Chery Automobile Maintenance Manual 1

Foreword

Engine Maintenance Manual of Chery Oriental Son is mainly for the

reference of maintenance operators of Chery Automobile special
maintenance station. Engine Maintenance Manual consists of mechanics
section and electronic section, which introduces basic parameters of
Oriental Son engine, brief introduction, fitting, assembling and adjustment
tips of assembly components and general troubleshooting. It is convenient
for maintenance staff to refer to related documents.
Chery Automobile Co., Ltd. reserves the right to change manual contents
and have no obligation to notice the end users in advance.

Service Department
Chery Automobile Co., Ltd., AnHui
Dec. 22nd, 2003

Contents
Chapter 1 Overview 3
I. Basic specifications 3
II. Maintenance Specifications 4
III. Special tools 5
IV. System Principle Figure 7
V. Electronic System Control Process 8
Chapter 2 Air Intake System 10
I. Airflow Sensor 10
II. Throttle Position Sensor 12
III. Intake Air Temperature Sensor 16
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IV. Barometric Pressure Sensor 18

V. Idle Speed Motor 20
VI. Throttle Body Structure 21
VII. Throttle Body Cleanness 22
Chapter 3 Ignition control system 23
I. Engine coolant temperature sensor 23
II. Crank angle sensor 25
III. Camshaft position sensor 27
IV. Ignition coil 29
V. Spark plug 31
VI. Knock sensor 32
Chapter 4 Emission Control System 33
Chapter 5 Charging System 38
Chapter 6 Engine ECU Control Unit 48
Chapter 7 Diagnostic Troubleshooting 53

Chapter 1 Overview
Oriental Son car adopts electronic multi-point sequential fuel injection system. Engine
electronic unit uses all kinds of sensors installed in different engine parts to measure engine
operation parameters. It will control injection volume precisely by controlling injector according to
pre-setup computer-embedded control program, which will adjust the mixture density to the most
suitable under different environment. Additionally, electronic fuel injection system may implement
these functions such as start enrichment, warming up enrichment, acceleration enrichment, full load
enrichment, deceleration dilution, enforce idle speed fuel cutoff and automatic idle speed control etc.
by computer control program, which will satisfy mixture requirements under special environment,
improve excellent engine fuel economy and emission performance, as well as motor vehicle usage
performance.

I. Basic Specifications
Item Specifications
Throttle tank 54
Throttle position sensor Rheostat meter
Idle speed control servo Stepper motor type (Bypass air control
Throttle Body
system, with air mass limiter)
Idle speed position switch Rotation touch type within throttle
body sensor
Sensor Airflow sensor Karman vortices airflow meter
Barometric pressure sensor Semiconductor
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Intake air temperature sensor Thermo resistance

Coolant temperature sensor Thermo resistance
Vehicle speed sensor Magneto-resistive component
Anti manual shift switch Contact switch
Cam position sensor Hall component
Crank angle sensor Hall component
Power steering switch Contact switch
Actuator Engine control relay Contact switch
Fuel pump relay type Contact switch
Injector type and number Solenoid, 4 pcs
Injector model CDH240
EGR control solenoid Load circular solenoid
Fuel pressure Adjustment Pressure kPa 329
regulator
 Chery Automobile Maintenance Manual 4

II. Maintenance Specifications

Item Specifications
Basic idle speed r/min 750±50
Throttle position sensor adjustment voltage mV 400~1000
Throttle position sensor resistance 28~33（at 20°C）
Intake air temperature sensor 20°C 2.3~3.0
resistance k 80°C 0.30~0.42
Coolant temperature sensor 20°C 2.1~2.7
resistance k 80°C 0.26~0.36
Fuel pressure kPa Vacuum soft tube disconnected About 324~343 at idle
limitation speed
Vacuum soft tube connected About 265 at idle limitation
speed
Injector coil resistance 13~16（at 20°C）
Mixture adjustment bolt (Rheostat) Resistance k 4~6
 Chery Automobile Maintenance Manual 5

III. Special Tools

Tools Number Name Purpose

MB9912223 Wring assembly Fuel indicator
A：MB991219 A：Wiring for test simple check
B：MB991220 B：LED wiring A ： Connector pin
C：MB991221 C ： LED wiring contact pressure
D：MB991222 header check
D：Detect pin B ： Power supply
circuit check
C ： Power supply
circuit check
D: Marketing
measurement table
measure rod
MB991502 MUT-II accessories  Read error code
 MPI system
check

MB991348 Wiring assembly for  Measure

test voltage during
diagnostic
troubleshooting

MB991709 Wiring for test

MB991519 Alternator wiring Measure voltage

connector during diagnostic
troubleshooting

MD998463 Test wiring  Idle speed

(6-pin, square) control servo check

Tools Number Name Purpose

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MD998478 Test wiring  Measure

(3-pin, 3 shape) voltage during
diagnostic
troubleshooting

MD998709 Connecting soft tube Fuel pressure

measurement

MD998742 Soft tube joint

MD998706 Injector experimental Check the spray

assembly shape of injector.

MD991607 Injector experimental

wiring

MD998741 Injector experimental

joint

MD991608 clip

IV. System Principle Figure



Oxygen
Sensor
Oxygen
（前） Sensor
（后）

Crank Angle
 Chery Automobile Maintenance Manual 7

进气温度传感器 Intake air temperature sensor

怠速控制伺服机构 Idle speed control servo
空气流量传感器（带气压传感器）Airflow sensor (Sensor with air pressure)
凸轮轴位置传感器 Camshaft position sensor
空气滤清器 Air cleaner
进气 Air inlet
燃油压力调节器 Fuel pressure regulator
至燃油箱 to fuel tank
接自输油泵 Connected from fuel feed pump
节气门位置传感器（带怠速位置开关）Throttle position sensor (With idle speed position switch)
PCV 阀 PCV valve
喷油器 Injector
EGR 阀 EGR valve
EGR 控制电磁阀 EGR control solenoid
滤毒器 Canister
发动机冷却液温度传感器 Engine coolant temperature sensor
氧传感器 Oxygen sensor
曲轴角度传感器 Crank angle sensor
V. Electronic System Control Process
Fuel Injection Control
ECU will control injector drive time and injection timing to make mixture of best density for
engine under different environment. There is an injector at each cylinder inlet port. Fuel pump in
fuel tank will pump out fuel and transfer it to fuel distribution pipe. Fuel pressure regulator will keep
fuel pressure stable and injector will inject fuel gas directly to each cylinder port. In each engine
operation cycle (every two cycles for crank), each cylinder injects oil once (Injection sequence is 1-
3-4-2, which is named sequential injection). When engine is at cold or high load running, ECU will
implement open loop control and provide dense mixture for good performance. When engine is at
 Chery Automobile Maintenance Manual 8

normal status (medium/small load), ECU will implement close loop control and make the best
proportion of air and fuel gas according to the signal feed backed by oxygen sensor, which will make
three-way catalytic converter at best purge efficiency.
Idle Speed Control
It will control throttle bypass airflow according to idle speed status and engine load variety at idle
speed, which will keep idle speed at most suitable speed. According to engine coolant temperature
and air conditioner load, ECU will driver idle speed control motor (ISC) to make engine running at
target idle speed. Additionally, when engine is running at idle speed, please open or close air
conditioner switch. ISC motor will adjust airflow according to engine load status to prevent instable
idle speed.
Ignition Timing Control
Electronic unit control power transistor ON/OFF controls primary current conductivity in ignition
coil. Ignition timing control is to get the best ignition time, which will satisfy engine requirement
under different environment. ECU will confirm ignition time according to engine speed, airflow,
airflow temperature, engine coolant temperature and barometric pressure.
Self-Diagnostic
（1） When one sensor and actuator detect abnormality, engine failure indictor will light up to warn
the driver.
（2）When one sensor and actuator detect abnormality, the error code related to the failure will be
output.
（3） RAM data related to sensor and actuator inside engine ECU may be read through MUT-II.
Additionally, the actuator will be driven by force in some case.
Other Control Operation
（1） Fuel pump control;
During engine starting on and running, fuel pump relay starts and provides fuel pump with
current.
（2）A/C relay control
Air conditioner compressor ON/OFF
（3） Purge solenoid control
（4） EGR solenoid control
（5） Fan motor control
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Electronic System Relation Schematic Map

Input Output

Barometric pressure Sensor

Injector
Intake air temperature sensor
Ignition transistor

Inflow sensor
Air conditioner relay
Engine coolant sensor E
Crank angle sensor
C EGR solenoid

Camshaft position sensor

U Canister
valve
control solenoid

Oxygen Sensor Engine check interface

Knock sensor Stepper motor for idle speed

adjustment
Idle speed switch signal
Engine failure indicator
Throttle position sensor

Start limitation switch signal Fuel pump relay

Power steering pump pressure signal

Air conditioner fan relay

Ignition switch signal

Engine coolant temperature switch Other control

Ignition timing adjustment interface

Engine main relay

Engine check interface

Air conditioner switch signal

Ignition switch start signal