Chery QQ Service manual

CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
CONTENT
1. NOTICE TO THE EFI SYSTEM SERVICE .........................................................................................3
1.1. GENERAL SERVICE ...........................................................................................................................3
1.2. NOTICE DURING THE SERVICE.............................................................................................3
1.3. SERVICE TOOLS .........................................................................................................................4
1.4. EXPLANATIONS OF THE ABBREVIATION IN THE MANUAL .........................................7
2. ME7.9.7 SYSTEM INTRODUCTION....................................................................................................7
2.1. SYSTEM BASIC PRINCIPLE .....................................................................................................7
2.1.1 SYSTEM GENERAL INTRODUCTION: ME7.9.7-MOTRONIC EMS .......................7
2.2. CONTROL SIGNAL: ME7.9.7 SYSTEM INPUT/OUTPUT SIGNAL ....................................9
2.3. INTRODUCTION OF SYSTEM MALFUNCTION DIAGNOSIS FUNCTION...................10
2.3.1. MALFUNCTION INFORMATION RECORD .............................................................10
2.3.2, CONTROL STRATEGY OF FAILURE LAMP ............................................................10
2.3.3, DIAGNOSIS METER CONNECTION ..........................................................................11
2.3.4, READ MALFUNCTION INFORMATION BY WINK CODE ....................................11
3. WORKING PRINCIPLE AND CHARACTER OF EFI SYSTEM ELEMENT...............................11
3.1 ELECTRONIC CONTROL UNIT - ECU ..................................................................................11
3.2 COOLANT TEMPERATURE SENSOR....................................................................................15
3.3 KNOCK SENSOR ........................................................................................................................16
3.4 OXYGEN SENSOR ......................................................................................................................17
3.5 SPEED SENSOR (CRANKCASE POSITIONING SENSOR).................................................18
3.6 PHASE SENSOR (CAM SHAFT POSITIONING SENSOR) ..................................................20
3.7 ELECTRIC FUEL PUMP............................................................................................................21
3.8 ELECTROMAGNETIC INJECTOR .........................................................................................22
3.9 AIR FLOW SENSOR ...................................................................................................................23
3.10 DOUBLE SPARK IGNITION COIL ........................................................................................24
3.11 CARBON CANISTER SOLENOID VALVE............................................................................26
3.12 FUEL PRESSURE REGULATOR............................................................................................27
3.13 ELECTRONIC THROTTLE VALVE AND ACCELERATOR..............................................28
3.14 FAN CONTROL .........................................................................................................................29
3.15 AIR CONDITIONER CONTROL ............................................................................................30
4 ME7 SYSTEM TEST AND REPAIR ACCORDING TO TDC ...........................................................31
4.1 ENGINE DTC (DIAGNOSTIC TROUBLE CODE) LIST .......................................................32
4.2 DIAGNOSIS FLOW WHEN THERE IS DIFFERENT DTC...................................................33
5. TYPICAL FAILURE AND ITS DIAGNOSIS FLOW.........................................................................56
5.1 EXPLANATION ...........................................................................................................................56
5.2 TYPICAL FAILURE DIAGNOSIS FLOW................................................................................57
1. The engine does not rotate or rotate slowly when it is started ............................................57
2. The engine can draw rotating but can not start successfully when it is started. ...............58
3. It is hard to start the heating car. ..........................................................................................59
4. It’s hard to start the cold car..................................................................................................60
5. Normal engine speed but hard to start at any time..............................................................61
6. Regular starts but the idle speed is not steady at any time..................................................62
7. Regular starts but the idle speed is not steady during engine heating. ..............................63
1
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
8. Regular starts but idle speed is not steady after the engine heating...................................64
9. Regular starts but idle speed is not steady or dying out when there is partial loading.....65
10. Regular starts with high idle speed......................................................................................66
11. Low engine speed or dying out exists when it is accelerated. ............................................67
12. React slowly when it is accelerated......................................................................................68
13. The performance is poor when it is accelerated. ................................................................69
2
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
EFI SERVICE MANUAL
A21 car is equipped with ME7.9.7 EFI system which developed by UAES. This manual will
introduce the general service and the operational principle and character of sensor elements
of EFI system in detail. At last there will be some diagnostic method and flow for the typical
problems.
1. NOTICE TO THE EFI SYSTEM SERVICE
1.1. GENERAL SERVICE
●
Digital multimeter is the only permitted instrument to inspect the EFI system.
●
Please use the quality spare parts for service, otherwise can not make sure the EFI work
properly.
●
Please use lead free gasoline during service.
●
Please be obedient to the service and diagnose flow.
●
It is forbidden to disassembly the EFI part during service.
●
It should be careful to take the electronic component (ECU, sensor, etc.) for preventing
from dropping to the ground.
●
Please protect the environment, deal with the rejectamenta carefully and effectively.
1.2. NOTICE DURING THE SERVICE
●
Do not disassemble any part or inserts of the EFI system from its original position at
random to prevent from damaging parts or that moisture and dirt oil come into the inserts.
And that will keep the system from working properly.
●
Please leave the ignition switch at shut off position when you disconnect and connect the
inserts otherwise it will damage the electric element.
●
It is must keep the ECU under 80★, when you do the work of hot status simulation and
other works which may cause the temperature increase.
●
The supplying oil pressure is high(around 300kPa), all the fuel pipe is made up of anti
high pressure pipe. There is high pressure in fuel pipe even the engine does not run. So do
3
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
not disassemble the fuel pump at random when carrying out service for fuel system.
Before disassemble the fuel pipe please carry out discharge pressure procedure. The
method is as below: Disassemble the fuel pump relay (or disconnect the connector plug),
start engine at its idle running and it dies out by itself. After the service supply fuel to
engine fuel pipe at first, the method is: turn ignition key to ON position and wait a while,
repeat this four or five times. Disassembly of fuel pipe and fuel filter should be carried
out at a place with good ventilation and done by professional maintainer.
●
Do not give electricity to fuel pump when the electrical pump is taken out of fuel tank in
order to prevent from electrical spark and cause fire.
●
Fuel pump is not allowed to carry out running test at dry or water situation, which will
decrease its life. And do not exchange anode and cathode of the pump.
●
Carry out jump spark inspection at necessary time when inspect the ignition system, and
the time to inspect must be short. Do not open the throttle valve to prevent a lot of
unburned gasoline entering exhaust pipe and damage the 3-way catalytic converter ( It is
better to take off the corresponding injector insert during the jump spark testing)
●
The adjustment of idle speed is done completely by EFI without manual work. The
accelerator stop screw of throttle valve has been fixed well in advance by manufacturer so
that it is not allowed to change it original position by the customer.
●
Do not exchange the anode and cathode of the accumulator to prevent damaging the
electronic component. This system uses cathode ground.
●
Do not disassemble accumulator cable when the engine is running.
●
Disassemble the cable of accumulator anode and cathode, and ECU when there is welding
work on the car.
●
Do not inspect the input and output signal of component by impaling the lead surface.
1.3. SERVICE TOOLS
4
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
Tool name:
EFI system diagnostic tester
Function:
Read/clear the breakdown code in EFI and
inspect data, test part motion.
Tool name:
Ignition timing lamp
Function:
Inspect engine ignition timing.
Tool name:
Digital multimeter
Function:
Inspect the character parameter of voltage,
current, resistance.
Tool name:
Fuel pressure gauge
Function:
Inspect the pressure in fuel system, judge the
status of fuel pump and fuel pressure
regulator.
5
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
Tool name:
Pressure gauge for cylinder
Function:
Inspect the pressure in every cylinder.
Tool name:
Fuel injector cleaner and analyzer
function:
Analyze and clean the injector.
Tool name:
Vacuum meter
function:
Inspect the pressure of intake manifold
6
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
1.4. EXPLANATIONS OF THE ABBREVIATION IN THE MANUAL
DG Speed Sensor
DVE Electronic Throttle Valve
DR Fuel Pressure Regulator
FPM Accelerator Pedal
ECU Electronic Control Unit (Computer)
EKP Fuel Pump
EMS Engine Management System
EV Fuel Injector
LSH Heating Oxygen Sensor
KS Knock Sensor
KSZ Fuel Distributing Pipe Assembly
KVS Fuel Distributing Pipe
ROV Ignition System with Distributor
PG Phase Sensor
RUV Ignition System without Distributor
TEE Oil Pump Bracket Assembly
TF-W Coolant Temperature Sensor
TEV Purge Canister Control Valve
HFM Air Flow Sensor
ZSK Ignition Coil
2. ME7.9.7 SYSTEM INTRODUCTION
2.1. SYSTEM BASIC PRINCIPLE
2.1.1 SYSTEM GENERAL INTRODUCTION: ME7.9.7-MOTRONIC EMS
Engine management system (EMS)is composed mainly by three components: sensor, ECU,
and actuator. And these three parts control the intake air quantity, fuel injection quantity and
ignition advance angle. The basic frame is shown in chart 2.1.
Diagnose
Diagnose
Sensor
ECU
Actuator
Engine
Chart 2.1 compose of engine electronic control system
In engine electronic control system, the sensor is the input part used for measuring all kinds
of physics signal (temperature and pressure etc.) and change them to corresponding electronic
signal; the function of ECU is accepting the signal and calculate it according to the
programmed program and generate corresponding output signal to power drive circuit; and
the power drive circuit makes the engine running according to established strategy by driving
every actuator to do different action; at the same time the malfunction diagnosis system of
ECU monitors all parts or control function, and if a malfunction is detected and confirmed it
will memorize malfunction code, transferring “ limping home” function, and when the
malfunction is deleted, the normal value will be desterilized.
7
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
Engine electronic control system schematic of ME7.9.7
chart 2.2
Phase Sensor
Ignition Coil
Canister Control Valve
Fuel Distribution Pipe Assembly
Phase Sensor
Air intake temperature sensor
Oxygen Sensor
Front Catalytic Converter
Knock Sensor
Throttle Valve
Temperature Sensor
Speed Sensor
Oxygen Sensor
Main Catalytic Converter
Accelerator Pedal
Trouble Light
Diagnosis Access
Electric Fuel Pump
Anti Theft
Electronic Accelerator
Onboard Diagnosis (Europe)
Returnless Fuel Supply System
UAES Parts
Chart 2.2
The basic component of ME7.9.7 engine electronic control system:
Electronic Control Unit(ECU)
Accelerator
Electronic Throttle Valve
Air Quality Flow Meter
Injector
Electronic Fuel Pump
Coolant temperature sensor
Fuel Pressure Regulator
Throttle position sensor
Fuel Pump Bracket
Camshaft Position Sensor Fuel Distributing Pipe
Speed Sensor
Oxygen Sensor
Knock Sensor
Ignition Coil
Canister Control Valve
8
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
ME7.9.7 engine management system is an electronic gasoline control system, and it can
provide lots of control characters about operator and vehicle or equipment. The system adopts
a combination method of open loop and closed loop (feed back) control to provide all kinds
of control signal to engine. The main function of the system:
1) The basic functions of applying physics mode engine
 For the system structure based on torque, the airflow sensor will confirm the loading
of cylinder and improve the mixture air control function closed loop control.
 Fuel injects ignition timing on the order of cylinder order, including knock control
and emission control functions.
 3 way catalytic convert heating
 Canister control
 Idle speed control
 Limping home
2.2. CONTROL SIGNAL: ME7.9.7 SYSTEM INPUT/OUTPUT SIGNAL
The main sensor input signal of ECU of ME7 system:

Air flow signal

Throttle valve corner signal

Coolant temperature signal

Engine speed signal

Phase signal

Knock sensor signal

Oxygen sensor signal

Speed signal

Air conditioner pressure signal
The above information after the transaction of ECU, there will generate required actuator
control signal, and this signal will be magnified in output driving circuit and was transferred
to its corresponding actuator. The signals include below information:

Injection timing and injection continuous time

Fuel pump relay

Opening degree of canister control valve

Ignition coil closing angle and ignition angle of advance

Air conditioner compressor relay
9
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL

ENGINE EFI SYSTEM
Cooling fan relay
2.3. INTRODUCTION OF SYSTEM MALFUNCTION DIAGNOSIS FUNCTION
2.3.1. MALFUNCTION INFORMATION RECORD
The ECU monitors sensor, actuator, related circuit, malfunction indicator and accumulator
voltage etc., and EUC itself continuously. At the same time the ECU inspect the reliability
test on sensor signal output, actuator driving signal and internal signal (e.g.: closed loop
control, coolant temperature, knock control, idle engine speed and accumulator voltage etc.).
ECU will set the malfunction record on RAM malfunction memory immediately once the
malfunction or the unlikelihood signal is detected. The malfunction information is recorded
by malfunction code and displayed according to its appeared order, dividing malfunction into
“steady malfunction”and “contingency malfunction”(for example the malfunction is caused
by short time cable braking or bad contact of the inserts) according to its appeared frequency.
Function Diagnosis
Function Diagnosis
ECU
Data Collection
Control Order
Actuator
Sensor
Engine
Chart 2.4
EFI System Malfunction Diagnosis Principle Chart
2.3.2, CONTROL STRATEGY OF FAILURE LAMP
When there is no trouble:
★ The failure lamp is lighting and die out within 4 seconds after the ignition switch is ON
★ Starting within 4 seconds, the failure lamp dies when the engine speed signal is found;
★ The failure lamp winking at 2HZ frequency when the K cable contact to ground more
than 2.5 seconds.
When there is a trouble:
★ The failure lamp always on light when the ignition switch is ON;
★ Start and die out when the engine speed signal is detected; if the failure lamp was defined
as lighting mode, it will always on light after reach its confirmed conditions;
10
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
★ Output winking code that is P-CODE value after the K cable contact with the ground
more than 2.5 seconds. For example: the winking mode of P0203 is: wink 10 times
continuously –intermission –wink 2 times continuously –intermission - wink 10 times
continuously –intermission –wink 3 times continuously.
2.3.3, DIAGNOSIS METER CONNECTION
This system adopts “K” cable communication protocol and use ISO 9141-2 standard
diagnosis joint, please see chart 2.5. This standard diagnosis joint is connected to engine
harness fixed. The pins of No.4, 7 and 16 on the standard diagnosis joint are used for EMS.
The pin of No. 4 on standard diagnosis joint is ground wire; Pin of No.7 is connecting to
No.71 pin of ECU, which is engine data “K”cable; No.16 pin is connecting to accumulator
anode.
Chart 2.5
ISO9141-2 Standard Diagnosis Joint
2.3.4, READ MALFUNCTION INFORMATION BY WINK CODE
Switch on ignition switch and use engine data K cable(that is standard diagnosis joint 7#)to
ground(use one lead connect pin of diagnosis joint 4# and pin of 7#) more than 2.5 seconds,
if there are malfunction code in ECU malfunction memorizer, the malfunction light wink
code of engine now is P-CODE value. Such as: P0203 winking type is: wink 10 times
continuously – intermission – wink 2 times continuously – intermission - wink 10 times
continuously –intermission –wink 3 times continuously.
3. WORKING PRINCIPLE AND CHARACTER OF EFI SYSTEM ELEMENT
3.1 ELECTRONIC CONTROL UNIT - ECU
1)Exterior drawing
2)Purpose: ECU accepts and deals with engine status signals inputted from sensors and
drives the actuators to work. Making engine working as the established program, insure
power good, fuel consuming effectively and low emission.
3)Mounting position: Passenger compartment
4)Functions

Multipoint injection in order

Control ignition
11
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL

Idle speed control

Knock control

Provide sensor power: 5V/100mA

Closed loop control

Control carbon canister solenoid valve

Air conditioner switch

engine malfunction indicator

Fuel fix quantity modification

Engine speed signal output(TN signal)

Input of speed signal

Malfunction self diagnosis

Accept engine loading signal etc.
ENGINE EFI SYSTEM
5)Definition of pin
Pin
point
Pin
Connection point
1
Oxygen sensor heating
42
Air intake temperature
2
Ignition coil 2
43
3
Ignition
44
Non persistent power
4
Oxygen sensor heating
45
Non persistent power
5
Ignition coil 1
46
Canister valve
6
Injection nozzle 4(cylinder No. 2)
47
Injection nozzle 3(cylinder
No.4)
7
Injection nozzle 2(cylinder No.3)
48
8
Engine speed
49
9
Coolant temperature
50
Fan control 1
10
Fuel consuming
51
electronically 2
11
Trouble light
52
12
Persistent power
53
electronically 1
13
Ignition coil
54
14
Main relay
55
Electronic throttle valve
position
Downstream oxygen sensor
15
Engine speed sensor A
56
12
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
16
Accelerator position sensor
57
17
Sensor 1
58
Brake switch
18
Upstream oxygen sensor
59
Speed signal
19
Knock sensor A
60
Medium switch
20
Knock sensor B
61
Power 1
21
Brake light
62
CAN communication
63
Non persistent power
64
68
Electronic throttle valve
control
Electronic throttle valve
control
Electronic throttle valve
control
Electronic throttle valve
control
Cooling fan
28
69
Air conditioner relay
29
70
Fuel pump relay
30
71
Diagnosis K cable
22
23
Accelerating sensor
24
65
25
66
26
67
27
Injection nozzle 1(cylinder No.1)
31
EOBD inspection light
72
32
5V power supply 2
73
Anti theft device
33
5V power supply 1
74
Clutch switch
34
Engine speed sensor B
75
Air conditioner switch
35
Sensor 3
76
Power steering switch
36
Sensor 2
77
Headlamp switch
37
Air flow sensor
78
Sensor
38
Electronic throttle valve control
79
Phase sensor
39
Engine coolant temperature sensor
80
Power 2
40
Accelerator position sensor
81
CAN communication
41
Air conditioner pressure
6)Normal working voltage: 9--16V
Normal working temperature: -40--70★
7)Malfunction phenomena and diagnosis method
13
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM

Malfunction phenomena: idle speed not stable, accelerating not good, can not start, idle
speed is too high, exhaust gas exceed standard, difficult to start, air conditioner failure,
injector control failure, engine dies out etc..

Reasons for general malfunction: 1, ECU component was burnt down caused by
overloading of the exterior connected electrical device; 2, circuit board was rust and
erode caused by water in ECU.

Service notice: 1, do not disassemble ECU at random during the service; 2, disassemble
accumulator 5 minutes prior to disassemble ECU; 3, keep the disassembled ECU
carefully; 4, prohibit to connect any circuit to ECU connecting line.

Simple measurement method:
1、(connect ECU joint)Read engine malfunction record by K line.
2、(disassemble ECU joint)Check the connecting line of ECU, and pay more attention to
check the power supply and ground line of ECU;
3、Check the working conditions of exterior sensor and its output signal and its circuit;
4、Check actuator and its circuit;
5、At last change ECU and have a test.
14
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
3.2 COOLANT TEMPERATURE SENSOR
1)exterior drawing and pin
This sensor has two exchangeable pins.
2)Purpose: The sensor provide the coolant
temperature signal to ECU for ignition timing
and modifying fuel injection of starting, idle
speed and normal working.
3)Installation position
Coolant temperature sensor was installed on the
water outlet of cylinder block and the copper
heat conducted socket was inserted into water.
There are thread on the socket, and screw in
coolant temperature sensor onto the threaded
hole on cylinder block by the hexagon head of
the socket. The maximum moment is 20Nm.
Chart 3-2 Outlook drawing of the
coolant temperature sensor
4)Working principle
This sensor is a thermistor of negative
temperature coefficient (NTC), and its value
will decrease with the coolant temperature
increasing but the changes are not linearity.
There are several different resistance values at
different temperature:
T(★)
Resistance value(kΩ)
-10
8.62----10.28
20
2.37----2.63
80
0.299----0.345
Coolant Temperature Sensor
5)Normal working temperature: -30----130 ★
Chart 3-3 Circuit diagram of coolant
temperature sensor
Normal working voltage: 5V DC
6)Malfunction phenomenon and diagnosis
method

Malfunction phenomenon: Difficult to
start.

Reasons of malfunction: man made

Simple measurement method:
15
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
(Disassemble the joint)leave the digital
multimeter at ohm shift and contact the No.1
and No. 2 pin of the sensor by its two meter
pens. When it is 20★Rated the resistance is
2.5kΩ±5%. The other temperature can get
reference from above chart.
3.3 KNOCK SENSOR
1)Exterior drawing and pin
Chart 3-4
This sensor has three pins; No.1 and No.2 pin
connect with ECU, and No. 3 pin connects with
shield.
Exterior drawing of knock
sensor
2)Purpose: This sensor provides engine
knock information to ECU, and carries
out knock control.
3)Installation position
There is a hole in the middle of knock sensor,
and the sensor is assembled on the block
between No.2 and No.3 cylinder head. For the
aluminum alloy block, using long bolt with
30mm long; for the casting iron, using 25mm
long bolt. And the moment is 20±5Nm.
4)Working principle
Knock sensor is a kind of vibrating acceleration
sensor and is assembled on cylinder block. The
sense organ of the sensor is a piezoelectric
element. The vibration of cylinder block is
transferred to piezoelectric crystal by mass
block inside of sensor. The piezoelectricity
crystalloid gets pressure from mass block
vibration, producing voltage on two polar and
transferring vibration signals to voltage signal
and output it. Because the frequency of knock
vibration signal is much higher than the normal
engine vibration signal, the ECU can separate
the signal into knock signal and non knock
signal.
Knock sensor
Chart 3-5 circuit diagram of knock
sensor
5)Normal working temperature: -40--130★
6)Malfunction phenomenon and diagnosis
method
16
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM

Malfunction
accelerating.

Normal malfunction reason: all kinds of
liquid such as oil, coolant, braking liquid
and water contact with sensor for a long
time and erode the sensor.

Simple measuring method: (disassemble the
joint) put digital multimeter at ohm shift,
and contact the No.1, No. 2 and No.3 pin
with its two meter pens. The resistance
value should be more than 1MΩ at normal
conditions. Leave the digital multimeter at
millivolt shift, and tap around the sensor
using little hammer, there should be voltage
signal output.
phenomenon:
badness
3.4 OXYGEN SENSOR
1)Exterior drawing and pin
There are 4 pins on this oxygen sensor
No. 1 connect to heating power anode (white)
No. 2 connects to heating power cathode (white)
No. 3 connects to signal cathode (gray)
No. 4 connects to signal anode (black)
2)Installation position: Assemble it on the top
of exhaust pipe.
Chart 3-6 Exterior drawing of oxygen
sensor
3)Purpose: The oxygen sensor checks the
oxygen percent in exhaust gases and transfer the
signal to ECU, and ECU will control the fuel
closed loop according to this information. This
will make engine working at its optimum
conditions. And transfer and purify CO, HC,
NOx compound in 3-way catalytic converter of
the tail gas maximally.
Main relay
4)Working principle
Sensing element of oxygen sensor is a kind of
ceramic tube with holes, and outside of tube
walls are surrounded by engine exhaust gas and
inside is air. Ceramic sensor element is a kind of
solid state electrolyte with electrical heating
Oxygen sensor
Chart 3-7 circuit diagram of oxygen
sensor
17
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
tube inside. The working of oxygen sensor is
carried out by transferring the concentration
difference of the oxygen ion outside of ceramic
tube to voltage (100mv— 900mv)signal and
output.
5)Working voltage:12— 14V
6)Malfunction and diagnosis method

Malfunction: badness idle speed, badness
acceleration, badness tail gas, over fuel
consume etc.

Reason: 1, moisture entering inside of
sensor, and when the temperature is
changed pin is broken; 2, sensor
poisoning( Pb,S,Br,Si)

Notice: it is forbidden to use cleaning liquid,
oiliness liquid or volatility solid during
service.

Measuring method: a) disassemble joint,
put digital multimeter to ohm shift, connect
meter pen to No.1(white) and No.2(white)
pins of the sensor. Normally the resistance
value is 1~6Ω. b) Connect the joint and
keep it at idle speed status. When the
oxygen sensor reaches to its working
temperature 350★, keep digital multimeter
to DC volt shift and connect meter pen to
No.3 (gray) and No.4 (black) pins of sensor.
Now the voltage should be fluctuate
between 0.1- 0.9V quickly (the data also
can be gotten from data flow inspected by
diagnosis meter).
3.5 SPEED
SENSOR
(CRANKCASE
POSITIONING SENSOR)
1)Exterior drawing and pin
No.1pin connects to shield
No.2 and No.3 pin provide signal to ECU.
2)Installation position: on the flywheel plane
at rear of engine.
Chart 3-8 Exterior Drawing Of Speed
Sensor
18
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
Service notice:

For the inductive engine speed sensor, it is
permitted to take out from its pack before it
is assembled to the auto or testing device
right away.

Inductive engine speed sensor is assembled
by press in method but not hammer tapping.

Tightening torque is 8.2Nm. Gas clearance
between inductive engine speed sensor and
pulse disc is 0.8 - 1.2mm.
3)Purpose: Speed sensor provides engine speed,
crankshaft angle and top dead center signal to
ECU. That will control engine ignition and
injection timing.
4)Working principle: The inductive engine
speed sensor work together with pulse disc, it is
used in ignition system without distributor
providing engine speed and crank shaft top dead
center information. Speed sensor is made up of
a permanent magnet and coil outside of magnet.
Pulse disc is a tooth disc with 60 teeth originally
but there are two teeth opening. Pulse disc is
assembled on crank shaft and rotate with
crankshaft. When the tip of the tooth passed the
end of inductive engine speed sensor, the
magnet pulse disc incises the magnetic line of
force, generating rotating speed signal and
output.
5)Working temperature:-40--120★
Speed sensor
Chart 3-9 Circuit diagram of speed
sensor
Resistance of coil in room T:731--989Ω
6)Malfunction and diagnosis method:

Malfunction: can not start etc.

Reason: man failure

Service notice: use pressing method but not
a hammer to install it.

Simple measure method: disconnect the
joint, put digital multimeter to ohm shift,
connecting two meter pen to No. 2 and No.
19
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
3 sensor connectors. The rated resistance is
860Ω±10% When it is 20★
3.6 PHASE
SENSOR
(CAM
POSITIONING SENSOR)
SHAFT
1)Exterior drawing and pin
This sensor has three pins: No. 1 grounding, No.
2 for signal output and No. 3 connecting to
power anode.
2)Installation position: on the valve cover.
There is only one hole on this sensor casing for
tightening M6, and the torque is: 8±0.5Nm.
3)Purpose: This sensor provides crankshaft
phase information to ECU, that is to say, to
separate crankshaft compression top dead center
and exhaust top dead center.
4)Working principle
Chart 3-10 Exterior drawing of phase
sensor
It is a Hall sensor.
Grounding point
5)Working temperature: -30--130★
Working voltage: 4.5— 16V
Trigger gap: 0.1— 1.8mm
6)Malfunction and diagnosis method

Malfunction: can not start, emission exceed
standard, fuel consume increased.

Reason: Man made.

Simple measuring method: (connect the
joint) switch on ignition switch but do not
start the engine; put digital multimeter on
DC volt, connect two meter pen to No. 3
and No. 1 sensor connectors and make sure
there is 12V reference voltage. Start the
engine, checking if it is in good conditions
of No. 2 pin by oscillograph on vehicle.
Phase sensor
Connect to main relay
Chart 3-10 Exterior drawing of phase
sensor
20
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
3.7 ELECTRIC FUEL PUMP
1)Exterior drawing and pin
The electric fuel pump has two pins connecting
to pump relay. There are “+”and “-” showing
anode and cathode on the pump housing near to
pins.
2)Installation position: inside fuel tank
3)Purpose: Deliver the fuel to engine fuel
supplying pipe at certain flow and fuel pressure
and keep the stable fuel pressure (realized by
fuel pressure regulator)
Chart 3-12 Exterior Drawing of Electric
Fuel Pump
4)Working principle
The electric fuel pump is made up of DC
electromotor, vane pump and end cover (it’
s an
integration of check valve, relief valve and an
anti electromagnetic interference element).
Pump and electromotor are coaxial assembly
and within the same casing. The pump and
electromotor are full of gasoline for coolant and
greasing inside of the casing. The accumulator
provide power to electric fuel pump via fuel
pump relay, and the relay switches on electric
fuel pump only when engine starting and
running. When the engine stops for some reason,
the pump will stop to run by itself.
5)Working voltage:8— 14V
Fuel Pump Relay
Working temperature:-30--70★
System pressure: 300KPa
6)Malfunction and diagnosis method

Malfunction: big running noise, badness
acceleration, can not start (difficult to start)
etc..

Reason: use of low quality fuel and cause 1,
colloid became insulation layer; 2, fuel
pump bushing and armature come to
together; 3, components of fuel level sensor
eroded.

Service notice: 1, the electric fuel pump can
Electric Fuel Pump
Connect
To Main
Relay
Power Supply
Chart 3-10 Exterior Drawing Of Phase
Sensor
21
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
has different flow according to the
requirement of engine, but with the same
exterior looking.
The pump which can be assembled to perhaps
is not the fittest. For service the replaced
electric fuel pump must has the same part
number as the original pump; 2, do not change
the pump at dry status to prevent the pump
from accident; 3, when it needs changing fuel
pump, please clean fuel tank and fuel filter.

Simple measuring method: (disconnect joint)
leave digital multimeter at ohm shift, connect
two meter pen to two pins of pump, measure
the resistance, it is not zero or infinite(that is
non short circuit, open circuit).(connect the
joint)connect the fuel pressure meter to fuel
intake pipe and start the engine, observing if the
fuel pump works; If it is not running, check if
there is power or not on the pin of”+”; if it is
running, at the condition of idle speed, check
the fuel pressure if it is around 260kPa; plug
off the fuel pressure regulator vacuum pipe if it
is around 300kPa.
Chart 3-14 Exterior Drawing of Injector
3.8 ELECTROMAGNETIC INJECTOR
1)Exterior drawing and pin
There are two pins on each injector. One of them is
No. 87 pin aside of casing marked with plus and
connected to main relay output; and another one
connect with ECU No. 27,6,7,47 pins.
2)Installation position: On the air intake manifold
near the end of air intake port. When
you .disassemble and reassemble the fuel injector
the O ring must be changed. And pay attention not
to damage the sealing surface of the injector.
3)Purpose: Inject some fuel to its correspondent
cylinder at proper time to meet the engine
requirement of different power and different torque.
1, O Ring
2, Screen
3, Injector with Elec. Plug
4, Coil
5, Spring
6, Valve Pin with Coil Armature
7, Valve Seat with Injection Hole
Chart 3-15 Cutaway View Of Injector
4)Working principle: ECU sends electrical
impulse to injector coil and form magnetic field
force. When magnetic field force increase to
22
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
conquer Return spring pressure, needle valve
gravity and friction force, the needle valve begin to
rise up and start the injection process. The pressure
of return spring makes needle valve close again
when the injection impulse is stopped.
5)Working voltage:6— 16V
Working injection pressure: 350KPa
Connect To Main
Relay Pin No. 87
6)Malfunction and diagnosis method

Malfunction: badness idle speed, badness
acceleration, can not start (difficult to start) etc..

Reason: lack of maintenance causes invalid by
the colloid inside of injector became insulation
layer.

Cylinder No.1, No.2, No.3, No.4
Chart 3-16 Circuit Diagram of Injector
Simple measure method: (disconnect the joint)
leave digital multimeter at ohm shift, connect the
meter pen to the two pins of injector. The rated
resistance should be 11 - 13Ωwhen it is 20★.
3.9 AIR FLOW SENSOR
1)Exterior drawing and pin definition
This sensor is 5 pins: No. 1 is intake temperature
pressure signal; No. 2 is accumulator pressure; No. 3
is grounding; No. 4 is reference voltage 5V; No. 5 is
intake airflow signal output.
2)Installation position
It is behind the air cleaner of the air intake tube.
3)Purpose:
This sensor is hot cable airflow sensor, which check
the temperature and air intake flow entering to
cylinder and provide evidence to ECU to calculate
fuel injection quantity.
Chart 3-17 Exterior Drawing of Airflow
Sensor
4)Working principle
If there are no airflow passing when the air quality
and flow meter works, temperature grads of both
sides of the heating area spread symmetry, and
temperature of these two points are same. When the
air passes here just one way, the air will be heated
when it passes the central heating area and this will
23
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
make the heat exchange different of the heat
diaphragm of both sides.
This will make the temperature of two sensing
element measuring point inside of the flowmeter
Changes differently and appears difference in
temperature. And the difference of the temperature
will increase with the increase of the airflow.
Big/small and positive/negative of the temperature
difference improved the quality and direction of the
airflow. And the inside evaluate circuit will transfer
the temperature difference to voltage signal and
output.
5)Working temperature:-40--125★
6)Malfunction and diagnosis method

Reason: sensing element is polluted by the dust
particle, oil and water and causes the part invalid.

Service notice: 1, it is prohibited to use erosion
liquid to clean sensing element during service; 2,
not to use high pressure air to impact sensing
element; 3, make sure there are no dust into air
pipe when you change air cleaner and no
unqualified air into air cleaner.

Simple measuring method: static measurement:
(zero flow measurement) No. 3 grounding; No. 4
input 5V reference voltage; No.2 input 14V rated
voltage; check No. 5 output voltage, if the output
is bigger than 1.025V, we can confirm the
function of this sensor is not qualified. Dynamic
measurement: if it is confirmed the sensor is
broken, connect a tail gas analysis meter to
exhaust pipe and check it by using “two working
conditions method”: 1, idle speed working
conditions; 2, 2000rpm stable working conditions.
Check the reading of HC 、CO、CO2, normally
HC<100ppm CO<0.5%,CO2 >13.5%
3.10 DOUBLE SPARK IGNITION COIL
1)Exterior and pin definition
No. 1 coil primary winding connect with No.5 pin of
ECU; No. 2 coil primary winding connect with No. 2
24
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
pin of ECU; No. 3 and No.4 pins connect with power
anode.
2)Installation position: on the engine
3)Purpose: Ignition coil transfers the low voltage of
primary winding to high voltage of secondary
winding, and produce spark by spark plug discharging
then burning the combustible gas inside of the
cylinder.
4)Working principle
Ignition coil ZS - K22 is made up of two primary
windings, two secondary windings, mandrel, and
casing. When one of the primary windings grounding
chunnel is connected, the primary winding is in
charging. Once the circuit is cut off by ECU, the
charging is stopped. At the same time the high voltage
is sensed in the secondary winding and making the
spark plug discharging. There is a different with the
distributor ignition coil: for the ignition coil ZS - K22,
there is one spark plug on both side of the secondary
winding, and the both spark plugs can ignite at the
same time. These two primaries connect and
disconnect
to
power
alternatively.
And
correspondently these two secondary windings
discharge alternatively.
Chart 3-18 Exterior Drawing of Ignition
Coil
5)Working voltage:14V
Working temperature:-40— 120★
6)Malfunction and diagnosis method

Malfunction: can not start.

Reason: current is too big and got burnt, damaged
by outside force etc..

Service notice: forbid to use "short circuit test
igniting method” to test ignition function,
prevents the electronic controller from damaging.

Simple measuring method: (disassemble the joint)
leave digital multimeter at ohm shift, connect two
meter pen to two pins of primary winding, the
resistance value is 0.42- 0.58Ωwhen it is 20★;
secondary winding resistance value is 11.214.8kΩ.
Connect To Main
Relay Pin No.87
Chart 3-19 circuit Diagram of Ignition
Coil
25
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
3.11 CARBON CANISTER SOLENOID VALVE
1)Exterior drawing and pin definition
Canister control valve only has two pins; one is
connect to No.87 pin of main relay output end; and
another pin connected to No. 5 pin of ECU.
2)Installation position: Canister vacuum pipe of
intake manifold
3)Purpose: Control the quantity of the cleaning
flow from canister to air intake chief pipe. The
absorption of the canister is limited so if the
gasoline vapor adhesive to canister can not be
consumed the gasoline vapor will volatility to
outside and pollute the air.
Chart 3-20 Exterior Drawing of Canister
Solenoid
4)Working principle
Canister is made up of electromagnetic coil,
armature and valve etc.. There is strainer on the
intake. The flow quantity passes canister valve is
correlate not only to electrical impulse duty ratio of
canister control valve output by ECU, but also to
the pressure difference between canister valve
intake and outlet. When there is no electronic
impulse, the canister control valve will shut down.
Connect To Main Relay
5)Working voltage:9— 16V
Working temperature:-30--120★
Canister Solenoid Valve
6)Malfunction and diagnosis method
Chart 3-21 Circuit Diagram of Canister
Solenoid

Malfunction: Function invalidation.

Reason: some particle coming to inside of valve
causes erosion or poor sealing.

Service notice: 1, let the airflow direction be
accord with the regulation; 2, when there are
black particle inside of valve and causes the
control valve invalidation, the valve need to be
changed, please check the canister working
conditions; 3, avoid the water, fuel and other
liquid into valve during the service; 4, hang the
valve on the tube to avoid the transferring of
solid sound.

Simple measurement method: (disassemble the
26
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
joint) leave digital multimeter to ohm shift, two
meter pen connect to the pins of canister valve,
it is 26±4 Ω when it is 20★.
3.12 FUEL PRESSURE REGULATOR
1)Exterior drawing
2)Installation position: Fuel bracket assembly
3)Purpose: Adjust the pressure inside of fuel pipe,
keep the System pressure around 350Kpa.
4)Working principle: See chart 3- 23, one piece of
flexible film made up of rubber and fiber separate the
fuel pressure regulator into two compartments. The
upper compartment communicates to the air, and
there is spring inside. The lower compartment is full
of fuel entering from the fuel intake under the fuel
pressure regulator. The lower part of the film gets the
pressure from fuel and the upper part gets the pressure
from air and spring. The film can distort and drive
valve seat making the valve open and close, but the
distortion is smaller the acting force of the spring may
be seemed as not changed. So the opening and closing
of the valve is decided by the pressure difference of
the fuel pressure from lower compartment and the air
pressure from the upper compartment. If the valve is
closed at first, then the fuel pressure increased
causing the pressure difference between upper and
lower compartments increased. At last the film was
raised up by the fuel pressure and valve is opened.
The fuel return to fuel tank from oil return port of
pressure regulator, the fuel pressure decreased until
the valve is closed. If the engine changes its working
conditions now, the pressure difference of fuel system
and the air pressure is about the same.
Chart 3-22 Fuel Pressure Regulator
5)Malfunction and diagnosis method

Malfunction: fuel pressure is too high or too low,
difficult to start.

Reason: long time using without maintenance
causing: 1, strainer jammed; 2, particle causes big
leaking; 3, man made mechanical damages.

Service notice: 1, prohibit to use high pressure air
blowing film element; 2, Forbid using strong
Chart 3-23cutaway View of Fuel
Pressure Regulator
27
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
causticity liquid to wash it; 3, avoid it from
distorting by outside force.
Accelerator Pedal
Simple measurement method: connect fuel
pressure gauge at fuel intake pipe, start the
engine and make the engine running at idle speed;
check the fuel pressure around 350kPa or not;
step on the gas until the engine speed to
2500rpm,and observe if the fuel pressure at
around 350kPa.
3.13 ELECTRONIC THROTTLE VALVE AND
ACCELERATOR
1)Exterior drawing and pin

Accelerator pin definition
Pin No.3 and No.5 is the cathode of 5V reference
voltage
Pin No. 4 and No. 6 is output voltage signal

Electronic Throttle Valve
Pin No.1 and No.2 is the anode of the 5V
reference voltage
Electronic throttle valve pin definition
Chart 3-24 Electronic Throttle Valve
and Accelerator
Pin No. 1 is motor anode.
Pin No. 2 is potentiometer anode.
Pin No. 3 is potentiometer cathode.
Pin No. 4 is motor cathode.
Pin No. 5 is signal output 1.
Pin No. 5 is signal output 2.
2)Installation position: Electronic throttle valve:
front end of intake manifold; accelerator: driver
cockpit.
3)Working principle: The engine on time torque
requirement was transferred from accelerator to ECU,
and ECU sends impulse electronic signal to electronic
throttle valve according to torque requirement
information; the motor is running and drive throttle
valve to its opening required degrees; this throttle
valve can stay at one fixed position or change to
another position upon required to meet the
Chart 3-25 Circuit Diagram of
Accelerator
28
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
requirement of the engine working conditions
according to the impulse signal frequency and width
of impulse.
3.14 FAN CONTROL
ECU control the fan according to water
temperature of the engine and the requirement
signal and control the fan system delay at the fit
conditions.
1) Conditions for fan running at low speed:
a) Engine coolant temperature between 96★ to
102★.
b) There is air conditioner requirement and the
air conditioning compressor begins to work.
2) Conditions for fan running at high speed:
a) Engine coolant temperature sensor broken
b) Engine coolant temperature higher than
102★.
3) Conditions of fan continue to work after the
engine stops working
A) Engine air intake temperature sensor is
broken and delay 60 seconds.
B) Engine coolant temperature sensor is broken
and delay 60 seconds.
C) Engine coolant temperature higher than
100.5★, high speed delay 60 seconds.
D) Temperature of intake air more than 70.5★,
delay 60 seconds.
Power Supply
High-Speed Relay Of Fan
4) Malfunction diagnose
Short circuits from high relay line to power
supply
Low-Speed Relay Of Fan
Double-Speed Fan
Short circuits from high-speed relay line to
ground
Chart 3-26 Fan control schematic
Open circuits of high-speed relay line
Short circuits from low-speed relay to power
supply
29
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
Short circuits from low-speed relay line to
ground
Open circuits of low-speed relay line
Engine coolant temperature sensor failure
Engine intake air temperature sensor failure
3.15 AIR CONDITIONER CONTROL
1)Working principle
Switch on the air conditioner and blower; air
conditioner pressure is regular; evaporator
temperature sensor inspect the right data;
requirement signal of air conditioner is sending by
these switches to ECU, and ECU controls air
conditioning relay attracting and provide rotating
speed signal to step motor and open the electronic
fan and air conditioning chart to work.
2)Air conditioner control strategy
a) The air condition can be switched on after 5
seconds of the engine starts.
b) Cut off the air conditioner when temperature of
intake air higher than 140.3★.
c) Cut off air conditioner when the coolant
temperature higher than 114.8★; resume the air Power Supply
conditioning control after its lower than 11.8★.
Request
d) Cut off air conditioner when the engine speed is
higher than 6520rpm or lower than 520rpm.
Signal
Form
Air
Conditioner
e) Cut off air conditioner when the pressure inside
of air conditioner high pressure pipe is higher
than 20bar and resume the control when the
pressure is lower than 9.5bar.
Air Conditioner Compressor Clutch
f) Cut off air conditioner when the evaporator
temperature is lower than 1.5★; and resume the
control when it is higher than 4.5★.
g) Cut off air conditioner when the system pressure
is lower than 8.04V; consume the control when
it is higher than 10.01V.
Chart 3-27 Air conditioner control
schematic
3) Malfunction diagnosis
30
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
Blower circuit malfunction (fuse is burnt, relay
circuit is open circuit or short circuit)
Irregular pressure of air conditioner (much higher of
the high voltage or the much lower of the low
voltage)
Malfunction of evaporator temperature sensor
Air conditioner relay circuit is failure (short circuit
to ground, short circuit to power supply, open
circuit).
4 ME7 SYSTEM TEST AND REPAIR ACCORDING TO TDC
Explanation:
1. When it is confirmed that malfunction is steady we can carry out the test and repair as
below, otherwise this will cause wrong diagnosis.
2. There is multimeter mentioned below, it is referred to digital multimeter; prohibit to use
finger multimeter check the EFI system.
3. Check and repair the vehicle with anti theft system please re-program the replaced ECU
when there is the occasion of changing the ECU at “flow up steps”.
4. In this items when the TDC of P0171、P0172、P0335、P0336、P1651 existing, the engine
trouble light will not light on.
5. If it shows much lower of the voltage in some circuit in DTC explanation, it refers to
perhaps there is ground short circuit inside of this circuit; If it shows much higher of the
voltage in some circuit in DTC explanation, it refers to perhaps there is power supply
short circuit inside of this circuit; If it shows circuit failure in DTC explanation, it refers
to perhaps there is open circuit or multi circuit malfunction inside of this circuit.
Diagnosis help: 1. DTC can not be deleted; it is steady failure; if it is occasional failure,
check if it is because of the loosening of cable joint.
2.
Check according to the above steps and find noting wrong;
3. During check and repair pay attention that the influence of vehicle
maintenance, cylinder pressure and mechanical ignition timing to
the system;
4. Change ECU and test it. If the DTC can be deleted, the malfunction
is inside of ECU; if the DTC can not be deleted, change back to the
original ECU and check it again according to above items.
31
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
4.1 ENGINE DTC (DIAGNOSTIC TROUBLE CODE) LIST
DTC
P0107
P0108
P0112
P0113
Definition
Much lower voltage of the air intake
pressure sensor
Much higher voltage of the air intake
pressure sensor
Indicated temperature is much lower of
the air intake temperature sensor
Temperature is much higher indicated by
the air intake temperature sensor
DTC
Definition
P0340
Phase sensor signal failure
P0342
P0343
P0443
P0117
Temperature is much lower indicated by
P0444
engine coolant temperature sensor
P0118
Temperature is much higher indicated by
P0445
engine coolant temperature sensor
P0122
P0123
P0130
P0132
P0134
The circuit voltage of throttle position
sensor is much lower
The circuit voltage of throttle position
sensor is much higher
Unreasonable failure of the upstream
oxygen sensor signal
Much higher voltage of upstream oxygen
sensor
P0201
P0202
P0203
P0204
P0230
Fuel pump control circuit failure
P0325
Knock sensor circuit failure
P0171
P0172
P0500 Unreasonable failure of speed signal
P0506
P0507
Signal failure of upstream oxygen sensor P0508
Heating circuit failure of upstream
oxygen sensor
Closed loop air fuel ratio control self
adapting exceeds it maximum limit
Closed loop air fuel ratio control self
adapting exceeds it minimum limit
The 1st cylinder injector circuit failure
The 2nd cylinder injector circuit failure
The 3rd cylinder injector circuit failure
The 4th cylinder injector circuit failure
P0135
P0480
Much lower voltage of the phase
sensor
Much higher voltage of the phase
sensor
Canister control valve drive grade
control circuit failure
Much lower voltage of canister
control valve drive grade control
circuit
Much higher voltage of canister
control valve drive grade control
circuit
Air conditioner condenser cooling
fan relay control circuit failure
P0509
P0511
Rotating speed of idle speed is lower
than target idle speed
Rotating speed of idle speed is
higher than target idle speed
Idle speed regulator control circuit
voltage is too low
Idle speed regulator control circuit
voltage is too high
Idle speed regulator control circuit
failure
P0560 System voltage signal unreasonable
P0562
System voltage is too low
P0563
System voltage is too high
P0601
ECU testing code failure
P0602 ECU diagnosis data ID code failure
Air conditioner compressor relay
P0645
control circuit failure
Much lower voltage of air
P0646 conditioner compressor relay control
circuit
32
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
Much higher voltage of air
P0335 Crank shaft position sensor signal failure P0647 conditioner compressor relay control
circuit
Crank shaft position sensor signal
P0336
P1651 Trouble light control circuit failure
unreasonable failure
4.2 DIAGNOSIS FLOW WHEN THERE IS DIFFERENT DTC
P0107 Much lower voltage of the air intake pressure sensor
No.
1
2
3
4
5
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”
Observe “air intake pressure”item in data flow, if it is
about 101kpa (specific data is correlated to that time
air pressure).
Take off the joint of cable air intake pressure sensor,
check the voltage between pin No. 3 and pin No. 1 by
multimeter and look if it is around 5V.
Check if it is short circuit to ground between ECU pin
No. 17, No. 33, No. 37 and sensor connector No.1,
No.3 and No. 4.
Start the engine at idle speed. Step on the accelerator
slowly approach to open completely and observe the
value changes of diagnostic tester “air intake
pressure”, the changes should be not big; step on the
accelerator quickly to complete open, the displayed
value should be reach up to 90kpa instantaneous.
Result
Follow up steps
Next step
Yes
To step No. 5
No
Next steps
Yes
To step No. 5
No
Next step
No
Repair or replace
cable
Next step
Yes
Diagnosis help
No
Replace the sensor
Yes
DTC: P0108 Much higher voltage of the air intake pressure sensor
No.
1
2
3
4
5
Operating steps
Result Follow up steps
Connect the diagnostic tester and commutator, put the
Next step
ignition switch to “ON”
Observe “air intake pressure”item in data flow, if it is
Yes
To step No. 5
about 101kpa(specific data is correlated to that time air
No
Next steps
pressure)
Take off the joint of cable air intake pressure sensor,
Yes
To step No. 5
check the voltage between pin No. 3 and pin No. 1 by
No
Next step
multimeter and look if it is around 5V.
Check if it is open circuit or short circuit to power supply
Repair or replace
Yes
between ECU pin No. 17, No. 33, No. 37 and sensor
cable
connector No.1, No.3 and No. 4.
No
Next step
Start the engine at idle speed. Step on the accelerator
Yes
Diagnosis help
slowly approach to open completely and observe the
No
Replace the
33
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
value changes of diagnostic tester “air intake pressure”,
the changes should be not big; step on the accelerator
quickly to complete open, the displayed value should be
reach up to 90kpa instantaneous.
sensor
34
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
DTC P0112 Circuit voltage is much lower of the throttle position sensor
No.
1
2
3
4
5
6
Operating steps
Result Follow up steps
Connect the diagnostic tester and commutator, put the
Next step
ignition switch to “ON”
Observe “air intake temperature”item in data flow, if it is Yes
To step No. 5
same temperature with air intake pipe(specific data is
correlated to the engine temperature at that time)
No
Next step
Notice: if the value is - 40★ there is perhaps open circuit
failure in the circuit.
Take off the joint of cable air intake temperature sensor,
Yes
Next step
check the resistance values using multimeter between
sensor connector No. 1 and No. 2 and check if it is
No
Replace sensor
corresponding to its temperature (please reference the
related section of this service manual)
Take off the joint of cable air intake temperature sensor,
Yes
To step 5
check the voltage between pin No.1 and pin No.2 by
No
Next step
multimeter and look if it is around 5V.
Repair or
Check if it is open circuit or short circuit to power supply
Yes
replace
between ECU pin No. 17, No. 40 and sensor connector
cable
No.1, No.2
No
Next step
Start the engine at idle speed. Observe the value changes Yes
Diagnosis help
of diagnostic tester “air intake temperature”, the value
Replace the
No
should increase with the increase of the engine intake air.
sensor
DTC: P0113 Temperature is much higher indicated by the air intake temperature sensor
No.
1
2
3
4
Operating steps
Result Follow up steps
Connect the diagnostic tester and commutator, put the
Next step
ignition switch to “ON”.
Observe “air intake temperature”item in data flow, if it is Yes
To step No. 5
same temperature with air intake pipe(specific data is
correlated to the engine temperature at that time)
No
Next step
Notice: if the value always is - 40★ there is perhaps open
circuit failure in the circuit.
Take off the joint of cable air intake temperature sensor,
Yes
Next step
check the resistance values using multimeter between
sensor connector No. 1 and No. 2 and check if it is
No
Replace sensor
corresponding to its temperature (please reference the
related section of this service manual).
Take off the joint of cable air intake temperature sensor,
Yes
To step 5
check the voltage between pin No.1 and pin No.2 by
No
Next step
multimeter and look if it is around 5V.
35
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
5
6
ENGINE EFI SYSTEM
Check if it is short circuit to ground between ECU pin
No. 17, No. 40 and sensor connector No.1, No.2
Yes
Start the engine at idle speed. Observe the value changes
of diagnostic tester “air intake temperature”, the value
should increase with the increase of the engine intake air.
No
Yes
No
Repair or
replace
cable
Next step
Diagnosis help
Replace the
sensor
DTC: P0117 Temperature is much lower indicated by engine coolant temperature sensor.
No.
1
2
3
4
5
6
Operating steps
Connect the diagnostic tester and commutator, put
the ignition switch to “ON”.
Observe “coolant temperature”item in data flow, if
it is same temperature with engine temperature
(specific data is correlated to the engine temperature
at that time).
Notice: if the value always is - 40★ there is perhaps
open circuit failure in the circuit.
Take off the joint of coolant temperature sensor on
the cable, check the resistance values using
multimeter between sensor connector No. 1 and No.
2 and check if it is corresponding to its temperature
(please reference the related section of this service
manual).
Take off the joint of coolant temperature sensor on
the cable, check the voltage between pin No.1 and
pin No.2 by multimeter and observe if it is around
5V.
Check if it is open circuit or short circuit to power
supply between ECU pin No.39, No. 35 and sensor
connector No.1, No.2.
Start the engine at idle speed. Observe the value
changes of diagnostic tester “coolant temperature”,
the value should increase with the increase of the
engine coolant temperature.
Result
Follow up steps
Next step
Yes
To step 6
No
Next
Yes
Next step
No
Replace sensor
Yes
To step 6
No
Next step
No
Yes
Repair or replace
cable
Next step
Diagnosis help
No
Replace sensor
Yes
DTC: P0118 Temperature is much higher indicated by engine coolant temperature sensor
No.
1
2
Operating steps
Result
Connect the diagnostic tester and commutator, put
the ignition switch to “ON”.
Observe “coolant temperature”item in data flow, if
it is same temperature with engine temperature
(specific data is correlated to the engine temperature
Follow up steps
Next step
Yes
To step 6
No
Next
36
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
3
4
5
6
ENGINE EFI SYSTEM
at that time).
Notice: if the value always is - 40★ there is perhaps
open circuit failure in the circuit.
Take off the joint of coolant temperature sensor on
the cable, check the resistance values using
multimeter between the sensor connector No. 1 and
the No. 2 and check if it is corresponding to its
temperature (please reference the related section of
this service manual).
Take off the joint of coolant temperature sensor on
the cable, check the voltage between pin No.1 and
pin No.2 by multimeter and observe if it is around
5V.
Yes
Next step
No
Replace sensor
Yes
To step 6
No
Next step
Check if it is short circuit to ground between ECU
pin No.39, No. 35 and sensor connector No.1, No.2.
Yes
Repair or replace
cable
No
Next step
Start the engine at idle speed. Observe the value
changes of diagnostic tester “coolant temperature”,
the value should increase with the increase of the
engine coolant temperature.
Yes
Diagnosis help
No
Replace sensor
DTC: P0122 Indicated temperature is much lower of the air intake temperature sensor.
No.
1
2
3
4
5
6
Operating steps
Result
Connect the diagnostic tester and commutator, put
the ignition switch to “ON”.
Observe “throttle valve absolute opening”item in
data flow, check the value if it is between 4% and
10% (specific data is correlated to the vehicle type).
Step on the accelerator slowly to complete opening
and observe “throttle valve absolute opening”item
in data flow, check if the value is increased to around
85-90% with the opening of the throttle valve
(specific data is correlated to the vehicle type).
Repeat step 3 and observe “throttle valve absolute
opening”item in data flow, and check if there is
jump during the changes.
Take off the joint of throttle valve positioning sensor
on the cable, check if there is short circuit to ground
between pin No.17, No.32, No.16 of ECU and pin
No.1, No.2, No.3.
Check the voltage between pin No.1 and pin No.2 by
multimeter and observe if it is around 5V.
Follow up steps
Next step
Yes
Next step
No
To step No. 5
Yes
Next step
No
To step No. 5
Yes
Replace the sensor
No
Next step
Yes
Repair or replace
cable
No
Next step
Yes
Replace sensor
No
Diagnosis help
37
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
DTC: P0123 Circuit voltage is much higher of the throttle position sensor
No.
1
2
3
4
5
6
Operating steps
Result
Connect the diagnostic tester and commutator, put
the ignition switch to “ON”
Observe “throttle valve absolute opening”item in
Yes
data flow, check the value if it is between 4% and
No
10% (specific data is correlated to the vehicle type).
Step on the accelerator slowly to complete opening
Yes
and observe “throttle valve absolute opening”item
in data flow, check if the value is increased to around
No
85-90% with the opening of the throttle valve
(specific data is correlated to the vehicle type).
Repeat step 3 and observe “throttle valve absolute
Yes
opening”item in data flow, and check if there is
No
jump during the changes.
Take off the joint of throttle valve positioning sensor
Yes
on the cable, check if there is open circuit or short
circuit to power supply between pin No.17, No.32,
No
No.16 of ECU and pin No.1, No.2, No.3 of sensor
Check the voltage between pin No.1 and pin No.2 by
multimeter and observe if it is around 5V.
Follow up steps
Next step
Next step
To step No. 5
Next step
To step No. 5
Replace the sensor
Next step
Repair or replace
cable
Next step
Yes
Replace sensor
No
Diagnosis help
DTC: P0130 Unreasonable failure of the upstream oxygen sensor signal
(Notice: below diagnosis process is fit for those without P0135 at the same time; if there is
P0135 failure, please deal with P0135 failure at first and then check as below.)
No.
1
2
3
Operating steps
Connect the diagnostic tester and commutator, put
the ignition switch to “ON”
Start the engine and leave it at idle speed until its
coolant reaches to the normal value. Observe the
value changes of “oxygen sensor voltage”item on
diagnostic meter, the displayed value should change
rapidly from 100mV-900mV.
Result
Check if there is short circuit to ground between pin
No.36, No.18, of ECU and pin A (opposite to oxygen
sensor gray connecting line), B (opposite to oxygen
sensor black connecting line).
Follow up steps
Next step
Yes
Diagnosis help
No
Next step
Yes
Repair or change
cable
No
Next step
DTC: P0132 Much higher voltage of upstream oxygen sensor
(Notice: below diagnosis process is fit for those without P0135 at the same time; if there is
P0135 failure, please deal with P0135 failure at first and then check as below.)
38
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
No.
1
2
3
4
ENGINE EFI SYSTEM
Operating steps
Result
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”.
Start the engine and leave it at idle speed until its
Yes
coolant reaches to the normal value. Observe the value
changes of “oxygen sensor voltage”item on diagnostic
No
meter, the displayed value should change rapidly from
100mV-900mV.
Check if there is short circuit to power supply between
Yes
pin No.36, No.18, of ECU and pin A (opposite to
oxygen sensor gray connecting line), B (opposite to
No
oxygen sensor black connecting line).
A, check if the exhaust system is jammed
Yes
B, check if the injector is leaking
C, check if the fuel pressure is over higher
D, check if the valve clearance is over smaller etc.
No
Follow up steps
Next step
Diagnosis help
Next step
Repair or change
cable
Diagnosis help
Check and repair
according to
diagnosis
Diagnosis help
DTC: P0134 Signal failure of upstream oxygen sensor
(Notice: below diagnosis process is fit for those without P0135 at the same time; if there is
P0135 failure, please deal with P0135 failure at first and then check as below.)
No.
1
2
3
Operating steps
Result
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”.
Start the engine and leave it at idle speed until its
Yes
coolant temperature reaches to the normal value.
Observe the value changes of “oxygen sensor voltage”
No
item on diagnostic meter, the displayed value should
change rapidly from 100mV-900mV.
Check if there is open circuit between pin No.36,
Yes
No.18, of ECU and pin A (opposite to oxygen sensor
gray connecting line), B (opposite to oxygen sensor
No
black connecting line) of sensor joint.
Follow up steps
Next step
Diagnosis help
Next step
Repair or change
cable
Diagnosis help
DTC: P0135 Heating circuit failure of upstream oxygen sensor
No.
1
2
3
Operating steps
Result
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”.
Take off the oxygen sensor joint on the cable and
Yes
check the voltage between the pins of C (opposite to
oxygen sensor white connecting line) and D (opposite
No
to oxygen sensor white connecting line) by multimeter,
and observe if it is about 12V.
Check the resistance value between oxygen sensor
Yes
Follow up steps
Next step
Next step
To step No.4
Next step
39
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
4
5
ENGINE EFI SYSTEM
connectors C (white) and D (white) using multimeter,
and observe if it is 2-5Ω when it is 20★.
Check the fuse inside of oxygen sensor heating circuit
and observe if it is blow.
Check if there is open circuit or short circuit to power
supply between ECU pin No.1, main relay sensor
No.87 and pin C (opposite to oxygen sensor white
connecting line), D (opposite to oxygen sensor white
connecting line) of sensor joint.
No
Change sensor
Yes
Change fuse
Next step
Repair or change
cable
Yes
No
Diagnosis help
DTC: P0171 Closed loop air fuel ratio control self adapting exceeds it maximum limit
(Notice: below diagnosis flow is fit for when air intake pressure sensor failure, canister
control valve failure and oxygen sensor failure are not appeared at the same time; if there are
failures existing at the same time please deal with other failures at first and then do as below.)
No.
1
2
3
4
5
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”.
Start the engine and leave it at idle speed until its
coolant temperature reaches to the normal value.
Observe the value changes of “oxygen sensor voltage”
item on diagnostic meter, and the displayed value keeps
around the value of 100mV at some working conditions.
Connect the fuel pressure meter (connection position is
the front end of fuel distributing pipe assembly fuel
intake pipe); start the engine and check the fuel pressure
at idle speed conditions if it is around 260kpa; take off
the vacuum pipe on fuel pressure regulator, check the
pressure and observe if it is around 300kpa.
Check if there is short circuit to ground between ECU
pin No.36, No.18 and pin A (opposite to oxygen sensor
gray connecting line), pin B (opposite to oxygen sensor
black connecting line) of sensor joint.
A, check if there is a heavy leaking in air intake system
B, check if the injector is jammed
C, check if the clearance of spark plug is too big
D, check if the sub live wire resistance is too big
E, check if the valve clearance is too big etc.
Result
Follow up steps
Next step
Yes
Next step
No
Diagnosis help
Yes
Repair or replace
the cable
No
Next step
Yes
Repair or replace
cable
No
Next step
Yes
Repair according
to diagnosis data
No
Diagnosis help
40
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
DTC: P0172 Closed loop air fuel ratio control self adapting exceeds it minimum limit
(Notice: below diagnosis flow is fit for when air intake pressure sensor failure, canister
control valve failure and oxygen sensor failure are not appeared at the same time; if there are
failures existing at the same time please deal with other failures at first and then do as below.)
No.
1
2
3
4
5
Operating steps
Result
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”
Start the engine and leave it at idle speed until its
Yes
coolant temperature reaches to the normal value.
Observe the value changes of “oxygen sensor voltage”
item on diagnostic meter, and the displayed value
No
keeps around the value of 900mV at some working
conditions.
Connect the fuel pressure meter (connection position is
Yes
the front end of fuel distributing pipe assembly fuel
intake pipe); start the engine and check the fuel
pressure at idle speed conditions if it is around 260kpa;
No
take off the vacuum pipe on fuel pressure regulator,
check the pressure and observe if it is around 300kpa.
Check if there is short circuit to power supply between
Yes
ECU pin No.36, No.18 and pin A (opposite to oxygen
sensor gray connecting line), pin B (opposite to
No
oxygen sensor black connecting line) of sensor joint.
A, check if the injector is leaking
Yes
B, check if the exhaust pipe is jammed
C, check if the valve clearance is too small etc.
No
Follow up steps
Next step
Next step
Diagnosis help
Repair or replace
the cable
Check and repair
fuel system
Repair or replace
cable
Next step
Repair according
to diagnosis data
Diagnosis help
DTC: P0201 The 1st cylinder injector circuit failure
No.
1
2
3
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”
st
Take off the 1 cylinder injector joint from the cable,
check the voltage value between this joint pin No.1
and the power cathode by multimeter and observe if it
is 12V.
Result
Check if there is open circuit or short circuit to ground
between the 1st injector joint pin No.1 and main relay.
Yes
st
4
Check the resistance value by multimeter between 1
cylinder injector pin No.1 and No.2, and observe if it
is 11-13Ω when it is 20℃.
5
Check the voltage value by multimeter between 1st
Follow up steps
Next step
Yes
To step No.4
No
Next step
No
Yes
Repair or replace
the cable
Next step
Next step
No
Change injector
Yes
Repair according to
41
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
6
ENGINE EFI SYSTEM
cylinder injector pin No.2 and power supply cathode,
and observe if it is around 3.7V.
Check if there is open circuit or short circuit to ground
between 1st cylinder injector joint pin No.2 and the
ECU pin No.27.
No
diagnosis data
Diagnosis help
Repair or replace
cable
Diagnosis help
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”
nd
Take off the 2 cylinder injector joint from the cable,
check the voltage value between this joint pin No.1
and the power cathode by multimeter and observe if it
is 12V.
Result
Follow up steps
Check if there is open circuit or short circuit to ground
between the 2nd injector joint pin No.1 and main relay.
Yes
No
Yes
DTC: P0202 The 2nd cylinder injector circuit failure
No.
1
2
3
5
6
Yes
To step No.4
No
Next step
No
Yes
Repair or replace
the cable
Next step
Next
is 11-13Ω when it is 20℃.
No
Change injector
Check the voltage value by multimeter between 2nd
cylinder injector pin No.2 and power supply cathode,
and observe if it is around 3.7V.
Check if there is open circuit or short circuit to ground
between 2nd cylinder injector joint pin No.2 and the
ECU pin No.6.
Yes
Diagnosis help
No
Next step
nd
4
Next step
Check the resistance value by multimeter between 2
cylinder injector pin No.1 and No.2, and observe if it
No
Repair or replace
cable
Diagnosis help
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”
rd
Take off the 3 cylinder injector joint from the cable,
check the voltage value between this joint pin No.1
and the power cathode by multimeter and observe if it
is 12V.
Result
Follow up steps
Check if there is open circuit or short circuit to ground
between the 3rd injector joint pin No.1 and main relay.
Yes
Yes
DTC: P0203 The 3rd cylinder injector circuit failure
No.
1
2
3
5
Yes
To step No.4
No
Next step
No
Yes
Repair or replace
the cable
Next step
Next step
is 11-13Ω when it is 20℃.
No
Change injector
Check the voltage value by multimeter between 3rd
Yes
Diagnosis help
rd
4
Next step
Check the resistance value by multimeter between 3
cylinder injector pin No.1 and No.2, and observe if it
42
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
6
ENGINE EFI SYSTEM
cylinder injector pin No.2 and power supply cathode,
and observe if it is around 3.7V.
Check if there is open circuit or short circuit to ground
between 3rd cylinder injector joint pin No.2 and the
ECU pin No.7.
No
Next step
No
Repair or replace
cable
Diagnosis help
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”
th
Take off the 4 cylinder injector joint from the cable,
check the voltage value between this joint pin No.1
and the power cathode by multimeter and observe if it
is 12V.
Result
Follow up steps
Check if there is open circuit or short circuit to ground
between the 4th injector joint pin No.1 and main relay.
Yes
Yes
DTC: P0204 The 4th cylinder injector circuit failure
No.
1
2
3
5
6
Yes
To step No.4
No
Next step
No
Yes
Repair or replace
the cable
Next step
Next step
is 11-13Ω when it is 20℃.
No
Replace injector
Check the voltage value by multimeter between 4th
cylinder injector pin No.2 and power supply cathode,
and observe if it is around 3.7V.
Check if there is open circuit or short circuit to ground
between 4th cylinder injector joint pin No.2 and the
ECU pin No.47.
Yes
Diagnosis help
No
Next step
th
4
Next step
Check the resistance value by multimeter between 4
cylinder injector pin No.1 and No.2, and observe if it
No
Repair or replace
cable
Diagnosis help
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “OFF”
Take off the fuel pump relay and put ignition switch to
“ON”; check the voltage separately between fuel
pump relay power supply ends - that is relay pin No.
30 and No.86 and power supply cathode, and observe
if it is around 12V.
Result
Follow up steps
Check if there is open circuit or short circuit to ground
of the relay power supply ends circuit.
Yes
Yes
DTC: P0230 Fuel pump control circuit failure
No.
1
2
3
4
5
Check the voltage by multimeter between fuel pump
relay control ends that is relay pin No. 85 and power
supply cathode and observe if it is around 3.7V.
Check if there is open circuit or short circuit to ground
Next step
Yes
To step No.4
No
Next step
No
Repair or replace
the cable
To step No.2
Replace fuel
pump relay
Next step
Yes
Repair or replace
No
Yes
43
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
or to power supply between relay control ends that is
relay pin No.85 and ECU pin No.69.
DTC: P0325 Knock sensor circuit failure
No.
1
2
3
4
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “OFF”
Take off the knock sensor joint from the cable; check
the resistance value by multimeter between knock
sensor connector No.1and No.2 and observe if it is
1MΩ.
Check if there is open circuit or short circuit to ground
or to power supply between circuit of knock sensor
joint No.1, No.2 and ECU pin No.19, No. 20
Replace the knock sensor according to the regulation;
try running the vehicle and make the engine speed
exceed 2200rpm. Check if the DTC P0325 will appear
again.
No
cable
Diagnosis help
Result
Follow up steps
Next step
Yes
Next step
No
Change sensor
Yes
No
Yes
Repair or replace
the cable
To step No.2
Diagnosis help
No
Check if it is a
occasional fault
Result
Follow up steps
DTC: P0335 Crank shaft position sensor signal failure
No.
1
2
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “OFF”
Take off the speed sensor joint from the cable; check
the resistance value by multimeter between speed
sensor connector No.2and No.3 and observe if it is
Next step
Yes
Next step
No
Replace sensor
around 770-950MΩwhen it is 20℃
3
4
Check if there is open circuit or short circuit to ground
or to power supply between circuit of speed sensor
joint No.2, No.3 and ECU pin No.34, No. 15
Check the flywheel signal disc if it is in good
conditions.
Yes
No
Yes
No
Repair or replace
the cable
Next step
Diagnosis help
Replace signal
disc
DTC: P0336 Crank shaft position sensor signal unreasonable failure
No.
1
2
Operating steps
Connect the diagnostic tester and commutator, put
the ignition switch to “OFF”
Take off the speed sensor joint from the cable; check
the resistance value by multimeter between speed
sensor connector No.2and No.3 and observe if it is
Result
Follow up steps
Next step
Yes
Next step
No
Replace sensor
around 770-950MΩwhen it is 20℃
44
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
3
4
ENGINE EFI SYSTEM
Check if there is open circuit or short circuit to
ground or to power supply between circuit of speed
sensor joint pin No.2, No.3 and ECU pin No.34, No.
15
Check the flywheel signal disc if it is in good
conditions.
Yes
Repair or replace the
cable
No
Next step
Yes
No
Diagnosis help
Replace signal disc
45
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
DTC: P0340 Phase sensor signal failure
No.
1
2
3
4
5
6
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”
Take off the phase sensor joint from the cable; check the
voltage value by multimeter between phase sensor joint pin
No.3 and No.1; and observe if it is around 12V.
Check if there is open circuit or short circuit to ground
between circuit of phase sensor joint pin No.3 and main
relay pin No.87; check if there is bad contact of phase
sensor connector No.1.
Check the voltage if it is around 9.9V between phase sensor
joint pin No.2 and power supply cathode.
Check if there is open circuit or short circuit to power
supply or to ground between phase sensor joint pin No.2
and ECU pin No.79.
Check the camshaft signal disc if it is in good conditions.
Result Follow up steps
Next step
Yes
To step No.4
No
Next step
Yes
Repair or
replace the
cable
No
Next step
Yes
No
To step 6
Next step
Repair or
replace cable
Next step
Diagnosis help
Replace signal
disc
Yes
No
Yes
No
DTC: P0342 Much lower voltage of the phase sensor
No.
1
2
3
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”
Take off the phase sensor joint from the cable; check the
voltage value by multimeter between phase sensor joint pin
No.3 and No.1; and observe if it is around 12V.
Check if there is open circuit or short circuit to ground
between circuit of phase sensor joint pin No.3 and main
relay pin No.87; check if there is bad contact of phase
sensor connector No.1.
Result Follow up steps
Next step
Yes
To step No.4
No
Next step
Yes
Repair or
replace the
cable
No
Next step
To step 6
Next step
Repair or
replace cable
4
Check the voltage if it is around 9.9V between phase sensor
joint pin No.2 and power supply cathode.
Yes
No
5
Check if there is open circuit or short circuit to power
supply or to ground between the circuit of phase sensor
joint pin No.2 and ECU pin No.79.
Yes
6
Check the camshaft signal disc if it is in good conditions.
No
Next step
Yes
Diagnosis help
Replace signal
disc
No
46
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
DTC: P0343 Much higher voltage of the phase sensor
No.
1
2
3
4
5
6
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”
Take off the phase sensor joint from the cable; check
the voltage value by multimeter between phase sensor
joint pin No.3 and No.1; and observe if it is around
12V.
Check if there is open circuit or short circuit to ground
between circuit of phase sensor joint pin No.3 and main
relay pin No.87; check if there is bad contact of phase
sensor connector No.1.
Check the voltage if it is around 9.9V between phase
sensor joint pin No.2 and power supply cathode.
Result
Check if there is open circuit or short circuit to power
supply or to ground between the circuit of phase sensor
joint pin No.2 and ECU pin No.79.
Yes
Check the camshaft signal disc if it is in good
conditions.
Follow up steps
Next step
Yes
To step No.4
No
Next step
Yes
Repair or replace
the cable
No
Next step
Yes
No
To step 6
Next step
Repair or replace
cable
No
Next step
Yes
Diagnosis help
Replace signal
disc
No
DTC: P0443 Canister control valve drive grade control circuit failure
No.
1
2
3
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”
Take off the canister control valve joint from the cable;
check the voltage value by multimeter between this
joint pin No.1 and power supply cathode; and observe
if it is around 12V.
Result
Check if there is open circuit or short circuit to ground
of the canister control valve power supply ends circuit.
Yes
Check the resistance value if it is around 22-30Ωwhen
4
5
6
it is 20℃ between canister control valve pin No.1 and
pin No.2.
Check the voltage if it is around 3.7V between canister
control valve joint pin No.1 and power supply cathode.
Check if there is open circuit between the circuit of
canister joint pin No.2 and ECU pin No. 46.
Follow up steps
Next step
Yes
To step No.4
No
Next step
No
Yes
Repair or replace
the cable
To step No.2
Next step
No
Replace the valve
Yes
No
Diagnosis help
Next step
Repair or replace
cable
Diagnosis help
Yes
No
47
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
DTC: P0444 Much lower voltage of canister control valve drive grade control circuit
No.
1
2
3
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”
Take off the canister control valve joint from the cable;
check the voltage value by multimeter between this
joint pin No.1 and power supply cathode; and observe
if it is around 12V.
Check if there is open circuit or short circuit to ground
of the canister control valve power supply ends circuit.
Check the resistance value if it is around 22-30Ω when
4
5
6
it is 20℃ between canister control valve pin No.1 and
pin No.2.
Check the voltage by the multimeter if it is around
3.7V between canister control valve joint pin No.1 and
power supply cathode.
Check if there is short circuit to ground between the
circuit of canister joint pin No.2 and ECU pin No. 46.
Result
Follow up steps
Next step
Yes
To step No.4
No
Next step
Yes
No
Yes
Repair or
replace the
cable
To step No.2
Next step
No
Replace the
valve
Yes
Diagnosis help
No
Next step
Yes
No
Repair or
replace cable
Diagnosis help
DTC: P0445 Much higher voltage of canister control valve drives grade control circuit
No.
1
2
3
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”
Take off the canister control valve joint from the cable;
check the voltage value by multimeter between this joint
pin No.1 and power supply cathode; and observe if it is
around 12V.
Result
Check if there is open circuit or short circuit to ground of
the canister control valve power supply ends circuit.
Yes
Check the resistance value if it is around 22-30Ωwhen it
4
5
6
is 20℃ between canister control valve pin No.1 and pin
No.2.
Check the voltage by the multimeter if it is around 3.7V
between canister control valve joint pin No.1 and power
supply cathode.
Check if there is short circuit to power supply between
the circuit of canister joint pin No.2 and ECU pin No. 46.
Follow up steps
Next step
Yes
To step No.4
No
Next step
No
Yes
Repair or replace
the cable
To step No.2
Next step
No
Replace the
valve
Yes
Diagnosis help
No
Next step
Yes
Repair or replace
cable
48
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
No
Diagnosis help
DTC: P0480 Air conditioner condenser cooling fan relay control circuit failure
No.
1
2
3
4
5
Operating steps
Result
Connect the diagnostic tester and commutator, put the
ignition switch to “OFF”
Take off the air conditioner condenser cooling fan relay;
put the ignition switch to “ON”position, and check the
voltage value by multimeter between this relay power
supply end that is relay pin No.30, No.85 and power
supply cathode if it is around 12V.
Follow up
steps
Next step
Check if there is open circuit or short circuit to ground of
the air conditioner cooling fan relay power supply end
circuit.
Yes
To step
No.4
No
Next step
Yes
No
Check the voltage by the multimeter if it is around 3.7V
between air conditioner condenser cooling fan relay
control ends that is relay pin No.86 and power supply
cathode.
Yes
No
Check if there is open circuit or short circuit to power
supply or to ground between the circuit of relay control
end pin No.86 and ECU pin No. 50.
Yes
No
Repair or
replace the
cable
To step
No.2
Replace
relay
Next step
Repair or
replace
cable
Diagnosis
help
DTC: P0500 Unreasonable failure of speed signal
No.
1
2
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “OFF”.
If it is a vehicle with ABS, please check if there is
ABS DTC.
Result
Next step
Yes
No
Yes
3
Check if the speedometer finger works normally.
No
Yes
4
Check if the speed sensor works normally.
5
Check if there is open circuit or short circuit to power
Follow up steps
No
Yes
Check and
repair ABS
system
Next step
Next step
Check the
speedometer
line
Next step
Replace speed
sensor
Repair or
49
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
supply or to ground between the circuit of speed
sensor and ECU pin No. 59.
No
DTC: P0506 Rotating speed of idle speed is lower than target idle speed
No.
1
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “OFF”.
Result Follow up steps
Next step
Yes
2
Check if the throttle valve adjusting screw, accelerator
cable and throttle valve working in good conditions.
No
Yes
3
Check if the idle speed regulator works in good conditions.
4
E, check if the pressure of the fuel supplying system is too
low
F, check if the injector is jammed
G, check if the exhaust system is not straightway
replace cable
Diagnosis help
No
Yes
No
Next step
Carry out the
necessary
repair and
maintenance
Next step
Carry out the
necessary
repair and
maintenance
Next step
Replace speed
sensor
DTC: P0507 Rotating speed of idle speed is higher than target idle speed
No.
1
2
3
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “OFF”
Check if the throttle valve adjusting screw, accelerator
cable and throttle valve working in good conditions.
Result
Next step
Yes
Next step
No
Carry out the
necessary repair
and
maintenance
Yes
Next step
Check if the idle speed regulator works in good conditions.
No
4
A, check if the system is leaking;
B, check if the injector is leaking;
C, check if the pressure of fuel supplying system is too
high
Follow up steps
Yes
No
Carry out the
necessary repair
and
maintenance
Carry out the
necessary repair
and
maintenance
Diagnosis help
50
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
DTC: P0508 Idle speed regulator control circuit voltage is too low
No.
1
2
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”.
Take off the idle regulator joint and Check the resistance
value between idle speed regulator pin A and pin D, pin B
and pin C if it is around 53±5.3Ω when it is 20℃.
3
Check if there is short circuit to ground between the circuits
of idle speed regulator joint pin A, B, C, D and ECU pin
No. 65, No.66, No.67. No.64.
Result Follow up steps
Next step
Yes
Next step
No
Replace step
motor
Yes
No
Repair or
replace cable
Diagnosis help
DTC: P0509 Idle speed regulator control circuit voltage is too high
No.
1
2
3
Operating steps
Result Follow up steps
Connect the diagnostic tester and commutator, put the
Next step
ignition switch to “ON”.
Take off the idle regulator joint and check the resistance
Yes
Next step
value by multimeter separately between idle speed regulator
pin A and pin D, pin B and pin C if it is around 53±5.3Ω
Replace step
No
motor
when it is 20℃.
Check using multimeter separately if there is short circuit to
power supply between the circuits of idle speed regulator
joint pin A, B, C, D and ECU pin No. 65, No.66, No.67.
No.64.
Yes
Repair or
replace cable
No
Diagnosis help
Result
Follow up steps
DTC: P0511 Idle speed regulator control circuit failure
No.
1
2
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”.
Take off the idle regulator joint and check the resistance
value by multimeter separately between idle speed
regulator pin A and pin D, pin B and pin C if it is around
53±5.3Ω when it is 20℃.
3
Check using multimeter separately if there is open circuit
between the circuits of idle speed regulator joint pin A, B,
C, D and ECU pin No. 65, No.66, No.67. No.64.
Next step
Yes
Next step
No
Replace step
motor
Yes
No
Repair or
replace cable
Diagnosis help
DTC: P0560 System voltage signal unreasonable
No.
1
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “OFF”.
Result Follow up steps
Next step
51
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
2
Check the accumulator voltage by multimeter if it is around
12V.
3
Check if there is open circuit or short circuit to ground
between the circuits of ECU pin No.44, No.45, No.63 and
main relay pin No.87.
4
Start the engine and check if the entire generator recharging
voltage is around 9-16V at the different engine speed.
5
Check the engine cable harness contact position if it is in
good conditions.
Yes
No
Yes
No
Yes
No
Yes
No
Next step
Replace
accumulator
Repair or
replace cable
Next step
Next step
Replace
generator
Diagnosis help
Repair or
replace cable
DTC: P0562 System voltage is too low
No.
1
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “OFF”.
2
Check the accumulator voltage by the multimeter and
observe if it is around 12V.
3
Check if the resistance is over big between the circuits of
ECU pin No.44, No.45, No.63 and main relay pin No.87.
4
Start the engine and check if the entire generator recharging
voltage is around 9-16V at the different engine speed.
5
Check the engine cable harness contact position if it is in
good conditions.
Result Follow up steps
Next step
Yes
No
Yes
No
Yes
No
Yes
No
Next step
Replace
accumulator
Repair or
replace cable
Next step
Next step
Replace
generator
Diagnosis help
Repair or
replace cable
DTC: P0563 System voltage is too high
Resu
lt
No.
Operating steps
1
Connect the diagnostic tester and commutator, put the
ignition switch to “OFF”.
2
Check the accumulator voltage by the multimeter and
observe if it is around 12V.
3
4
Start the engine and check if the entire generator
recharging voltage is around 9-16V at the different engine
speed.
Check the engine cable harness contact position if it is in
good conditions.
Follow up steps
Next step
Yes
Yes
Next step
Replace
accumulator
Next step
No
Replace generator
Yes
No
Diagnosis help
Repair or replace
No
52
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
cable
53
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
DTC: P0601 ECU testing code failure
No.
1
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”.
2
Clean up the DTC and check the failure once again if it
is a steady failure.
3
Replace ECU
Result
Follow up steps
Next step
Yes
No
Next step
System if
correct
Finish
DTC: P0602 ECU diagnosis data ID code failure
No.
Operating steps
1
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”.
2
Clean up the DTC and check the failure once again if it is
a steady failure.
3
Result
Follow up
steps
Next step
Yes
No
Replace ECU
Next step
System if
correct
Finish
DTC: P0645 Air conditioner compressor relay control circuit failure
No.
1
2
3
Operating steps
Result
Connect the diagnostic tester and commutator, put the
ignition switch to “OFF”.
Take off air conditioner compressor relay; put ignition
switch to “ON”; check the voltage value between relay
power supply ends that relay pin No.30, No.85 and
power cathode and observe if it is around 12V.
Check if there is open circuit or short circuit to ground
of the relay power supplying ends circuit.
Next step
Yes
To step
No.4
No
Next step
Yes
No
4
5
Check the voltage value by the multimeter between air
conditioner compressor relay control ends that is relay
pin No.86 and power cathode and observe if it is around
3.7V.
Check if there is open circuit between the circuit of air
conditioner compressor relay control ends that is relay
pin No.86 and ECU pin No.70.
Follow up
steps
Yes
No
Yes
No
Repair or
replace
cable
To step
No.2
Replace
relay
Next step
Repair or
replace
cable
Diagnosis
help
54
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
DTC: P0646 Much lower voltage of air conditioner compressor relay control circuit
No.
1
2
3
4
5
Operating steps
Connect the diagnostic tester and commutator, put the
ignition switch to “OFF”.
Take off air conditioner compressor relay; put ignition
switch to “ON”; check the voltage value between relay
power supply ends that relay pin No.30, No.85 and
power cathode and observe if it is around 12V.
Result
Check if there is open circuit or short circuit to ground of
the relay power supplying ends circuit.
Yes
Check the voltage value by the multimeter between air
conditioner compressor relay control ends that is relay
pin No.86 and power cathode and observe if it is around
3.7V.
Check if there is short circuit to ground between the
circuit of air conditioner compressor relay control ends
that is relay pin No.86 and ECU pin No.70.
Follow up steps
Next step
Yes
To step No.4
No
Next step
No
Yes
Repair or
replace cable
To step No.2
Replace relay
No
Next step
Yes
No
Repair or
replace cable
Diagnosis help
DTC: P0647 Much higher voltage of air conditioner compressor relay control circuit
No.
1
2
3
4
5
Operating steps
Result
Connect the diagnostic tester and commutator, put the
ignition switch to “OFF”.
Take off air conditioner compressor relay; put ignition
switch to “ON”; check the voltage value between relay
power supply ends that relay pin No.30, No.85 and
power cathode and observe if it is around 12V.
Check if there is open circuit or short circuit to ground of
the relay power supplying ends circuit.
Check the voltage value by the multimeter between air
conditioner compressor relay control ends that is relay
pin No.86 and power cathode and observe if it is around
3.7V.
Check if there is short circuit to power supply between
the circuit of air conditioner compressor relay control
ends that is relay pin No.86 and ECU pin No.70.
Follow up
steps
Next step
Yes
To step No.4
No
Next step
No
Yes
Repair or
replace cable
To step No.2
Replace relay
No
Next step
Yes
Yes
No
Repair or
replace cable
Diagnosis
help
55
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
DTC: P1651 Trouble light control circuit failure
No.
1
2
3
4
Operating steps
Result
Connect the diagnostic tester and commutator, put the
ignition switch to “ON”.
Carry out action test to engine trouble light by using
diagnostic meter “actuator action test”item; and observe
the indicator if it is always at the status of extinguishing or
lighting on.
Follow up
steps
Next step
Yes
Next step
No
System is
correct
Check if there is open circuit or short circuit to ground of
the engine trouble light power supplying circuit.
Yes
Check if there is open circuit or short circuit to power
supply or short circuit to ground between the circuit of
engine trouble light control ends and ECU pin No. 28.
Yes
No
No
Repair or
replace cable
Next step
Repair or
replace cable
Diagnosis
help
5. TYPICAL FAILURE AND ITS DIAGNOSIS FLOW
5.1 EXPLANATION
Carry out the primary inspection before start the diagnosing according to the engine failure
phenomenon.
1) Make sure the engine trouble light is working properly;
2) Make sure that there is no failure information record checked by diagnostic meter;
3) Make sure that the failure phenomenon exists according to the customers’complaints, and
confirm the conditions causing the failure.
Then carry out the exterior inspection:
(1)
Check if there is any fuel pipe is leaking;
(2)
Check if the vacuum pipe is broken, kinked up or linked correctly;
(3)
Check if the air intake pipe is jammed, leaking, staved or damaged;
(4) Check the high voltage line of ignition system if it is broken or aging and if the
ignition order is correct;
(5)
Check the cable grounding place if it is clean and fastness;
56
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
(6)
ENGINE EFI SYSTEM
Check the sensor and actuator joint if it is loosening or bad contact.
Important notice: if the above phenomenon is appeared, you should repair the above the
failure at first otherwise it will influence the later service.
Diagnosis help:1 Confirm there is no engine failure record;
2 Confirm that the failure exists before the customer complaints;
3 Inspect the engine according to the above steps and find nothing wrong;
4 During the service please do not ignore the influence from vehicle
maintenance, cylinder pressure, mechanical ignition timing and fuel
conditions;
5 Replace ECU and carry out test. If the failure is deleted, the failure is in
ECU; if the failure can not be deleted, replace back to the original ECU and
repeat the flow and check and repair it again.
5.2 TYPICAL FAILURE DIAGNOSIS FLOW
1. The engine does not rotate or rotate slowly when it is started
The normal failure component: 1) accumulator; 2) starting motor; 3) cable or ignition
switch; 4) mechanical part of the engine.
The general diagnosis flow:
No.
1
2
3
4
5
Operating steps
Check the voltage value between the two wiring terminals
of the accumulator by multimeter; check if it is around
8-12V when the engine is starting.
Put the ignition switch at start position, checking the anode
terminal of starting motor by multimeter and observe the
voltage if it is above 8V.
Disassemble the starting motor and check its working
conditions. Check if there is open circuit or jammed by
poor lubricating.
If the failure is happened in winter time, check if it is
because of the wrong engine lubricant and gearbox oil
causes the big resistance of the starting motor.
Check the mechanical resistance inside of the engine if it is
too big causes the starting motor can not rotate or rotate
slowly.
Result Follow up steps
Yes
Next step
Replace
No
accumulator
Yes
No
Yes
No
Yes
No
Yes
No
Next step
Repair or
replace cable
Repair or
replace starting
motor
Next step
Change to
correct
lubricant
Next step
Repair the
engine inside
resistance
Repeat the
above steps
57
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
2. The engine can draw rotating but can not start successfully when it is started.
General failure component: 1) no fuel in fuel tank; 2) fuel pump; 3) speed sensor; 4)
ignition coil; 5) engine mechanical part.
Diagnosis flow:
No.
1
2
3
4
5
Operating steps
Connect the fuel pressure meter ( connecting point is
the front end of fuel distributing pipe assembly fuel
intake pipe); starting the engine by starter and check
fuel pressure if it is around 260kpa; take off the
vacuum pipe from fuel pressure regulator check the
fuel pressure if it is around 300kpa.
Result
Yes
Follow up steps
Next step
No
Repair the fuel
supplying
system
Connect EFI diagnostic meter; observe “engine speed”
data item and start the engine and check if there is
rotation speed signal is output.
Yes
Next step
Pull off one of the cylinder separating line and take off
this cylinder injector joint and connect spark plug to it;
keep the spark electrode around 5mm away from
engine body; start the engine by starter and check if
there is blue and white high pressure fire.
Yes
Check the pressure of each engine cylinder; check if
there is engine cylinder insufficient pressure.
Check if the power supply to ECU pin No.12, 13, 44,
45, 63 is correct; check if the pin armature of No. 3,
51, 53, 61, 80 are working correctly.
No
No
Repair the
sensor cable
Next step
Repair the
ignition system
No
Eliminate
engine
mechanical
failure
Next step
Yes
Diagnosis help
No
Check the
corresponding
line
Yes
58
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
3. It is hard to start the heating car.
General failure component: 1) water inside of fuel; 2) fuel pump; 3) coolant
temperature sensor; 4) fuel pressure regulator vacuum pipe; 5) ignition coil.
General diagnostic flow
No.
1
2
3
4
Operating steps
Result
Connect the fuel pressure meter ( connecting point is the
front end of fuel distributing pipe assembly fuel intake
pipe); starting the engine and check fuel pressure at idle
speed if it is around 260kpa; take off the vacuum pipe
from fuel pressure regulator check the fuel pressure if it
is around 300kpa.
Pull off one of the cylinder separating line and connect
spark plug to it; keep the spark electrode around 5mm
away from engine body; start the engine and check if
there is blue and white high pressure fire.
Take off the coolant temperature sensor joint and start
the engine; observe if the engine can be started
successfully. (or serial connecting a 300Ωresistance at
the joint of coolant temperature sensor; observe if we
can start the engine)
Yes
Check if there if loosen or leaking of the fuel pressure
regulator vacuum pipe..
Yes
5
Check fuel conditions and check if the failure is
appeared after the fuel refilling
6
Connect EFI system adaptor, turn on the ignition switch;
check the power supply of pin No.12, 13, 44, 45 and
No.63 if it is in right conditions; check pin armature of
No.3, 51, 53, 61 and No.80 if it is in right conditions.
No
Yes
No
Yes
No
No
Yes
No
Yes
Follow up
steps
Next step
Repair the
fuel supplying
system
Next step
Repair the
ignition
system
Repair circuit
or replace
sensor
Next step
Repair or
replace
Next step
Change fuel
Diagnosis
help
Diagnosis
help
Check
correspond
circuit
59
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
4. It’s hard to start the cold car.
General failure component: 1), water in the fuel; 2), fuel pump; 3), coolant temperature
sensor; 4), injector; 5), ignition coil; 6), throttle valve and idle speed by pass port; 7),
engine mechanical part.
General diagnosis flow:
No.
1
2
3
4
5
6
7
8
Operating steps
Result
Connect the fuel pressure meter ( connecting point is the
Yes
front end of fuel distributing pipe assembly fuel intake
pipe); start the engine and check fuel pressure at idle
speed if it is around 260kpa; take off the vacuum pipe
No
from fuel pressure regulator check the fuel pressure if it
is around 300kpa.
Pull off one of the cylinder separating line and connect
Yes
spark plug to it; keep the spark electrode around 5mm
away from engine body; start the engine and check if
No
there is blue and white high pressure fire.
Take off the coolant temperature sensor joint and start the
Yes
engine; observe if the engine can be started successfully.
(or serial connecting a 2500Ωresistance at the joint of
coolant temperature sensor; observe if we can start the
No
engine)
Step on the accelerator slightly and observe if it is easy to
be started
Disassemble the injector, check the injector using the
injector special cleaning analysis meter and observe if it
is leaking or jammed.
Check fuel conditions and check if the failure is appeared
after the fuel refilling
Check pressure conditions of every cylinder and observe
if there is insufficient pressure
Connect EFI system adaptor, turn on the ignition switch;
check the power supply of pin No.12, 13, 44, 45 and
No.63 if it is in right conditions; check pin armature of
No.3, 51, 53, 61 and No.80 if it is in right conditions.
Follow up steps
Next step
Repair the fuel
supplying system
Next step
Check and repair
ignition system
Repair circuit or
replace sensor
Next step
No
Yes
Clean throttle
valve and idle
speed air port
Next step
Replace the part
No
Next step
Yes
No
Yes
No
Yes
Change fuel
Next step
Trouble shoot
Next step
Diagnosis help
No
Check correspond
circuit
Yes
60
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
5. Normal engine speed but hard to start at any time.
General failure component: 1), water in fuel; 2), fuel pump; 3), coolant temperature
sensor; 4), injector; 5), ignition coil; 6), throttle valve and idle speed by pass port; 7), air
intake port; 8), ignition timing; 9), spark plug; 10), engine mechanical part.
General diagnosis flow:
No.
Operating steps
Result
1
Check the air cleaner if it is jammed; check the air
intake port if it is leaking.
Yes
2
3
Connect the fuel pressure meter ( connecting point is
the front end of fuel distributing pipe assembly fuel
intake pipe); start the engine and check fuel pressure
at idle speed if it is around 260kpa; take off the
vacuum pipe from fuel pressure regulator check the
fuel pressure if it is around 300kpa.
Pull off one of the cylinder separating line and connect
spark plug to it; keep the spark electrode around 5mm
away from engine body; start the engine and check if
there is blue and white high pressure fire.
4
Check spark plugs in every cylinder and observe its
type and clearance if it is accord with the regulation.
5
Take off the coolant temperature sensor joint and start
the engine; observe if the engine can be started
successfully.
6
7
8
Step on the accelerator slightly and observe if it is
easy to be started easily.
Disassemble the injector, check the injector using the
injector special cleaning analysis meter and observe if
it is leaking or jammed.
Check fuel conditions and check if the failure is
appeared after the fuel refilling
9
Check pressure conditions of every cylinder and
observe if there is insufficient pressure
10
Check the engine ignition order and ignition timing if
it is accord with the regulation.
No
Yes
Follow up steps
Repair the air
intake system
Next step
Next step
No
Repair the fuel
supplying system
Yes
Next step
No
Check and repair
ignition system
Yes
Next step
No
Adjust or replace
No
Repair circuit or
replace sensor
Next step
Clean throttle
valve and idle
speed air port
Next step
Yes
Replace the part
No
Next step
Yes
No
Yes
No
Change fuel
Next step
Trouble shoot
Next step
Yes
Next step
No
Repair the
ignition timing
Yes
No
Yes
61
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
6. Regular starts but the idle speed is not steady at any time.
General failure component: 1), water in fuel; 2), injector; 3), spark plug; 4), throttle
valve and idle speed by pass port; 5), air intake port; 6), idle speed regulator; 7),
ignition timing; 8), spark plug; 9), engine mechanical.
General diagnosis flow:
No.
Operating steps
Result
3
Check spark plugs in every cylinder and observe its type
and clearance if it is accord with the regulation.
4
Check the throttle valve and idle speed by pass if there is
carbon deposition.
Yes
Follow up steps
Repair the air
intake system
Next step
Clean or
replace
Next step
Next step
Adjust or
replace
Cleaning
1
Check the air cleaner if it is jammed; check the air intake
port if it is leaking.
Yes
No
Next step
Disassemble the injector, check the injector using the
injector special cleaning analysis meter and observe if it is
leaking or jammed.
Check fuel conditions and check if the failure is appeared
after the fuel refilling
Yes
Replace part
No
Next step
Yes
No
Change fuel
Next step
7
Check pressure conditions of every cylinder and observe if
there is big pressure difference between the cylinders.
Yes
Trouble shoot
8
Check the engine ignition order and ignition timing if it is
accord with the regulation.
No
Yes
9
Connect EFI system adaptor, turn on the ignition switch;
check the power supply of pin No.12, 13, 44, 45 and No.63
if it is in right conditions; check pin armature of No.3, 51,
53, 61 and No.80 if it is in right conditions.
Next step
Next step
Repair the
ignition timing
Diagnosis help
Repair the
corresponding
line
2
5
6
Check idle speed regulator if it is partial blocked
No
Yes
No
Yes
No
No
Yes
No
62
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
7. Regular starts but the idle speed is not steady during engine heating.
General failure component: 1), water in fuel; 2), coolant temperature sensor; 3), spark
plug; 4), throttle valve and idle speed by pass port; 5), air intake port; 6), idle speed
regulator; 7), engine mechanical.
General diagnosis flow:
No.
Operating steps
Result
1
Check the air cleaner if it is jammed; check the air
intake port if it is leaking.
Yes
2
3
4
5
6
7
8
Check spark plugs in every cylinder and observe its
type and clearance if it is accord with the regulation.
Disassemble the idle speed regulator and check the
throttle valve and idle speed by pass port if there is
carbon deposition
Pull off coolant temperature sensor joint and start the
engine; observe the engine if it is idle speed unsteady
during warming up the engine.
Disassemble the injector, check the injector using the
injector special cleaning analysis meter and observe
if it is leaking or jammed or overflowing.
Check fuel conditions and check if the failure is
appeared after the fuel refilling
Check pressure conditions of every cylinder and
observe if there is big pressure difference between
the cylinders.
Connect EFI system adaptor, turn on the ignition
switch; check the power supply of pin No.12, 13, 44,
45 and No.63 if it is in right conditions; check pin
armature of No.3, 51, 53, 61 and No.80 if it is in
right conditions.
No
Follow up steps
Repair the air
intake system
Next step
Next step
Adjust or replace
Cleaning the
related parts
Next step
Repair the line or
replace sensor
Next step
Yes
Replace part
No
Next step
Yes
No
Change fuel
Next step
Yes
Trouble shoot
No
Next step
Yes
Diagnosis help
No
Repair the
corresponding
line
No
Yes
No
Yes
No
Yes
63
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
8. Regular starts but idle speed is not steady after the engine heating.
General failure component: 1), water in fuel; 2), coolant temperature sensor; 3), spark
plug; 4),throttle valve and idle by pass port; 5), air intake port; 6), idle speed regulator;
7), engine mechanical part.
General diagnosis flow:
No.
Operating steps
1
Check the air cleaner if it is jammed; check the air intake
port if it is leaking.
2
Check spark plugs in every cylinder and observe its type
and clearance if it is accord with the regulation.
3
Disassemble the idle speed regulator and check the throttle
valve and idle speed by pass port if there is carbon
deposition
4
Pull off coolant temperature sensor joint and start the
engine; observe the engine if it is idle speed unsteady
during warming up the engine.
Result Follow up steps
Repair the air
Yes
intake system
No
Next step
Yes
Next step
Adjust or
No
replace
Cleaning the
Yes
related parts
No
Next step
Repair the line
Yes
or replace
sensor
No
Next step
Disassemble the injector, check the injector using the
injector special cleaning analysis meter and observe if it is
leaking or jammed or overflowing.
Check fuel conditions and check if the failure is appeared
just after the fuel refilling
Yes
Replace part
No
Next step
Yes
No
Change fuel
Next step
7
Check pressure conditions of every cylinder and observe if
there is big pressure difference between the cylinders.
Yes
Trouble shoot
8
Connect EFI system adaptor, turn on the ignition switch;
check the power supply of pin No.12, 13, 44, 45 and No.63
if it is in right conditions; check pin armature of No.3, 51,
53, 61 and No.80 if it is in right conditions.
No
Yes
Next step
Diagnosis help
Repair the
corresponding
line
5
6
No
64
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
9. Regular starts but idle speed is not steady or dying out when there is partial loading.
General failure component: 1) air conditioner system; 2) idle speed regulator; 3)
injector.
General diagnosis flow:
No.
1
2
3
4
5
6
Operating steps
Result
Disassemble the idle speed regulator and check the
Yes
throttle valve and idle speed by pass port if there is
carbon deposition.
No
Observe if the engine output power increased when
Yes
the air conditioner is switched on, that is using EFI
system diagnosis meter observing ignition angle of
No
advance, fuel injection pulse width and changes of air
intake flow.
Connect EFI system adaptor; break connecting line of
ECU pin No.75; check the cable end if it is up level
signal when the air conditioner is switched on.
Check air conditioning system pressure; check the
compressor solenoid clutch and air conditioner
compressor pump fuel conditions and check if it is
working correctly.
Disassemble the injector, check the injector using the
injector special cleaning analysis meter and observe if
it is leaking or jammed or overflowing.
Connect EFI system adaptor, turn on the ignition
switch; check the power supply of pin No.12, 13, 44,
45 and No.63 if it is in right conditions; check pin
armature of No.3, 51, 53, 61 and No.80 if it is in right
conditions.
Yes
No
Yes
Follow up steps
Cleaning the
related parts
Next step
To step No.4
Next step
Next step
Repair air
conditioning
system
Next step
No
Repair the air
conditioning sys.
Yes
Replace fault part
No
Next step
Yes
Diagnosis help
No
Repair the
corresponding
line
65
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
10. Regular starts with high idle speed.
General failure component: 1) throttle valve and idle speed by pass port; 2) vacuum
pipe; 3) idle speed regulator; 4) coolant temperature sensor; 5) ignition timing.
General diagnosis flow:
No.
1
2
3
4
Operating steps
Result Follow up steps
Yes
Adjust
Check accelerator cable if it is blocked or over tightening
No
Next step
Repair the air
Yes
in taking
Check the air intake system and its connecting vacuum pipe
system
if it is leaking.
No
Next step
Disassemble the idle speed regulator and check the throttle
Clean related
Yes
valve and idle speed by pass port if there is carbon
part
deposition
No
Next step
Repair line or
Yes
Take off the coolant temperature sensor joint; start the
replace sensor
engine and observe if it has high idle speed.
No
Next step
5
Check the engine ignition timing if it is accord with the
regulations.
6
Connect EFI system adaptor, turn on the ignition switch;
check the power supply of pin No.12, 13, 44, 45 and No.63
if it is in right conditions; check pin armature of No.3, 51,
53, 61 and No.80 if it is in right conditions.
Yes
No
Yes
No
Next step
Repair the
ignition timing
Diagnosis help
Repair the
corresponding
line
66
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
11. Low engine speed or dying out exists when it is accelerated.
General failure component: 1) water in fuel; 2) air intake pressure sensor and throttle
position sensor; 3) spark plug; 4) throttle valve and idle speed by pass port; 5) air intake
port; 6) idle speed regulator; 7) injector; 8) ignition timing; 9) exhaust pipe.
General diagnosis flow:
No.
Operating steps
Result
1
Check the air cleaner if it is jammed.
2
Connect the fuel pressure meter ( connecting point is the
front end of fuel distributing pipe assembly fuel intake
pipe); start the engine and check fuel pressure at idle speed
if it is around 260kpa; take off the vacuum pipe from fuel
pressure regulator check the fuel pressure if it is around
300kpa.
3
Check spark plugs in every cylinder and observe its type
and clearance if it is accord with the regulation.
4
Disassemble idle speed regulator and check throttle valve,
idle speed regulator and idle speed by pass port if there is
carbon deposition.
5
6
7
8
Inspect air intake pressure sensor, throttle position sensor
and its line if it is working correctly.
Disassemble the injector, check the injector using the
injector special cleaning analysis meter and observe if it is
leaking or jammed.
Check fuel conditions and check if the failure is appeared
after the fuel refilling
Check the engine ignition order and ignition timing if it is
accord with the regulation.
Yes
No
Yes
No
Yes
No
Yes
No
Yes
Check the exhaust pipe if the air exhausting is smooth
10
Connect EFI system adaptor, turn on the ignition switch;
check the power supply of pin No.12, 13, 44, 45 and No.63
if it is in right conditions; check pin armature of No.3, 51,
53, 61 and No.80 if it is in right conditions.
Repair the fuel
supplying
system
Next step
Adjust or
replace
Clean related
part
No
Yes
No
Next step
Next step
Repair line or
replace sensor
Replace fault
part
Next step
Replace fuel
Next step
Yes
Next step
No
Yes
No
Yes
9
Follow up steps
Repair the air
intake system
Next step
Next step
No
Repair ignition
timing
Next step
Repair or
replace exhaust
pipe
Yes
Diagnosis help
No
Repair
corresponding
line
67
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
12. React slowly when it is accelerated.
General failure component: 1) water in fuel; 2) air intake pressure sensor and throttle
position sensor; 3) spark plug; 4) throttle valve and idle speed by pass port; 5) air intake
port; 6) idle speed regulator; 7) injector; 8) ignition timing; 9) exhaust pipe.
General diagnosis flow:
No.
Operating steps
1
Check the air cleaner if it is jammed.
2
Connect the fuel pressure meter ( connecting point is the
front end of fuel distributing pipe assembly fuel intake
pipe); start the engine and check fuel pressure at idle speed
if it is around 260kpa; take off the vacuum pipe from fuel
pressure regulator check the fuel pressure if it is around
300kpa.
3
Check spark plugs in every cylinder and observe its type
and clearance if it is accord with the regulation.
4
Disassemble idle speed regulator and check throttle valve,
idle speed regulator and idle speed by pass port if there is
carbon deposition.
5
6
7
8
Inspect air intake pressure sensor, throttle position sensor
and its line if it is working correctly.
Disassemble the injector, check the injector using the
injector special cleaning analysis meter and observe if it is
leaking or jammed.
Check fuel conditions and check if the failure is appeared
after the fuel refilling
Check the engine ignition order and ignition timing if it is
accord with the regulation.
Result Follow up steps
Repair the air
Yes
intake system
No
Next step
Yes
Next step
No
Yes
No
Yes
No
Yes
Check the exhaust pipe if the air exhausting is smooth
10
Connect EFI system adaptor, turn on the ignition switch;
check the power supply of pin No.12, 13, 44, 45 and No.63
if it is in right conditions; check pin armature of No.3, 51,
53, 61 and No.80 if it is in right conditions.
Next step
Adjust or
replace
Clean related
part
No
Yes
No
Next step
Next step
Repair line or
replace sensor
Replace fault
part
Next step
Replace fuel
Next step
Yes
Next step
No
Yes
No
Yes
9
Repair the fuel
supplying
system
No
Repair ignition
timing
Next step
Repair or
replace exhaust
pipe
Yes
Diagnosis help
No
Repair
corresponding
line
68
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
13. The performance is poor when it is accelerated.
General failure component:1) water in fuel; 2) air intake pressure sensor and throttle
position sensor; 3) spark plug; 4) ignition coil; 5) throttle valve and idle speed by pass
port; 6) air intake port;7) idle speed regulator; 8) injector; 9) ignition timing; 10)
exhaust pipe.
General diagnosis flow:
No.
Operating steps
Result
Yes
1
Check if there are failures like clutch skidding, low tyre
pressure, brake dragging, wrong tyre size, and wrong four
wheel positioning etc..
2
3
4
Check the air cleaner if it is jammed.
Connect the fuel pressure meter ( connecting point is the
front end of fuel distributing pipe assembly fuel intake
pipe); start the engine and check fuel pressure at idle speed
if it is around 260kpa; take off the vacuum pipe from fuel
pressure regulator check the fuel pressure if it is around
300kpa.
Pull off one of the cylinder separating line and connect
spark plug to it; keep the spark electrode around 5mm away
from engine body; start the engine and check the high
pressure fire strength if it is regular.
5
Check spark plugs in every cylinder and observe its type and
clearance if it is accord with the regulation.
6
Disassemble idle speed regulator and check throttle valve,
idle speed regulator and idle speed by pass port if there is
carbon deposition.
7
8
9
10
Inspect air intake pressure sensor, throttle position sensor
and its line if it is working correctly.
Disassemble the injector, check the injector using the
injector special cleaning analysis meter and observe if it is
leaking or jammed.
Check fuel conditions and check if the failure is appeared
after the fuel refilling
Check the engine ignition order and ignition timing if it is
accord with the regulation.
Follow up
steps
Repair
Next step
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Repair the air
intake system
Next step
Next step
Repair the
fuel supplying
system
Next step
Repair
ignition
system
Next step
Adjust or
replace
Clean related
part
Next step
Next step
Repair line or
replace sensor
Replace fault
part
Next step
Replace fuel
Next step
Next step
Repair
ignition
timing
69
http://WWW.FORA-CLUB.RU
CHERY·A21 SERVICE MANUAL
ENGINE EFI SYSTEM
Yes
11
Check the exhaust pipe if the air exhausting is smooth
12
Connect EFI system adaptor, turn on the ignition switch;
check the power supply of pin No.12, 13, 44, 45 and No.63
if it is in right conditions; check pin armature of No.3, 51,
53, 61 and No.80 if it is in right conditions.
No
Yes
No
Next step
Repair or
replace
exhaust pipe
Diagnosis
help
Repair
corresponding
line
70
http://WWW.FORA-CLUB.RU