Geely FC 2007, FC 2008, FC 2006, FC 2009, FC 2010 User Manual
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Preface
Geely “FC” is an automobile with high performance/price ratio and it meets the requirement
of national safety, energy saving, emission regulations and personal use. This automobile is
a completely new and excellent model produced by Zhejiang Geely Automobile Co., Ltd with
development in self-reliance of Geely group and with self-dominated intellectual property
right. It characterizes elegant appearance, energy conservation and environmental protection,
safety and comfort. “FC” is a product opening a completely new viewpoint of automobile
selection, because it is developed on the basis of creative design thinking that breaks through
all established customs and it features perfectly balanced performance of power, space,
safety, manipulation and comfort. “FC” is a competitive product for Geely developing brand
and exploring mid-level automobile market, which takes over the company philosophy “make
good cars that common people can afford, and let Geely cars go to the whole world” of Geely
automobile. “FC” is combination of creativity and intelligence of quite a large number of
automobile experts, who have been developing and searching with great concentration for
more than 30 months, and it fully embodies persistent Geely style of fashion appearance
and high performance/price ratio.
“FC” is equipped with engine JL4G18 completely developed and produced by Geely group.
Engine JL4G18 applies the following advanced technology such as VVT, full aluminum cylinder body, plastic intake manifold, completely new VVT inside seal method, completely new
OCV valve filtering method etc. with M7.9.7 electric injection system of BOSCH, and its
index on power efficiency, economical efficiency, and safety efficiency etc. reaches leading
level of national model with the same type. This engine features strong power, low fuel
consumption, low noise and high power per liter etc.
We start to compile “FC” Automobile Maintenance Manual, which is divided into 27 sections with detailed description of overall structure and maintenance of engine 4G18.VVT;
inspection and repair of engine BOSCH M7.9.7 electric control fuel injection system; structure and maintenance of chassis; structure and maintenance of FC electrical equipment;
structure and maintenance of ABS anti-lock brake system; structure and maintenance of
SRS air bag; structure and maintenance of auto air conditioning system; structure and maintenance of vehicle body etc. Information is detailed and accurate, contents are in systematic
coherence and description is concise and comprehensive.
This manual is compiled from structure, which prompts “FC” service personnel to master
necessary maintenance, repair and malfunction knowledge on the basis of understanding
main structure characteristics and simple principle of vision automobile. Electric control system of “FC” automobile is particularly described with detail, and detailed steps and methods
are given for trouble shooting process. All kinds of malfunction could be eliminated quickly
and efficiently within the shortest time as long as you detect as the repair steps of this manual.
In addition, this manual is compiled with the following characteristics: in proper sequence,
clear demarcations, easy to understand, excellent in picture and its accompanying essay,
simple and clear, which is very applicable for a quite large number of “FC” automobile maintenance technicians and service personnel to refer to.
This manual is mainly compiled by Geely International Corporation; Geely Automobile Engine No. 2 Plant and engineering technicians of service corporation help complete this work.
Defects and mistakes are inevitable in this manual for limited level of compiler and limited
time, please contact Geely International Corporation if you find mistakes and careless omissions in using and we can correct in time and reverse in next version.
Geely International Corporation
Nov. 2007
Note
This manual is mainly for qualified vehicle technicians, but it does not include all items on repair and maintenance.
In order to avoid personnel injury and vehicle damage caused by dangerous
operation, please observe the following regulations.
z Please read this manual carefully, and particularly fully master all con-
tents in “Precautions”.
z Maintenance methods described in the manual are quite useful for vehicle
maintenance. Please adopt specified or recommended tools in maintaining vehicle as steps described in this manual; maintaining vehicle with
tools or methods not specified or recommended in this manual will cause
personnel injury or vehicle damage. Therefore, please consider ensuring
the safety of technicians and vehicle at first before performing maintenance.
z If it is necessary to replace parts, please replace with parts of the same or
similar size with original ones. It is forbidden to use inferior parts.
z In order to effectively avoid technician injury and vehicle damage and hid-
den danger caused by incorrect operation, it is very important to observe
“Warning” and “Notes” in this manual. It particularly needs to mention that
not all precautions on safety are included in “Warning” and “Notes” etc. in
this manual. Therefore, please fully realize that perform maintenance not
as regulations will cause dangerous consequences.
Contents
Brief introduction on Geely model “FC”
Basic parameters
Maintenance period
Regular maintenance items
Table on maintenance period at normal conditions5
Table on maintenance period at severe conditions..7
Engine control system
EFI system
On-vehicle inspection
Inspection
Throttle body assembly
Removing, installing and disassembling, assembling
Fuel
Fuel system
Precautions
On-vehicle inspection
Inspection
Injection nozzle assembly
Replacement
Fuel pump assembly
Removing, installing and disassembling, assembling
Fuel tank assembly
Removing, installing and disassembling, assembling
Exhaust gas control
Exhaust gas control system
On-vehicle inspection
Inspection
Engine mechanism
Engine assembly
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13
13
14
14
16
17
18
18
20
20
21
21
23
23
25
26
Inspection
1
4
8
8
9
Drive belt
Replacement
Valve clearance
Adjustment
Engine assembly
Replacement
Timing chain assembly
Replacement
Camshaft
Replacement
Crankshaft front oil seal assembly
Replacement
Crankshaft rear oil seal assembly
Replacement
Cylinder cover gasket components
Replacement
Exhaust
Exhaust pipe assembly
Removing, installing and disassembling, assembling
Cooling
Cooling system
On-vehicle inspection
Inspection
Cooling fan system
On-vehicle inspection
Inspection
Water pump assembly
Replacement
Temperature regulator components
Replacement
Radiator with electronic fan assembly
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26
29
29
30
30
36
36
45
45
52
52
60
60
62
62
63
63
65
65
66
66
66
68
68
68
69
69
71
71
72
Replacement
Coolant
Lubrication
Lubricating system
Oil filter assembly
Oil pump assembly
Ignition
Ignition system
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Replacement
On-vehicle inspection
Replacement
Replacement
Inspection
On-vehicle inspection
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72
73
73
74
74
75
75
76
76
77
77
77
Front stabilizer bar
Overhaul
Front left lower control arm ball joint assembly
Replacement
Rear suspension
Rear suspension system
Table on trouble occurrence
Rear wheel alignment
Adjustment
Rear strut assembly
Overhaul
Handling
Rear stabilizer bar
Overhaul
Rear shaft assembly
Overhaul
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100
100
101
101
102
102
104
105
105
106
106
96
96
99
99
Starting and charging
Starting system
Inspection
Charging system
Precautions
On-vehicle inspection
Alternator components
Replacement
Starter components
Replacement
Front suspension
Front suspension system
Table on trouble occurrence
Front wheel alignment
Adjustment
Front absorber and helical spring
Overhaul
Handling
Lower left control arm assembly
Replacement
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79
79
81
81
82
84
84
85
85
86
86
87
87
90
90
93
94
94
Tire and wheel
Wheel and tire system
Inspection
Drive shaft
Drive shaft
Notes
Malfunction phenomenon table
Inspection on automobile
Front drive shaft
Overhaul
Left front shaft hub assembly
Change
Left front shaft hub bolt
Change
Left rear shaft hub and bearing assembly
Change
Left rear shaft hub bolt
Change
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109
109
111
111
111
112
113
113
123
123
128
128
129
129
131
131
Brake
Brake system
Notes
Remove malfunction
Malfunction phenomenon table
Brake liquid
Discharge the air in brake system
Brake pedal assembly
Adjustment
Change
Vacuum booster assembly
Inspection on automobile
Change
Front brake assembly
Overhaul
Rear brake assembly
Overhaul
Hydraulic pressure control unit (equipping with ABS)
Inspection on automobile
Change
Speed sensor of front wheel
Change
Speed sensor of rear wheels
Change
Parking brake
Parking brake system
Malfunction phenomenon table
Adjustment
Parking brake handle assembly
Change
Parking front bake pull cable assembly
Change
Parking rear brake pull cable assembly
Change
Parking brake assembly
Overhaul
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Transmission
132
132
133
133
135
135
136
136
137
138
138
138
141
141
144
144
...
148
148
148
151
151
152
152
154
154
154
155
155
156
156
158
158
161
161
Disassemble assembly
Assemble the assembly
Steering column
Steering system
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Note
Malfunction phenomenon table
Inspection on automobile
Steering column system
Overhaul
Power steering
Power steering system
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Note
Malfunction phenomenon table
Inspection on automobile
Power steering oil pump assembly
Overhaul
Power steering gear assembly
Overhaul
Air conditioner
Air conditioning system
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Note
Inspection on automobile
Inspection
Refrigerant
Inspection on automobile
Change
Refrigerant pipeline
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Parts
Control assembly, air conditioner control panel (AUTO A/C)
Overhaul
Fan assembly
Overhaul
Air conditioner central heating core assembly..227
Overhaul
Compressor assembly
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165
191
192
192
192
193
194
194
198
198
199
200
203
203
205
205
213
213
213
214
215
215
221
222
222
...
223
223
224
224
227
234
Change
Condenser Assembly
Inspection on the automobile
Overhaul
Supplemental restraint system
Note
Malfunction treatment
Repair
Inspection
Remove malfunction
Malfunction table
Diagnosis of impacted automobile
Disassemble and assemble
Electronic control unit of safety airbag (ECU)..261
Safety airbag assembly at the side of driver..261
Safety airbag assemble at the side of passenger
Scrap treatment for safety airbag
Safety belt
Safety belt
Note
Treatment
Subassembly
Change
Rear safety belt
Subassembly
Change
Light
Light System
Notes
The phenomena table
Inspect the car
Inspect
Front combination light (LH)
Subassembly
Change
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234
236
236
236
239
244
247
249
251
251
260
261
263
264
270
270
270
273
274
275
275
277
279
279
279
281
283
286
286
287
Adjustments
Front fog light
Components
Change
Adjustment
Side turning light
Components
Rear combination light (LH)
Components
Change
Rear fog light
Components
Change
Number plate light
Change
High brake light assembly
Change
Left combination switch
Change
Wiper and cleaner
Wiper and cleaner system
Malfunction phenomena table
Inspect the car
Inspect
Right combination switch
Change
Wiper motor
Change
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Wiper
Change
Cleaner nozzle
Adjustments
Audio system
Audio system
Notes
Radio assembly
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287
289
289
290
290
291
291
292
292
293
294
294
295
296
296
297
297
298
298
299
299
299
300
302
302
303
303
305
305
306
306
307
307
308
Replacement
Left front door loudhailer
Change
Left front small loudhailer
Change
Rear loudhailer
Change
Outdoor antenna
Change
Circuitry
Power supply
Components
Horn system
Horn system
Position
Inspect
Windshield/window glass/wing mirror
Electric window control system
Position drawing
Inspect the car
Malfunction phenomena table
Inspect
Front windscreen
Change
Rear ventilation window
Change
Fog defrost system
Position drawing
Malfunction phenomena table
Inspect
Electric rearview mirror control system(option).329
Inspect the vehicle
Position drawing
Trouble table
INSPECT
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308
309
309
310
310
311
311
312
312
313
313
316
316
316
317
317
317
319
319
321
321
324
324
327
327
327
328
329
331
331
332
Panel / combination panel
combination panel
Trouble table
Vehicle inspection
Inspection
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Panel
Preparation
Change
Combination instrument assembly
Disassembly and assembly
Chair
Front chair
Subassembly
Overhaul
Rear chair (separating type)
Overhaul
Rear chair (fixing type)
Overhaul
Anti-stealing and door lock
Electric door lock control system
Position of parts
Inspection on automobile
Malfunction phenomenon table
Inspection
Electronic anti-stealing system
Electric sunroof
Sunroof
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Overhaul
Specification for sunroof function
Inspection for sunroof function
Inspection for sunroof switch
Position of parts
Malfunction phenomenon table
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334
334
335
339
340
340
340
347
347
348
348
349
352
352
354
354
355
355
355
358
359
361
362
362
364
364
365
365
365
Engine cover/automobile door
Engine cover
Adjustment
Front automobile door
Subassembly
Overhaul
Adjustment
Rear automobile door
Overhaul
Adjustment
Trunk cover
Adjustment
Torsion spring of trunk cover
Change
Exterior/inner trim board
Front bumper
Subassembly
Change
Rear bumper
Subassembly
Change
Name plate
Change
Exterior seal tape of left front door glass (LH)
Change
Exterior seal tape of left rear door glass
Change
Light fender
Change
Top left trim tape
Replacement
Left lower fender of automobile body (LH)
Subassembly
Change
Inner trim board of top
Change
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Automobile control system
366
366
367
367
369
372
373
373
375
377
377
378
378
379
379
380
381
381
382
383
383
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384
384
385
385
386
386
387
387
388
388
389
390
390
Ignition switch and anti-versa lock key warning switch.394
Malfunction phenomenon table
Inspection
Electrical schematic diagram
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394
394
395
Brief introduction on Geely model “FC” Basic parameters
Brief introduction on Geely model “FC”
Basic parameters
Table 1 Complete vehicle basic parameters
Number
Item name
Length
Overall
dimension
Width
Height
Front wheel
Wheel track
Rear wheel
Wheel base
Front suspension
Dimension parameters
Rear suspension
Passenger number
Complete vehicle herb mass
Max. total mass
No
load
Full
Mass parameters
load
Weight distribution
Front axle
Rear axle
Front axle
Rear axle
Min. turning diameter
Unit
Person
Parameters
±15
±15
±20
±10
±10
±30
±30
Min. gound clearance
Approach angle (full load)
Departure angle (full load)
Traverse ability
Front wheel camber
Kingpin inclination angle
caster angle
parameters
Convergence of front wheels
Front wheel alignment
Rear wheel camber
Convergence of rear wheels
alignment
Rear wheel
parameters
Left wheel: inside/outside
wheel
steering
Right wheel:inside/outside
Front wheel
Head lamp light
Luminous intensity of
high beam of head lamp
Left and
right
inclination
Down
High beam
optical axis
inclination
Candera
Left lamp
Right lamp
Left lamp
Right lamp
1
Brief introduction on Geely model “FC” Basic parameters
Table 2 Types and parameters of main assembly
Number
Item name
Electric injection system model
Delivery capacity
Engine
Compression ratio
Max. power
Max. torque
Idling speed
Ignition sequence
Min. fuel consumption
Each gear ratio
Transmission
Main gear box ratio
Clutch type
Steering gear
Front brake
system
Braking
Rear brake
Front suspension type
Rear suspension type
Sus-
pension
Radial
Tire
tire
Model
Type
Bore
Stroke
Type
1st gear
nd
gear
2
3rd gear
4th gear
5th gear
Reverse gear
Type
Specification
Air pressure
Unit
//
.//
/
/.
Types and parameters
JL4G18
4-cylinderin-line, four-stroke, water-cooling, double over-head
camshaft, 16-valve, CVVT multipoint injection gasoline engine
United Automotive Electronic Systems Co., Ltd. M7.9.7 electric injection system
5 gears synchronizer of constant mesh gear
Dry single, diaphragm spring, constant pressure
Rack-and-pinion steering gear with hydraulic power
Double pipeline, vacuum boosterwith ABS +EBD anti-lock system
Disc brake
Disc brake
Strut-type front independent suspension
Longitudinal swinging arm and anti-twist beam compound rear suspension
2
axle
Drive
Drive shaft
Body structure
Tail gas
Catalytic converter
Air
Compressor type
condi-
Nominal refrigerating capacity
tioning
system
Refrigerant
Rim
Type
Breakaway
BalI cage and tripot type constant velocity universal joint
Loaded all-metal body
Honeycomb cordierite carrier, noble metal catalyst
Swirl or swash plate compressor
Brief introduction on Geely model “FC” Basic parameters
Table 3 Main performance parameters of complete vehicle
Number
Item name
Max. vehicle speed
0-100 km/h accelerating time
Accelerating time from 30km/h to 100km/h at 4th gear
Min. stable vehicle speed at 4th gear
Power performance
Slide Distance (full-load, initial speed 50km/h)
Max. climbing speed
Fuel consumption with 4 operating modes
Economy
Average fuel consumption at specified operating mode
performance
Dust sealing degree
Seal
perfor-
Ride
perfor-
mance
mance
Rain protection seal limit value
Weighted acceleration root of mean square
Equivalent mean value
Reduced comfort boundary
Average mileage to first failure
Average mileage between failures
Reliability
Efficient degree
Unit
Parameters Remarks
3
Maintenance period-Regular maintenance items
Maintenance period
Regular maintenance items
Your precious automobile should be maintained according to maintenance period
at normal conditions (see table on maintenance period at normal conditions)
If your precious automobile is mainly driven under one or more of the following conditions, some
maintenance items must be performed more frequently (see table on maintenance period at severe
conditions).
A. Road conditions
1. Driving on rugged, muddy or melting snow road.
2. Driving on dusty road.
B. Driving conditions
1. Towing tail vehicle, equipped with camp frame or top storage racks.
2. Repeated on short-distance driving within 8 km and the temperature is below 0 .
3. Vehicles driven for long distance under idle speed or low speed over a long period of time,
such as police car, taxi or delivery truck.
4. Continuously driving at high speed for more than 2 hours frequently. (With 80% of max. vehicle speed)
5. Vehicles driven with idle speed or low speed over a long period of time or frequently accelerated or decelerated, such as training car of driving training class.
4
Maintenance period-Table on maintenance period at normal conditions
Table on maintenance period at normal conditions
Maintenance content:
I: Inspection and correction or replacement if necessary R: Replacement
Maintenance period
(Odometer readings or
operating months subject to
the first coming)
Engine basic elements
1. V alve clearance*
1
2. Drive belt
3. Engine oil (APLSJ,SL or ILSAC) *
4. Oil filter*
5. Cooling and heating system hose and joint*3*
6. Engine coolant*5*
2
6
7. CVVT oil duct filter screen
8. Exhaust pipe and fixed mount
Ignition system
9. Spark plug
10. Battery
Fuel and exhaust gas control system
11. Fuel filter
mileage
reading
1000km
7. 5 1 5 22.5 30 37.5 45 53.5 60 67.5 7 5 82.5 90
2
4
months
12. Air filter core
Connecting conditions of fuel tank cover,
13.
fuel pipe and fuel evaporation control valve*
7
14. Activated carbon canister
Chassis and vehicle body
15. Brake pedal and parking brake
16. Brake pad and brake disc
17. Brake fluid
18. Brake Pipe and hose
19. Power steering oil
20. Steering wheel, steering linkage and gear box oil
21. Drive shaft dust cover
22. Ball joint and dust cap
23. Transmission oil
24. Front and rear suspension
25. Tire and tire pressure
26. All light, horn, wiper and washer
27. Air conditioner cleaning filter screen
Air conditioning system/ secondary refrigerant
5
Maintenance period-Table on maintenance period at normal conditions
Note: *1 Indicating that check valve noise and engine vibration condition, and adjust them if necessary.
*2
It is suggested that see operating modes on page 116 of operating instruction to perform.
*3
Indicating that check once every 20000km or 12 moths after 80000km or 48 months.
*4
Indicating that check water tank and condenser are blocked by leaves, dust or insects, and clean
hose connections.
*5
Replace at initial 60000km, and replace every 30000km in future.
*6
Only “Geely genuine ultra-long engine coolant” or equivalent high-quality ethylene glycol engine
coolant without silicate, amines, nitrite, borate and with long-life compound organic acid technology
are allowed to use, and coolant should be repeated several times until it is filled up.
*7
Indicating that check once every 20000km or 12 moths after 80000km or 48 months.
6
Maintenance period-Table on maintenance period at severe conditions
Table on maintenance period at severe conditions
According to the driving conditions listed below, maintenance should be performed to the items that
should be maintained more frequently (for other items not listed, please see Table on maintenance
period at normal conditions)
A-1: Driving on rugged, muddy or melting snow road
Inspection of brake pad and brake disc Every 5,000 km or 3 moths
Inspection of brake pipeline and hose Every 10,000 km or 6 moths
Inspection of ball joint and dust cover Every 10,000 km or 6 moths
Inspection of drive shaft dust cover Every 10,000 km or 12 moths
Inspection of the steering wheel, steering linkage and gear box oil
Check of front and rear suspension Every 10,000 km or 6 moths
A-2: Driving on dusty road
Replacement of engine oil Every 5,000 km or 6 moths
Replacement of engine oil filter Every 5,000 km or 6 moths
Inspection or replacement of air filter core I: Every 2,500 km or 3 moths
Inspection of brake block and brake disc Every 5,000 km or 3 moths
Replacement of air conditioner cleaning filter screen Every 15,000 km
B-1: Towing tail vehicle, equipped with camp frame or top storage racks
Every 5,000 km or 3 moths
R: Every 10,000 km or 6 moths
Replacement of engine oil Every 5,000 km or 6 moths
Replacement of engine oil filter Every 5,000 km or 6 moths
Inspection of brake pad and brake disc Every 5,000 km or 3 moths
Inspection or replacement of transmission oil Every 60,000 km or 24 moths
Inspection of front and rear suspension Every 10,000 km or 6 moths
Screwing down the bolts and nuts of the chassis and vehicle body
Every 10,000 km or 6 moths
B-2: Repeated on short-distance driving within 8 km and the temperature is below 0 °C
Replacement of engine oil Every 5,000 km or 6 moths
Replacement of engine oil filter Every 5,000 km or 6 moths
Vehicles driven for long distance under idle speed or low speed over a long period of time, such as police car, taxi or delive rytruck
B-3:
.
Replacement of engine oil Every 5,000 km or 6 moths
Replacement of engine oil filter Every 5,000 km or 6 moths
Inspection of PCV valve and pipelines Every 5,000 km or 6 moths
Inspection of brake block and brake disc Every 5,000 km or 3 moths
Continuously driving at high speed for more than 2 hours frequently (With 80% of max. vehicle speed)
B-4:
Replacement of transmission oil Every 40,000 km or 12 moths
Vehicles driven with idle speed or low speed over a long period of time or frequently accelerated or
B-5:
decelerated, such as student car of driving training class.
Replacement of engine oil Every 3,000 km or 3 moths
Replacement of engine oil filter Every 3,000 km or 3 moths
Inspection of PCV valve and pipelines Every 3,000 km or 3 moths
7
Engine control system·- EFI system
Engine control system
EFI system
On-vehicle inspection
1. Inspection of the voltage of power steering oil pres-
sure sensor
Measure the voltage between PS terminal and E2 terminal
with ohmmeter
Conditions Voltage (V)
Not turning steering wheel with
engine at idle speed
Turning steering wheel with
engine at idle speed
2. Inspection of stepping motor
(a) With engine running at idle speed, pull out the connection harness of stepping motor, and the change
of engine rotating speed indicates that the stepping motor operates normally.
(b)Pull out the connection harness of stepping motor, and measure the terminal current with universal
meter. When engine is running, there being impulse current output at the terminal indicates that there
is no trouble with ECU and stepping motor control system, and if idling is not stable at the moment
and deviates greatly from specified value, the stepping motor should be replaced. If there is no
impulse current output at the terminal, turn on air conditioner to test again, and still no impulse
current output indicates that there is trouble with ECU and stepping motor control system circuit.
(c) Check the malfunction of stepping motor circuit with diagnostic instrument.
0-1.5
8
Engine control system·- EFI system
Inspection
1. VVT control solenoid valve assembly (4G18-1006200)
(a)Resistance inspection
(1)Measure the resistance between terminals with ohmmeter
Resistance:
(b)Operation inspection
Connect battery positive (+) wire to No.1 terminal and negative (-) wire to No. 2 terminal, and check
valve operation.
Note: ensure that the valve is not stuck.
Hint: if there are foreign matters in the valve, the valve could not be closed tightly and will
thus result in slight pressure being lifted toward higher direction.
2. Throttle body components (4G18-1001240)
(a)Inspection of throttle body
(1)Throttle valve shaft should not swing.
(2)All channels should not be blocked.
(3)Throttle valve plate should rotate flexibly and act smoothly.
(4) When the throttle is at closed position, there should be no clearance between throttle stop bolts and
throttle lever.
Note: it is not allowed to adjust the throttle stop bolts.
3. Throttle position sensor (4G18-3600080)
(a)Resistance inspection
(1)Remove the wiring harness connectors of throttle posi-
tion sensor.
(2)Measure the resistance between 1# pin and 2# pin with
ohmmeter, resistance value: .
(3)Connect 2 terminals respectively to 1# pin and 3# pin,
and turn the throttle, the resistance value varies linearly
with the opening of throttle, but 2# pin and 3# pin are
contrary to this.
Note: pay attention whether there is great jump with
resistance value when observing resistance change.
9
Engine control system·- EFI system
4. Knock sensor (4G18-3600020)
Measuring method:
(Removing the joint) place digital universal meter at ohm gear,
and connect 2 terminals respectively to 1# pin and 2# pin, and
the resistance under normal temperature should be more than
1M . Place digital universal meter at millivolt gear, and knock
around knock sensor with a hand hammer, there should be voltage
signal output at the moment.
1 Vibration block
2 Housing
3 Piezoelectric ceramics
4 Contact
5 Electric connection
5. Water temperature sensor (4G18-3600040)
This sensor applies sealing NTC thermal resistor in temperature sensor, and resistance value varies with
ambient temperature, thus slight change of outside temperature could be measured. Measuring its output resistance could reflect the temperature of contact media. Signals from A and C are sent to ECU,
and Signals from B and earth are sent to instrument.
Operating principle (Fig. 1):
Fig. 1
Note: A, B and C represent 3 pins of sensor, and see pin root for the mark.
10
Engine control system·- EFI system
Use digital universal meter to measure:
Resistance-temperature characteristics of temperature sensor
Temperature range(
Resistance at A and C
Resistance at B
6. Intake air temperature sensor (4G18-3600090)
Intake air temperature sensor is a resistor with negative temperature coefficient (NTC), resistance varies with intake air
temperature, and this sensor sends a voltage indicating change
of intake air temperature to controller.
Simple measuring method:
(Removing the joint) place digital universal meter at ohm gear,
and connect 2 terminals respectively to 1# pin and 2# pin of
sensor, and rated resistance at 5%, and
other corresponding resistance values could be measured according to the characteristic curve in above drawing. Analog
method could also be applied in measurement. Use an electric blower to blow air into the sensor (pay attention not to
keep them too near), and observe the change of resistance,
which should decrease at the moment.
7. Stepping motor (4G18-3600070)
Schematic diagram and pins
Characteristic curve of
temperature sensor
Characteristic curve of intake air
temperature sensor NTC resistor
Stepping motor of idle speed actuator
11
Engine control system·- EFI system
Electrical
Pins: Pin A is connected to ECU No. 65 pin
Pin B is connected to ECU No. 66 pin
Pin C is connected to ECU No. 67 pin
Pin D is connected to ECU No. 64 pin
wiring
diagram
on stepping motor
of idle
speed
actuator
Maintenance precautions:
1. It is not allowed to apply any force at axial direction with the purpose of pressing into or pulling out the
axle;
2. Before idle speed regulator with stepping motor is mounted into throttle body, its shaft must be at fully
retractive position;
3. Pay attention to clean and maintain bypass air passage frequently;
4. After removing battery or ECU, pay attention to self-teach stepping motor in time.
Self-teach method of M7 system: turn on ignition switch but not start engine immediately, and start it
after 5 seconds. If engine idle speed is found bad at the moment, it is
necessary to repeat the above steps.
Simple measuring method: (removing the joint) place digital universal meter at ohm gear, and connect
2 terminals respectively to Ad pin and BC pin of regulator, and rated resistance at
12
Engine control system·- Throttle body assembly
Throttle body assembly
Removing, installing and disassembling, assembling
1. Discharge coolant (see Page 73).
2. Remove air cleaner hose assembly.
3. Remove engine plastic hood components [4G18-1000310].
4. Remove throttle pull cable assembly.
5. remove throttle body assembly [4G18-1008240].
(a ) Uncouple throttle position sensor joint and stepping motor joint.
(b)Disassemble ventilation hose.
(c) Remove 2 bolts and throttle control pull cable bracket.
(d)Remove 2 preheating water inlet and outlet hoses of throttle.
(e)Remove 2 bolts and 2 nuts, and remove throttle body from intake air manifold.
6. Remove stepping motor of throttle body [4G18-3600070].
Remove 3 screws and stepping motor.
7. Install stepping motor of throttle body.
Install stepping motor.
8. Install throttle body assembly.
(a)Install new seal gasket on intake air manifold.
(b)Install throttle body, 2 bolts and 2 nuts.
Torque:
9. Refill coolant.
10.Check there is leakage with coolant.
13
Fuel-Fuel system
Fuel
Fuel system
Precautions
1. Before repairing fuel system, uncouple battery negative (-) wire at first.
2. When operating on fuel system, do not smoke or repair near fire area.
3. Do not let gasoline come into contact with rubber or leather parts.
4. Take measures to prevent gasoline leaking.
(a)Uncouple electric fuel pump joint.
(b)Start engine and turn ignition switch to LOCK position
after the engine flames out.
(c) Uncouple battery negative (-) wire.
(d)Couple electric fuel pump joint.
5. Fuel system
(a ) There will be a great amount of gasoline flowing out
when disassembling high-pressure fuel pipe,
therefore, it is required to observe the following
procedures.
(1 ) T ake measures to prevent gasoline leaking.
(2 ) Disassemble fuel pipe.
(3 ) Completely discharge the oil in fuel pipe.
(4 ) Cover the fuel pipe with plastic bag to avoid pipe
damage and foreign matters entering.
(5 ) Place a container under the joint.
(b)When removing and installing injection nozzle, always
observe the following precautions.
14
Fuel-Fuel system
(1)It is not allowed to use o-ring repeatedly.
(2)When installing o-ring, always be careful to avoid dam-
aging o-ring.
(3) Before installing, coat o-ring with spindle oil or gasoline.
It is not allowed to coat with engine oil, gear oil or
brake fluid.
(c) As shown in the diagram, install injection nozzle to oil feed
pipe and cylinder head.
Before installing, ensure that spindle oil and gasoline are
coated at the contact position between o-ring and oil feed
pipe.
injection nozzle
o-ring
oil feed pipe
Correct
Wrong
oil feed pipe
o-ring
washer
(d) When disassembling oil feed pipe, always observe the fol-
lowing precautions.
(1)Remove oil feed pipe clips.
(2)Remove oil feed hose.
(3)Cover oil inlet of fuel distribution pipe with plastic bag
to avoid foreign materials entering the fuel distribution
pipe.
6. Inspection of fuel leakage
(1)After completing maintenance, check there is leakage with the whole fuel system.
(2)Connect hand-held tester to diagnostic joint.
(3)Turn ignition switch to ON and turn main switch of hand-held tester to ON.
(4)Switch hand-held tester to function test state.
(5)For further details, please see hand-held tester operating instruction.
(6)If there is no hand-held tester, connect battery anode and cathode to electric fuel pump joint.
(7)Ensure that there is no leakage with all parts of electric fuel pump.
(8)Turn ignition switch to LOCK.
(9)Disassemble hand-held tester from diagnostic interface joint.
15
Fuel-Fuel system
On-vehicle inspection
1. Inspection of fuel pump function
(a)Connect hand-held tester to diagnostic joint.
(b)Turn ignition switch to ON and turn main switch of hand-
held tester to ON.
Note: do not start the engine.
(c) Switch hand-held tester to function test state.
(d)For further details, please see hand-held tester operating
instruction.
(e)If there is no hand-held tester, connect battery positive (+)
wire to P+ terminal and negative (-) wire to P- terminal.
2. Inspection of fuel pressure
(a)Preparation of inspection.
Purchase new fuel hose and take out fuel pipe joint.
(b)Take measures to prevent gasoline leaking.
(c) Disassemble fuel pipe clamp at fuel pipe joint of fuel rail
component.
(d) Disassemble fuel hose from fuel pipe of fuel rail component.
(e)As shown in the diagram, install special tool (pressure
gauge) with special tool and fuel pipe joint.
(f) Check there is fuel leakage.
(g)Start engine.
(h)Measure the fuel pressure at idle speed state.
Fuel pressure: 390~400Pa
(i) Take measures again to prevent gasoline leaking.
(j) After measuring the fuel pressure, remove special tool.
(k) Connect back fuel hose.
(l) Install fuel hose fixing clip to fuel pipe joint.
(m)Check there is fuel leakage.
16
Special
tool
Fuel-Fuel system
Inspection
1. Fuel injector components [4G18-1112120]
(a)Check injection nozzle resistance.
(1) Measure the resistance between terminals with
ohmmeter.
Resistance:
Hint: if resistance is not within specification, replace injection nozzle.
(b)Injection nozzle test.
Warning: there should be no sparks during testing.
(1 ) Purchase new fuel pipe and take out fuel hose joint.
(2 ) Install special tool and fuel hose joint to fuel pipe.
Note: Only after performing precautions could the
connection operation of fuel hose joint (fastjoint mode) be allowed to perform.
Warning: before connecting fuel pipe joint (fast-joint
mode), please read precautions carefully
(3)Install o-ring to injection nozzle.
(4) Connect special tool (joint and hose) to injection nozzle,
and hold down the injection nozzle to prevent fuel splash.
(5 ) Place injection nozzle into measuring cup.
Hint: install proper hose on injection nozzle to prevent
gasoline injecting out of the cup.
(6)Connect special tool to injection nozzle joint.
(7)Connect special tool to battery for 15 seconds, and measure the injection volume with measuring
cup, each injection nozzle should be test for 2~3 times.
Injection volume:
Engine Injection volume Uneven volume between
each injection nozzle
Every 15 seconds
Hint: if injection volume is not within specification, replace
injection nozzle.
or less
Special
tool
o-ring
Special
tool
17
Fuel-Injection nozzle assembly
Injection nozzle assembly
Replacement
1. Take measures to prevent gasoline leaking.
2. Remove engine plastic hood components.
3. Uncouple engine wire harness [4G18-3724100].
(a)Remove injection nozzle joint.
(b)Remove exhaust gas hose.
4. Remove fuel pipe assembly
(a)Loosen oil feed hose clips.
(b)Pull oil feed hose away from fuse distribution pipe.
Notes:
z
Check there is dirt on fuel pipe and its joint before removing, and clean it off in the case of dirt.
z
It is only allowed to remove with hands.
z
Check there are foreign matters with the removed fuel pipe seal surface, and clean them off in the
case of foreign matters.
z
Cover the fuel pipe with plastic bag to avoid pipe damage and foreign matters entering.
5. Remove fuel pipe assembly
Remove 2 bolts and oil feed pipe (together with injection nozzle).
6. Remove injection nozzle components.
Pull out 4 injection nozzles from oil feed pipe.
7. Install injection nozzle components.
Coat a thin layer of gasoline on o-ring and rotate left and right to push injection nozzle into oil feed pipe.
Notes:
z Be careful not to rotate o-ring.
z Check injection nozzle could rotate smoothly after it is installed, and if not replace with new o-ring.
8. Install fuel hose assembly.
Install fuel hose to oil feed pipe.
Notes:
z Check there are damage or foreign matters in the binding site of fuel pipe.
z After installing, pull the fuel pump with hands to check the fuel pipe is bound firmly with joint.
18
Fuel-Injection nozzle assembly
9. Install fuel rail component [4G18-1112110].
(a)Check injection nozzle o-ring and replace if there is damage.
(b)Install isolator on cylinder head.
(c) Install fuel rail component together with injection nozzle.
Torque:
(d ) Install fuel pipe fixing clip.
Torque: m
10. Check the function of electric fuel pump and check there is fuel leakage.
19
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