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1、 江淮瑞风维修手册江淮瑞风维修手册 Emissions Control System 排放控制系统 Engine Electrical System 引擎电子系统 Engine Mechanical System 2.4 I4 引擎机械系统2.4 I4 Engine Mechanical System 2.5 TCI 引擎机械系统2.5 TCI Fuel System Gasoline 燃料系统汽油 Fuel System Diesel 燃料系统柴油机 Emissions Control System GENERAL . EC - 2 CRANKCASE EMISSION CONTROL SY
2、STEM . EC - 8 EVAPORATIVE EMISSION CONTROL SYSTEM EC -11 EXHAUST EMISSION CONTROL SYSTEM . EC -15 EC -2EMISSIONS CONTROL SYSTEM GENERAL SPECIFICATIONSEEHA0010 ComponentsFunctionRemarks Crankcase Emission System Positive crankcase ventilation (PCV) valve HC reduction Variable flow rate type Evaporati
3、ve Emission System EVAP Canister EVAP Canister Purge Solenoid Valve HC reduction Duty control solenoid valve Exhaust Emission System MFI system (air-fuel mixture control device) Three-way catalytic converter CO, HC, NOx reduction CO, HC, NOx reduction Heated oxygen sensor feedback type Monolithic ty
4、pe EVAP : Evaporative Emission SERVICE STANDARD EVAP Canister Purge Solenoid Valve Coil current0.45A or below (at 12V) TIGHTENING TORQUE ItemNmkgcmlbft Positive crankcase ventilation valve8-1280-1206-9 TROUBLESHOOTING SymptomProbable causeRemedy Engine will not start or hard to startVacuum hose disc
5、onnected or damaged EGR valve is not closed Malfunction of the EVAP Canister Purge Solenoid Valve Repair or replace Repair or replace Repair or replace Rough idle or engine stallsVacuum hose disconnected or damaged EGR valve is not closed Malfunction of the PCV valve Malfunction of the EVAP Canister
6、 Purge System Repair or replace Repair or replace Replace Check the system; if there is a problem, check its component parts Excessive oil consumptionPositive crankcase ventilation line clogged Check positive crankcase ventilation system Poor fuel mileageMalfunction of the exhaust gas recirculation
7、Check the system; if there is a problem, check its component parts GENERALEC -3 EMISSION CONTROLS LOCATIONEEUC0050 EEUC005A EC -4EMISSIONS CONTROL SYSTEM A. PCV valveB. EVAP Canister Purge Solenoid Valve EEA9005CEEA9005D C. EVAP. CanisterD. Catalytic Converter (MCC) EEA9005E MCC EEA9005G E. Catalyti
8、c Converter (UCC)F. Two-way Valve Catalytic converter EEA9005FEEA9005H GENERALEC -5 SCHEMATIC DRAWING (2.4 I4-EOBD)EEAC5070 *1. HEATER OXYGEN SENSOR (HO2S) *2. MAP SENSOR *3. THROTTLE POSITION SENSOR (With Idle Switch) *4. CAMSHAFT POSITION SENSOR (CMP SENSOR) *5. CRANKSHAFT POSITION SENSOR (CKP SEN
9、SOR) *6. ENGINE COOLANT TEMP. SENSOR (ECT Sensor) *7. KNOCK SENSOR oIGNITION SWITCH oVEHICLE SPEED SENSOR oCOOLER LOAD SIGNAL o“PNP“ SWITCH (A/T ONLY) o POWER STEERING SWITCH o IGNITION DETECT SIGNAL o BATTERY VOLTAGE *1. FUEL INJECTOR *2. IGNITION COIL *3. ISC MOTOR (Linear Solenoid Type) *4. EVAP
10、Canister Purge Solenoid Valve o FUEL PUMP CONTROL o MFI CONTROL RELAY o COOLER RELAY o IGNITION TIMING CONTROL o DIAGNOSIS INPUTECMOUTPUT Air cleaner ECM : Engine Control Module EVAP : Evaporative Emission MCC : Manifold Catalytic Converter UCC : Under floor Catalytic Converter Breath Hose Fuel pump
11、 *2 *1 PCV Valve *4 *3 *3 *6 *7 *5 *1 MCC Fuel Pressure Regulator Canister Fuel Tank *4 *2 UNLEADED EEAC007A EC -6EMISSIONS CONTROL SYSTEM SCHEMATIC DRAWING (2.4 I4)EEAC5071 UNLEADED *1. HEATER OXYGEN SENSOR (HO2S)? *2. HOT FILM SENSOR? *3. THROTTLE POSITION SENSOR? (With Idle Switch)? *4. CAMSHAFT
12、POSITION SENSOR? (CMP SENSOR)? *5. CRANKSHAFT POSITION SENSOR? (CKP SENSOR)? *6. ENGINE COOLANT TEMP. SENSOR? (ECT Sensor)? *7. KNOCK SENSOR o IGNITION SWITCH? o VEHICLE SPEED SENSOR? o COOLER LOAD SIGNAL? o “PNP“ SWITCH (A/T ONLY)? o POWER STEERING SWITCH? o IGNITION DETECT SIGNAL? o BATTERY VOLTAG
13、E *1. FUEL INJECTOR? *2. IGNITION COIL? *3. ISC MOTOR? (Linear Solenoid Type)? *4. EVAP Canister Purge Solenoid Valve? o FUEL PUMP CONTROL? o MFI CONTROL RELAY? o COOLER RELAY? o IGNITION TIMING? CONTROL? o DIAGNOSIS INPUTECMOUTPUT ECM : Engine Control Module? EVAP : Evaporative Emission? UCC : Unde
14、rfloor Catalytic Converter Air cleaner UCC Breath Hose *3 *3PCV? Valve *2 *1 *4 *1 *6 *7 *5 Fuel? Pressure? Regulator *4 Canister Fuel Tank *2 EEAC007B GENERALEC -7 SCHEMATIC DRAWING (2.4 I4)EEUC0080 LEADED *1. MAP whentheenginecoolant temperature is low, and also during idling, the valve closes so
15、that evaporated fuel is not drawn into the surge tank.After engine warm-up during ordinary driving, it opens to let the stored vapors flow into the surge tank. EEAA024A INSPECTION NOTE When disconnecting the vacuum hose, make an iden- tification mark on it so that it can be reconnected to its origin
16、al position. EEA9020B 1.Disconnect the vacuum hose (black with red stripe) from the solenoid valve. 2.Detach the harness connector. 3.Connect a vacuum pump to the nipple to which the red-striped vacuum hose was connected. 4.Apply vacuum and check when voltage is applied to the EVAP Canister Purge So
17、lenoid Valve and when the voltage is discontinued. Battery voltageNormal condition When appliedVacuum is released When discontinuedVacuum is maintained EVAPORATIVE EMISSION CONTROL SYSTEMEC -13 12V EEAA020C 5.Measure the current between the terminals of the so- lenoid valve. EVAP Canister Purge Sole
18、noid Valve: Coil at 20 C (68 F) : 0.45A or below (at 12V) Coil resistance : 26at 20 C (68 F) EEAA020D VACUUM HOSE Engine coolant temperature : 80-95 C (176-205 F) 1.Disconnect the vacuum hose from the intake manifold purge hose nipple and connect a hand vacuum pump to the nipple. EEA9023A 2.Start th
19、e engine and check that, after raising the en- gine speed by racing the engine, vacuum remains fairly constant. NOTE If there is no vacuum created the intake manifold port may be clogged and require cleaning. Vacuum Engine speed(rpm) EEA9023B OVERFILL LIMITER (TWO WAY VALVE)EEAA0250 To inspect the o
20、verfill limiter (two-way valve), refer to the Fuel tank. EVAP Canister? side Air side Mark : V5EC201D FUEL FILER CAPEEAA0260 Check the gasket of the fuel filler cap, and the filler cap itself, for damage or deformation. Replace the cap if nec- essary. Gasket V5EC205A EC -14EMISSIONS CONTROL SYSTEM E
21、VAPORATIVE (EVAP) CANISTEREEHA0240 CANISTER For monitoring, a CCV and an air filter exists as in the illustration. 1.Look for loose connections, sharp bends or damage to the fuel vapor lines. 2.Look for distortion, cracks or fuel leakage. 3.After removing the EVAP Canister, inspect for cracks or dam
22、age. EEA9005E EEHA005E TWO-WAY VALVE 1.Inspect that air flows as shown. 2.Check to connect correctly such as the arrow mark on the valve. EVAP Canister? side Air side Mark : V5EC201D EXHAUST EMISSION CONTROL SYSTEMEC -15 EXHAUST EMISSION CONTROL SYSTEM VEHICLES WITH CATALYTIC CONVERTEREEA90270 Exhau
23、st emissions (CO, HC, NOx) are controlled by a combination of engine modifications and PCM fuel con- trol. Modifications to the combustion chamber, intake manifold, camshaft and ignition system form the basic control sys- tem.Additional control devices include a catalytic con- verter and the oxygen
24、sensors which monitor mixture con- trol. These systems have been integrated into a highlyeffective system which controls exhaust emissions while maintain- ing good driveability and fuel economy. AIR/FUEL MIXTURE RATIO CONTROL SYSTEM MULTIPORT FUEL INJECTION (MFI) SYSTEMEEA90280 The MFI system employ
25、s the signals from the heated oxy- gen sensor to activate and control the injector installed in the manifold for each cylinder, precisely regulating the air/ fuel mixture ratio and reducing emissions. This allows the engine to produce exhaust gases of the proper composition to permit the use of a th
26、ree-way cat- alyst. The three-way catalyst is designed to convert the three pollutants (1) hydrocarbons (HC), (2) carbon monox- ide (CO), and (3) oxides of nitrogen (NOx) into harmless substances. The two operating modes in the MFI system are as follows: 1.Open loop-air/fuel ratio is controlled by i
27、nformation programmed into the PCM during the manufacturing process. 2.Closed loop-air/fuel ratio varies by the PCM based on information supplied by the heated oxygen sensor. Engine Electrical System GENERAL . EE - 2 IGNITION SYSTEM (DOHC) EE - 6 CHARGING SYSTEM . EE - 9 STARTING SYSTEM EE -29 PREHE
28、ATING SYSTEM . EE -40 EE -2ENGINE ELECTRICAL SYSTEM GENERAL SPECIFICATIONSEBUC0010 IGNITION 2.4 I4 Type Primary coil resistance Secondary coil resistance 0.86 10% ( ) 12.1 15% (K ) SPARK PLUG 2.4 I4 Type Champion NGK Plug gap RN10PYP4 PGR5C-11 1.0-1.1 mm (0.039-0.043 in.) STARTER MOTOR 2.4 I4Diesel
29、Type Voltage Output Reduction drive (with planetary gear) 12V 1.2KW Reduction drive (with planetary gear) 12V 2.0KW No-load characteristics Terminal voltage Amperage Speed 11V 90A or below 2,800 RPM 11V 90A or below 2,800 RPM Number of pinion teeth813 Pinion gap0.5-2.0 mm (0.0197-0.079 in.)0.5-2.0 m
30、m (0.0197-0.079 in.) GENERATOR 2.4 I4Diesel Type Rated output Voltage regulator type Regulator setting voltage Temperature compensated Battery voltage sensing 13.5V / 95A Electronic built-in type 14.4 0.3 V -10 3 mV / C Battery voltage sensing 12V / 75A Electronic built-in type 14.4 0.3 V -10 3 mV /
31、 C BATTERY All Engines Type Ampere hours 5HR Cold cranking at -17.8 C (0 F) Reverse capacity Specific gravity at 25 C (77 F) MF 68 AH, MF 90 AH 55 AH or more 540 AH or more 122 min. 1.280 0.01 GENERALEE -3 NOTE COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain
32、a terminal voltage of 7.2 or greater at a specified temperature. REVERSE CAPACITY RATING is the amount of time a battery can deliver 25A and maintain a minimum terminal voltage of 10.5 at 26.7 C (80 F). TIGHTENING TORQUE ItemsNmKgcmIbft Generator terminal (B+)5-750-703.6-5.1 Starter motor terminal (
33、B+)10-12100-1207.3-8.8 Battery terminal4-640-602.9-4.3 Spark plug20-30200-30015-22 EE -4ENGINE ELECTRICAL SYSTEM TROUBLESHOOTINGEBUC0030 IGNITION SYSTEM Trouble symptomProbable causeRemedy Ignition lock switch faultyReplace ignition lock switch Ignition coil faultyInspect ignition coil Power transis
34、tor faultyInspect power transistor Spark plugs faultyReplace plugs Ignition wiring disconnected or brokenInspect wiring Engine will not start or is hard to start (Cranks OK) Spark plugs faultyReplace plugs Ignition wiring faultyInspect wiring Ignition coil faultyInspect ignition coil Rough idle or s
35、talls Spark plug cable faultyInspect spark plug cable Spark plugs faultyReplace plugsEngine hesitates/poor acceleration Ignition wiring faultyInspect ignition coil Poor mileageSpark plugs faultyReplace plugs CHARGING SYSTEM Trouble symptomProbable causeRemedy Fuse blownCheck fuses Light burned outRe
36、place light Wiring connection looseTighten loose connections Charging warning indicator does not light with ignition switch “ON“ and engine off Electronic voltage regulator faultyReplace voltage regulator Drive belt loose or wornAdjust tension or replace drive belt Battery cables loose, corroded or
37、wornRepair or replace cables Fuse blownCheck fuses Fusible link blownReplace fusible link ElectronicvoltageregulatororgeneratorfaultyTest generator Charging warning indicator does not go out with engine running (Battery requires frequent recharging) Wiring faultyRepair wiring Drive belt loose or wor
38、nAdjust tension or replace drive belt Wiring connection loose or open circuitTighten loose connection or repair wiring Fusible link blownReplace fusible link Poor groundingRepair ElectronicvoltageregulatororgeneratorfaultyTest generator, if faulty, repair or replace. Worn batteryReplace battery Elec
39、tronic voltage regulator faultyReplace voltage regulator Engine hesitates/poor acceleration Overcharge Voltage sensing wire faultyRepair wire GENERALEE -5 STARTING SYSTEM Trouble symptomProbable causeRemedy Battery charge lowCharge or replace battery Battery cables loose, corroded or worn outRepair
40、or replace cables Transaxle range switch faulty (Vehicle with automatic transaxle only) Adjust or replace switch Fusible link blownReplace fusible link Starter motor faultyRepair starter motor Ignition switch faultyReplace ignition switch Engine will not crank Ignition lock switch faultyReplace igni
41、tion lock switch Battery charge lowCharge or replace battery Battery cables loose, corroded or worn outRepair or replace cables Engine cranks slowly Starter motor faultyRepair starter motor Starter motor faultyRepair starter motorStarter keeps running Ignition switch faultyReplace ignition switch Sh
42、ort in wiringRepair wiring PiniongearteethbrokenorstartermotorfaultyRepair starter motor Starter spins but engine will not crank Ring gear teeth brokenReplace flywheel ring gear or torque converter GLOW CONTROL SYSTEM (DIESEL) Trouble symptomProbable causeRemedy Wiring connection loose or bad wiring
43、Repair or replace wiring ECT sensor malfunctionReplace ECT sensor Glow plug malfunctionRepair or replace glow plug Engine will not start below 50 C Glow plug control unit failedReplace glow control unit Wiring connection loose or bad wiringRepair or replace wiring Glow plug malfunctionCheck the resi
44、stance of glow plug and replace, if necessary Glow plug relay malfunctionCheck the relay and replace, if necessary After first combustion, engine stall or rough idle below 50 C Glow plug control unit failedCheck the control unit and replace, if necessary Open lampReplace lamp Wiring connection loose
45、 or bad wiringRepair or replace wiring Shorted wiringRepair or replace wiring Yellow glow lamp will not turn-ON Glow plug control unit failedReplace control unit, if necessary EE -6ENGINE ELECTRICAL SYSTEM IGNITION SYSTEM (DOHC) GENERAL INFORMATIONEBA90040 lgnition timing is controlled by the Engine
46、 control module (ECM). The ignition timing data for the engine operating conditions are programmed in the memory of the ECM. Engine operating conditions (speed, load, warm-up con- dition, etc.) are detected by the various sensors. Based upon these sensor signals and the data stored in the ECM, signa
47、ls to interrupt the primary current are sent to the power transistor. The ignition coil is activated and timing is controlled at the optimum point. *CKP : Crankshaft Position *CMP : Camshaft Position CMP CKP EBA9004A IGNITION COIL (I4 : POWER TRANSISTOR BUILT-IN)EBJB5070 1.Measurement of the primary
48、 coil resistance Connect the negative (-) terminal of a 3V power sup- ply to terminal 2 of the power transistor; then check whether there is continuity between terminal 3 and terminal 2 when terminal 1 and the positive (+) ter- minal are connected and disconnected. Terminal 3 and (+) terminal Termin
49、al 1 and (+) terminal 2 ConnectedContinuity (Approximately 0.86 ) DisconnectedNon continuity Replace the power transistor if there is malfunction. 123 EBHA007A 2.Measurement of the secondary coil resistance Measure the resistance between the high-voltage ter- minals of the ignition coil. Standard value: Approximately 12.1 k EBA9009D REMOVAL AND INSTALLATIONEBUC0060 1.Disconnect the negative battery terminal. 2.Remove the air bag module. CAUTION The SRS system is designed to retain enough power to deploy air bag for about 30 se
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