JAC HFC4DA1-2C engine. Instruction — part 12

Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines

178

Fault Tree:

关闭点火开关并检查喷油器接插件

接插件问题

做必要的修理

曲轴位置传感器间隙问题？

N

Y

检查曲轴位置传感器间隙

检查减震皮带轮与传感器

Y

重新调整曲轴减震皮带轮安装，
还不行，更换减震皮带轮并进行

齿讯学习

皮带轮与传感器是否干涉

调整曲轴位置传感器间隙

（0.6~0.7mm）

N

Y

检查曲轴位置传感器

N

曲轴位置传感器问题

Y

更换曲轴位置传感器

联系技术支持

N

Get the Technical Support.

Repair accordingly.

Connector fault

Turn off ignition switch and check fuel injector connectors.

Check crankshaft position sensor clearance.

Are faults in crankshaft position sensor clearance?

Check damping belt pulley and sensor.

Check belt pulley and sensor for interference.

Check crankshaft position sensor.

Faults are in crankshaft position sensor.

Adjust clearance of crankshaft position sensor

(0.6mm~0.7mm)

Readjust installation of crankshaft damping belt

pulley. If faults occur again, replace damping

belt pulley and carry out gear message learning

Replace crankshaft position sensor.

Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines

179

25.

DTC

P0401

Actual fresh air inflow is larger than target air inflow set by EGR system.

P0402

Actual fresh air inflow is smaller than target air inflow set by EGR system.

P0403

ECU internal drive module of EGR valve actuator control wire is
overheated.

P0404

EGR valve actuator control wire is open.

P0405

Voltage of EGR valve position sensor is below the lower limit (Connection is
short to ground).

P0406

Voltage of EGR valve position sensor is above the upper limit (Connection is
open short to high level).

P0489

EGR valve actuator control wire is open.

P0490

EGR valve actuator control wire is short to high level.

Fault Description: Exhaust gas recirculation system is applied in reduction of Nitrogen oxides emission due to high
temperature combustion. Main component of the system is electronic control exhaust gas recirculation valve. Exhaust
gas recirculation valve delivers a small amount of exhaust gas into intake manifold to reduce combustion temperature.
Recirculation gas flow is controlled by ECU according to changes in engine load. In the case of deceleration, gas flow
test for exhaust gas recirculation (EGR) system is carried out by ECU. Therefore, ECU gives a transient command to
open exhaust gas recirculation valve and simultaneously monitors signals of intake manifold air pressure (MAP)
sensor and exhaust gas recirculation position sensor. In the case of inconformity of intake manifold absolute pressure
signals with exhaust gas recirculation valve spool shaft position, ECU records measured D-value of intake manifold
absolute pressure and adjust calibrated failure counter to failure technical threshold value. For error quantities of
detected exhaust gas recirculation flow are different, required test times for exhaust gas recirculation flow concerned
excessive failure technical threshold value of may be different, too. When ECU detects incorrect control signals, DTC
occurs.

Diagnosis Hint: Carry out inspection to engine control system; check engine for historical faults; check exhaust gas
recirculation system for faults as follows—vacuum leaks between exhaust gas recirculation valve and intake manifold.
In the case of carbon deposition or exhaust gas noise around component faying surface, it is indicated there is external
leakage. Check passage and exhaust gas recirculation valve for clogging; check exhaust system for relevant faults
(such as leakage due to exhaust component damage, clogging due to excessive back pressure and too low engine
vacuum and etc.); finally, carry out inspection to mechanical system.

EGR5V Power supply

EGR position signal

EGR ground signal

EGR actuator power supply

EGR actuator ground

EGR position sensor

EGR actuator

Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines

180

Terminal ECU

K23

EGR position sensor 5V power supply

K31

EGR position sensor position signal

K39

EGR position sensor ground

A04

EGR actuator power supply

A19 EGR

actuator

ground

Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines

181

Fault Tree:

Repair accordingly.

Repair accordingly.

Repair the harness.

Get the Technical Support.

Replace components.

Does the problem still exist?

Electrical fault

Check for continuity and insulating property.

Replace the actuator.

Check ECU for connector faults.

Check actuator connectors.

Connector fault

Check actuator resistance.

Actuator resistance faults

Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines

182

26.

DTC

P0480

ECU Fan I control wire is open

P0481 ECU Fan II control wire is open.

P0483

ECU Fan I control wire internal drive module is overheated.

P0484

ECU Fan II control wire internal drive module is overheated.

P0691

ECU Fan I control wire is short to ground.

P0692

ECU Fan I control wire is short to high level.

P0693

ECU Fan II control wire is short to ground.

P0694

ECU Fan II control wire is short to high level.

Fault Description: ECU provides low-speed relay with grounding via so-called “drive” internal solid component in
order to control cooling fan low speed operation. For cooling fan high speed operation, ECU adopts the method of
high speed and S/P replay control circuit grounding with simultaneous low-speed control circuit grounding. Battery
positive voltage is provided to low-speed, high-speed and S/P fan relays. When ECU commands fan relay to be
connected, control circuit voltage is low level which is close to 0V. When ECU commands fan relay to be
disconnected, control circuit voltage should be high level which is close to battery voltage. ECU monitors relay
control circuit for conditions as follows:

It is short to ground.

It is short to voltage.

It is open.

When ECU detects incorrect voltage in low-speed or high-speed drive circuit, DTC occurs and corresponding drive
will stop operating.

Cooling Fan Relay I control circuit controls low-speed cooling fan relay.

Cooling Fan Relay II control circuit controls high-speed cooling fan relay.

Diagnosis Hint: Check harness for intermittency and good contact.

Prior to maintenance, remove all fragments from connector surface. Check connector pads for correct installation to
prevent contamination from entering prior to diagnosis and component replacement.

z Poor terminal connection—Check harness connectors for looseness, mismatching, retainer damage, improper

shape or damage and connection failure with wires. Apply corresponding matching terminals for test of proper
tension.

z Harness damage—Check wire harness for damage. In the case of no harness faults, move relevant connectors and

wire harness and observe display of fault diagnostic apparatus. Fault diagnostic apparatus displays changes to
indicate fault positions.

z Check ECU and engine ground connection for reliability and cleanness. If it is determined that DTC is an

intermittent fault, please refer to Fault Record to check the time of last DTC occurrence.

Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines

183

Fault Tree:

Repair accordingly.

Check relay connectors.

Connector fault

Check ECU connectors.

Connector fault

Check continuity and insulating property..

Electrical fault

Repair the harness.

Repair accordingly.

Replace the relay (carry out ISO cycle).

ISO cycle faults

Get the Technical Support.

Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines

184

27.

DTC

P0487

Throttle valve actuator control wire is open.

P0488 ECU internal drive module of throttle valve actuator is overheated.

P2141 Throttle valve actuator control wire is short to ground.

P2142

Throttle valve actuator control wire is short to high level.

Fault Description: ECU is the control center for throttle valve actuator control system. ECU can judge driver’s
intention and then calculate corresponding throttle valve response. ECU realizes throttle valve positioning via
providing throttle valve actuator control motor with pulse width modulation (PWM) voltage. Throttle valve actuator
control system adopts circuits as follows:

Motor control 1

Motor control 2

Besides, two processors are applied in throttle valve actuator control system data monitoring. These two processors
are located in ECU, testing data of each other to prove correctness of throttle valve position.

Diagnosis Hint: Check for connection and disconnection faults or seizures due to temperature. Under extremely hot
or cold condition, existed contaminations or freeze may lead to unsmooth component movement.

If it is an intermittent fault, the possible causes may be poor contact, worn wire insulating layer or damaged wire in
insulating layer.

Check for the following conditions:

z Poor contact of ECU or exhaust brake valve—Check harness connectors.

– Terminal looseness

– Poor fit of matching parts

–Locking plate fracture

–Terminal deformation or damage

–Poor contact between terminal and wire

z Harness damage—Check harness for damage.

Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines

185

Fault Tree:

Check throttle valve actuator

connection.

Connector fault

Repair or replace.

Check throttle valve appearance.

Throttle valve faults

Check ECU connectors.

Replace the ECU.

Repair or replace.

Replace the throttle valve.

Get the Technical Support.

Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines

186

28.

DTC

P0615

ECU starting motor control wire is open or drive module is overheated.

P0616 ECU starting motor control wire is short to ground.

P0617

ECU starting motor control wire is short to high level.

Fault Description: ECU provides starting motor with grounding via so-called “drive” internal solid component in
order to control starting motor operation. Under starting motor control circuit command, when fault diagnostic
apparatus is connected, it is indicated that starting motor circuit is grounded via control module in order to provide
starting motor with voltage; when fault diagnostic apparatus is disconnected, it is indicated that starting motor circuit
is not connected via control module command currently. ECU monitors starting motor circuit for conditions as
follows:

It is short to ground.

It is short to voltage.

It is open.

When ECU detects incorrect voltage signals, DTC occurs and corresponding drive will stop operating.

Diagnosis Hint: Check harness for intermittency and good contact.

Prior to component maintenance, remove all fragments from connector surface. Check connector pads for correct
installation to prevent contamination from entering prior to diagnosis and component replacement.

z Poor terminal connection—Check harness connectors for looseness, mismatching, retainer damage, improper

shape or damage and connection failure with wires. Apply corresponding matching terminals for test of proper
tension.

z Harness damage—Check wire harness for damage. In the case of no harness faults, move relevant connectors and

wire harness and observe display of fault diagnostic apparatus. Fault diagnostic apparatus displays changes to
indicate fault positions.

z Check ECU and engine ground connection for reliability and cleanness. If it is determined that DTC is an

intermittent fault, please refer to Fault Record to check the time of last DTC occurrence.

Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines

187

Fault Tree:

Get the Technical Support.

Repair the harness.

Repair accordingly.

Repair accordingly.

Check starting motor connectors.

Connector fault

Check ECU connectors.

Connector fault

Check for continuity and insulating property

Electrical fault

Replace starting motor relay.

Are faults still in existence?

Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines

188

29.

DTC P1605

ECU instrument panel engine speed output connecting wire is short to high
level.

P1606

ECU instrument panel engine speed output connecting wire is short to
ground.

P1607

ECU instrument panel engine speed output connecting wire is open.

Fault Description: Vehicle speed sensor (VSS) provides ECU with vehicle speed information. When rotor teeth on
transmission output shaft go through sensor magnetic field, vehicle speed sensor generates signal voltage. Frequency
of this signal voltage increases with vehicle speed increase. ECU transforms the signal voltage into vehicle speed and
displays the speed on instrument panel via control circuit. ECU determines vehicle operation condition with vehicle
speed signals in order to guide driver operation. ECU monitors the circuit between ECU and instrument panel for
conditions as follows:

It is short to ground.

It is short to voltage.

It is open.

When ECU detects incorrect voltage signals, DTC occurs

Diagnosis Hint: Check harness for intermittency and good contact.

Prior to component maintenance, remove all fragments from connector surface. Check connector pads for correct
installation to prevent contamination from entering prior to diagnosis and component replacement.

z Poor terminal connection—Check harness connectors for looseness, mismatching, retainer damage, improper

shape or damage and connection failure with wires. Apply corresponding matching terminals for test of proper
tension.

z Harness damage—Check wire harness for damage. In the case of no harness faults, move relevant connectors and

wire harness and observe display of fault diagnostic apparatus. Fault diagnostic apparatus displays changes to
indicate fault positions.

z Check ECU and engine ground connection for reliability and cleanness. If it is determined that DTC is an

intermittent fault, please refer to Fault Record to check the time of last DTC occurrence.

Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines

189

Fault Tree:

检查仪表板与ECU的连接

做必要的修理

接插件问题

检查连续性和绝缘性

Y

N

电气问题

Y

修理线束

更换相应的器件

N

问题仍存在

Y

联系技术支持

Get the Technical Support.

Repair the harness.

Repair accordingly.

Check connection between instrument panel

and ECU.

Connector fault

Check continuity and insulating property

Electrical fault

Replace corresponding components.

Does the problem still exist?

Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines

190

30.

DTC P1608

ECU instrument panel preheating indicator lamp output connecting wire is
short to high level.

P1609

ECU instrument panel preheating indicator lamp output connecting wire is
short to ground.

P160A

ECU instrument panel preheating indicator lamp output connecting wire is
open.

P160B

ECU instrument panel preheating indicator lamp output wire drive module
is overheated.

Fault Description: During glow plug operation, preheater relay will send a signal to ECU. Then, ECU sends
command to preheating indicator lamp on instrument panel via control circuit. Driver carries out the next operation
via observing preheating indicator lamp status. ECU monitors the circuit between ECU and instrument panel for
conditions as follows:

It is short to ground.

It is short to voltage.

It is open.

When ECU detects incorrect voltage signals, DTC occurs.

Diagnosis Hint: Check harness for intermittency and good contact.

Prior to component maintenance, remove all fragments from connector surface. Check connector pads for correct
installation to prevent contamination from entering prior to diagnosis and component replacement.

z Poor terminal connection—Check harness connectors for looseness, mismatching, retainer damage, improper

shape or damage and connection failure with wires. Apply corresponding matching terminals for test of proper
tension.

z Harness damage—Check wire harness for damage. In the case of no harness faults, move relevant connectors and

wire harness and observe display of fault diagnostic apparatus. Fault diagnostic apparatus displays changes to
indicate fault positions.

z Check ECU and engine ground connection for reliability and cleanness. If it is determined that DTC is an

intermittent fault, please refer to Fault Record to check the time of last DTC occurrence.

Terminal ECU

K92 Preheating

time

indicator

lamp

Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines

191

Fault Tree:

Get the Technical Support.

Repair the harness.

Repair accordingly.

Check connection between instrument

panel and ECU.

Connector fault

Check for continuity and insulating

property.

Electrical fault

Replace corresponding components.

Does the problem still exist?

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

192

31.

DTC

P2228

Atmosphere pressure sensor output voltage is too low.

P2229

Atmosphere pressure sensor output voltage is too high.

Fault Description: Atmosphere pressure indicates connection of ignition switch. When engine stops operation,
control module calculates atmosphere pressure with signals sent by intake manifold absolute pressure sensor. Intake
manifold absolute pressure sensor responses to internal pressure changes of intake manifold and the pressure changes
according to different engine loads. Intake manifold absolute pressure sensor possesses circuits as follows:

5V reference voltage circuit

Low reference voltage circuit

Intake manifold absolute pressure sensor signal circuit

ECU provides intake manifold absolute pressure sensor with 5V voltage via 5V reference voltage circuit. ECU
supplies grounding via low reference voltage circuit and intake manifold absolute pressure sensor provides ECU with
a signal via signal circuit. This signal is related to intake manifold internal pressure changes. When ignition switch is
connected and engine is shut down, intake manifold absolute pressure sensor displays signals of atmosphere pressure.
In the case of engine running with wide open throttle, reading of atmosphere pressure will be renewed. ECU
determines whether voltage exceeds normal range via detecting intake manifold absolute pressure sensor signals.
When intake manifold absolute pressure sensor displays atmosphere pressure, if sensor signal voltage is not in
specified range, DTC occurs.

Diagnosis Hint: When ignition switch is connected and engine is shut down, intake manifold pressure equals to
atmosphere pressure and signal voltage is low level. ECU takes this information as vehicle elevation indication.
Moreover, to make comparison between this reading with that of an intact vehicle which possesses the same sensor is
a good method for sensor accuracy inspection. D-value of two readings should not exceed 0.4V. It is necessary to
carry out comprehensive inspection to pressure source of supercharger pressure sensor in order to check intake system
for clogging.

In the case of engine start, intake manifold absolute pressure sensor can detect any change of manifold pressure. This
test is carried out to determine sensor lag at a certain value.

In the case of normal intake manifold absolute pressure sensor, it will make rapid response to changes of acceleration
pedal positions and it should not be “lagged” or slower than changes of acceleration pedal position.

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

193

Fault Tree:

Get the Technical Support.

Repair the harness.

Repair accordingly.

Check sensor connection.

Connector fault

Check sensor resistance (for conformity with

vehicle status).

Electrical fault

Sensor resistance faults

Does the problem still exist?

Repair accordingly.

Check ECU for connector faults.

Replace the sensor.

Check continuity and insulating property

Replace components.