2
＜0．3V
04.0 04.1
B+
18
04.2
B- 2
Earth wire terminal 2
Load resistance terminal 18 and 2
＜0．3V
04.3
B- 4
Earth wire terminal 4
Load resistance terminal 18 and 4
＜0．3V
04.4
B- 19
Earth wire terminal 19
Load resistance terminal 18 and 19
＜0．3V
04.5
B- 24
Earth wire terminal 24
Load resistance terminal 18 and 24
＜0．3V
04.6
B+
27
Voltage drop terminal 27
Load resistance terminal 18 and 27, ignition turned on
＜0．3V
04.7
B+
37
Voltage drop terminal 37
Load resistance terminal 18 and 37, ignition turned on
＜0．3V
05.1
Hall sensor 1...3
Power supply hall sensor
Ignition closed, controller plug inserted. Connect voltmeter, and turn on ignition.
About 5
122
Common Malfunction Diagnosis Flow of Geely Automobile
Hall sensor signal
Close ignition, insert controller plug and connect voltmeter. Take out socket connector of When replacing shading ignition coil with ignition switch, and take out distributor cover. With ignition turned on, slowly rotor, one voltage larger rotate belt pulley of engine crankshaft manually, and observe shading rotor of measuring than 2V must be displayed instrument and hall sensor.
05.2
Hall sensor 1...2
05.3
Hall sensor based terminal 12 and ECU
on To anode conductor Close ignition, take out controller plug and connect the multimeter. connection of hall sensor
＜0.5Ω
05.4
Hall sensor based terminal 48 and ECU
on To cathode conductor Same as Step 5.3, with multimeter connected to another terminal connection of hall sensor
＜0.5Ω
05.5
Hall sensor based terminal 49 and ECU
on
Connection from hall sensor to controller Same as Step 5.3, with multimeter connected to another terminal conductor
＜0.5Ω
06.1
Pressure sensor terminal power supply from intake Ignition closed, and connect controller. Connect the voltmeter to plug of pressure sensor, and 约5 3...1 pipe pressure sensor ignition turned on
06.2
Pressure sensor terminal Intake pipe 4...1 sensor signal
06.3
Intake pipe pressure Pressure sensor terminal sensor signal when the Same as Step 6.2, with engine running at idling speed 4...1 engine is no-load running
10.8V 1.3
06.4
Intake pipe pressure Pressure sensor terminal sensor signal when 4...1 increasing throttle
电压变化
06.5
Anode Pressure sensor terminal connection 3 and ECU terminal 12 sensor
to
conductor pressure Ignition closed, take out controller plug, and connect resistance and measure
＜0.5Ω
06.6
Cathode Pressure sensor terminal connection 1 and ECU terminal 30 sensor
to
conductor pressure Same as Step 6.5; connect multimeter
＜0.5Ω
06.7
Pressure sensor terminal Signal conductor Same as Step 6.5; connect multimeter 4 and ECU terminal 7 connection to controller
07.1
Pressure sensor terminal Power supply from intake Close ignition, connect controller plug, and take out connection of socket connector of pressure About 5V 1...2 temperature sensor sensor, and connect voltmeter to plug of pressure sensor, ignition
07.2
Pressure sensor terminal Intake temperature sensor Same as Step 07.1, connect plug of pressure sensor. Note: this value is related to temperature 0.5…3V 1...2 signal
07.3
Pressure sensor terminal Intake temperature sensor Close ignition, take out plug of pressure sensor. Connect multimeter of pressure sensor. Note: At 20 1...2 resistance this value is related to temperature
pressure
Same as Step 6.1, with voltmeter connected to another terminal
Same as Step 6.2; step on the throttle, and observe voltmeter
123
3．8V 4.2V
＜0.5Ω
Common Malfunction Diagnosis Flow of Geely Automobile 07.4
Pressure sensor terminal Intake temperature sensor Close ignition, take out controller plug, and connect multimeter 2 to controller terminal 44 signal conductor
＜0.5Ω
08.1
Throttle position sensor Power supply from throttle Close ignition, connect controller plug, and connect voltmeter, ignition turned on terminal 1..2 sensor
About 5V
08.2
Throttle sensor signal Throttle position sensor voltage, throttle closed, Same as Step 8.1, voltmeter connected to throttle, closed terminal 2..3 throttle sensor signal voltage
0.1…0.9V
08.3
Throttle position sensor Throttle all opened terminal 2..3
3.0…4.8V
08.4
Throttle sensor signal voltage inspection. Note: Throttle position sensor Same as Step 8.2, but connect one oscillograph to replace voltmeter, with throttle quickly Oscillograph without this inspection only terminal 2..3 opened and closed sever voltage interference possible with connecting one oscillograph
08.5
Throttle position sensor Connection between terminal 1 and ECU anode conductor to Close ignition, take out controller plug, and connect resistance and measure terminal 12 throttle sensor
＜0.5Ω
Throttle position sensor Connection between terminal 2 and ECU cathode conductor to Same as Step 8.5, with multimeter connected to terminal terminal 30 throttle sensor
＜0.5Ω
Throttle position sensor Signal conductor terminal 3 and ECU controller conductor terminal 53
Same as Step 8.5, with multimeter connected to terminal
＜0.5Ω
Close ignition, take out controller plug, and connect multimeter
＜0.5Ω
08.6
08.7
Same as Step 8.2, whole throttle opened
to
09.1
Knocking sensor terminal Cathode conductor 2 and ECU terminal 30 controller conductor
to
09.2
Connection between Knocking sensor terminal signal conductor to Same as Step 9.1 1 and ECU terminal 11 controller
＜0.5Ω
09.3
Knocking sensor terminal Shielded 3 and ECU terminal 19 connection
Same as Step 9.1, with multimeter connected to another terminal
＜0.5Ω
09.4
Knocking sensor terminal Internal resistance 1…2 knocking sensor
Disconnect socket connector of knocking sensor, and connect multimeter
4.5…5.5V
10.1
Oxygen sensor terminal Power supply for heating Close ignition, plug in controller, with voltmeter connected to two white conductors connecting 12...14V 1…2 element of oxygen sensor to socket connector of oxygen sensor, and start the engine to be running at idling speed
10.2
Oxygen sensor terminal Internal resistance of PTC Close ignition, and disconnect socket connector of oxygen sensor, and connect multimeter to 0.2...20 1…2 heating element two white conductors of oxygen sensor. Note: this value is related to temperature.
10.3
Oxygen sensor 1…2
conductor of
Current consumption of Close ignition, ampere meter with suitable commutator conductor, connecting to one white 124
Common Malfunction Diagnosis Flow of Geely Automobile heating element of oxygen conductor. The engine is started and running at idling speed. Note: this value is related to sensor temperature. 10.4
Oxygen sensor
Insulated resistance heating element primary element
of Close ignition, disconnect socket connector of oxygen sensor. Measure signal line (black) and ＞30MΩ at -20℃; ＞10MΩ to signal cathode conductor (grey) of oxygen sensor and two white conductors one by one with at 350℃; ＞ 100KΩ at multimeter. Note: this value is related to temperature. 850℃.
10.5
Oxygen sensor
Reference voltage controller terminal 10
of Close ignition, plug in controller, and disconnect socket connector of oxygen sensor, and voltmeter connected to black wire and central earthing, with ignition turned on.
10.6
Oxygen sensor
Signal voltage of oxygen Close ignition, and connect socket connector of oxygen sensor. Connect voltmeter to black and Display slowly sensor grey cables of oxygen sensor. The engine is started and running at idling speed, and observe 0.2…0.8V display of measuring instrument after several minutes.
10.7
Oxygen sensor
Close-cycle control of Same as Step 10.6. When swinging at display, take out vacuum hose with fuel regulator and Display stable within short time. Then re-swing. oxygen sensor, seal it. After inspection, plug in hose at pressure regulator. interference identification of signal voltage
10.8
Grey cable
Cathode conductor signal Close ignition, take out controller plug, and disconnect socket connector of oxygen sensor, and connection connect multimeter/
10.9
Oxygen sensor Black cable
Anode conductor signal Same as Step 10.8; connect multimeter to black cable. After inspection, connect socket connection connector of oxygen sensor.
11.1
Cooling liquid temperature Supply voltage of cooling Close ignition, and turn on controller plug. Take out plug of cooling liquid temperature sensor. About 5V sensor liquid temperature sensor Connect voltmeter and turn on ignition.
11.2
Cooling liquid temperature Note: this value is related Same as Step 11.1, but connecting plug of cooling liquid temperature sensor. sensor to temperature
11.3
Cooling liquid temperature Connection sensor signal and conductor
11.4
Cooling liquid temperature Connection between Same as Step 11.3, with multimeter connected to another terminal. sensor cathode conductor and controller conductor
12.0
between Close ignition, take out controller, and take out plug of cooling liquid temperature sensor.
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