2008 GEELY CK fuel pump

42Section 2 Fuel Pump Inspection1. Fuel pump
(a) Check fuel pump resistance, 0.2~3.0 at 20°. Replace fuel pump if the resistance is not as specified.
See (Figure 93)
(b) Fuel pump running:
Check fuel pump by connecting with battery. Replace fuel pump or wire if the running is not as specified.
See (Figure 94).
The test should be conducted within 10s to prevent coil from damage.
2. Fuel injector assembly
Injection Volume: 40~50cm3/s
Error between each injector: less than 10 cm3Replace injector if the injection volume is not as specified.
(a) Check for leakage: Disconnect the cable from the battery. The fuel drop/min is no more than 1 drop.
Figure 93 Figure 94 Ohmmeter
Battery Ω

45Section 4 Fuel Pump ReplacementFigure 102

461. Avoid fuel ejection
2. Disconnect fuel tank hose
3. Disconnect fuel tank return hose
4. Disconnect fuel tank gas exhaust hose
5. Detach fuel pump assembly with filter screen. See (Figure 103)
Using special tool, loose fuel tank cap. Be careful not to bend the fuel
level sensor arm when pulling out fuel pump.
6. Install fuel pump assembly. See (Figure 104). Replace ring seal .
Align the tab on the fuel pump to the notch on the fuel tank port. Tighten
the fuel tank cap with special tool.
Torque: 40N. m
7. Install fuel gas exhaust hose
(a) Install return hose;
(b) Install fuel hose;
(c) Check fuel for leakage.Figure 103
Figure 104New Washer

64Chapter 9 General Engine Troubles and Their
TroubleshootingSection 1 Overview The wide application of the electronic technologies to the vehicles brings innovation on diagnosis of the
vehicle, many varieties of diagnosis instruments that are very effective and efficient for the vehicle diagnosis
are innovated. Once the fault occurs, the best choice is to go to service station for help. However, even the
most advanced instrument has its limit. For some faults, manual diagnosis is far more convenient and easier
than that of instrument. In case of the crack, distortion and leakage of the components, the manual diagnosis
is even superior to the instrument diagnosis. The faults occurred shall be carefully analyzed and troubleshot
in accordance with the repair manual for normal usage.Section 2 General Engine Fault and TroubleshootingI. Fuel pipeline and circuit fault causing the engine starting failureengine starting failure normally include: starter does not run or starter runs but fails to crank the engine, or
cranks the engine but cranks slowly; starter can crank but fail to start the engine. There are many causes that
result in starting failure, such as failures in starting system, ignition system, fuel injection system and engine
mechanical failure.
1. starter does not run or fails to crank the engine or cranks slowly
(1) Symptom: starter does not run or spongy rotation
(2) Causes:
b. Low battery voltage, excessive battery discharge, damaged generator or failure in charging circuit;
c. Battery terminal rust and backed out;
d. Failure in starting circuit, ECU can not receive STA signal;
e. Damaged starter.
2. engine can not start and crank
(1) Symptom
With the start switch on, starter can crank but fail to start the engine.
(2) Causes
a. Empty fuel tank;
b. Electrical fuel pump inoperative;
c. Injector inoperative;
d. Low fuel pressure;
e. Unreasonable starting operation;
f. Damaged throttle position sensor or no signal is sent to ECU due to the open in throttle position
sensor circuit;

65g. Ignition system failure;
h. Low engine compression pressure.
(3) Diagnosis and Troubleshooting
a. First, check the fuel tank for fuel level, turn on the ignition switch, if fuel gauge pointer does not
move or fuel level warning lamp lights, then the fuel tank is empty, fuel shall be filled at this time.
b. Check that the electrical fuel pump for operation. Remove the fuel tank, you may use a wire to
connect the two jacks of the fuel pump for short, then turn on the ignition switch. The fuel pump
operation sound shall be able to be heard from the fuel tank nozzle or fuel flow can be felt with hand
pinching the tube; or remove the return hose on the fuel pressure regulator, check that the fuel
flows out; Direct judgment can be made if it is equipped with fuel pressure gage.
If electrical fuel pump is inoperative, check whether the main fuse, main relay, fuel pump relay,
fuel pump control circuit and ECU are OK. If all of them are OK, check fuel pump circuit for open,
short or damaged check valve. Repair or replacement shall be made when problems are found.
c. If there is no injection sound in injector, check injector control circuit for fault. You may use a
testing lamp with big resistance to be connected to the injector wiring connector, turn on the ignition
switch. If the testing lamp lights up, it indicates that the injector has been damaged and shall be
replaced; if the testing lamp does not light up, check whether the main fuse, EFI relay, fuse, ignition
switch and ECU terminal are OK, repair or replace them if they are not OK.
d. If there is low fuel pressure, the injection amount would be small and the engine won't start, you
should check the fuel filter for block and fuel pump safety valve for damage and check whether the
fuel pressure regulator is within the normal range, otherwise those components shall be repaired or
replaced.
e. Electric injection engine normally spot contact start the engine.
f. Check for open in the throttle position sensor (TPS) circuit.
g. Check whether there is Diagnostic Trouble Code (DTC), if there is, check it by the DTC; if there
is not, check the high voltage spark for intensity, if it is too weak, check spark plug, high voltage
wire, high voltage coil, distributor cover for faults, if there are faults, repair or replace them.
h. Check the compression pressure in the cylinder, insert the compression pressure gauge into the
spark plug hole, completely open the throttle, measure the compression pressure while starting the
engine. If the compression pressure is less than 980kPa when engine speed is more than 250r/min,
remove and inspect the engine and troubleshoot it.
3. The engine cranks but can not start
(1) Symptom
When starting the engine, starter can crank the engine but fail to start the engine.
(2) Causes:
a. Ignition advance angle is unfavorable;
b. Ignition is out of sequence, there is misfire;
c. High voltage spark is too weak;
d. The fuel pressure is too low;
e. fuel pressure regulator leakage;

66f. The idle control valve is faulty;
g. The water temperature sensor is damaged;
h. The vacuum pressure sensor is damaged;
i. The air filter is blocked;
j. The injector leaks;
k. The compression pressure in the cylinder is too low;
l. The intake temperature sensor is damaged.
(3) Diagnosis and Troubleshooting
a. Check high pressure spark, check whether the high pressure spark on the ignition coil high pressure
bus and extension are OK, if the bus spark is week, replace the ignition coil, if the bus spark is OK
while the extension spark is too week, replace the ignition coil also; In addition, excessive spark
plug clearance will influence the starting feature, the clearance of the spark plug shall be adjusted
to normal value (0.8±0.1mm);
b. If there is low fuel pressure, check whether the battery voltage is OK, otherwise it shall be
troubleshot or replaced; check fuel pump check valve for leakage, check fuel filter and fuel pipe for
block, if there are leakage or block, replace or troubleshoot them;
c. If there is leakage for fuel pressure regulator, intake manifold is likely to be mixed with gasoline and
it is hard to start, troubleshoot or replace them;
d. Idle control valve can not be opened to maximum position due to mechanical wear, aging or control
circuit failure, the idle control valve shall be replaced and the control circuit failure shall be troubleshot;
e. If the water temperature sensor data is not accurate, it may cause small injection, check the water
temperature sensor based on the standard data and calibrate the data;
f. There is big time lag for intake pressure temperature sensor that makes it somewhat insensitive at
low speed and result in inaccurate injection, adjustment or replacement shall be made;
g. If the air cleaner filter is too dirty, the air flow resistance is excessively big, resulting in hard start,
as a result of it, the filter shall be replaced.
In a word, there are many factors causing the starting failure of the engine, analysis shall be made based on
the severe conditions of the faults. Generally speaking, check the ignition system first, then check intake
system, fuel system, control system, at last check the cylinder pressure, check the DTC before checking the
trouble. The diagnosis and troubleshooting procedures for starting failure of the engine are shown in (Figure
148).

67Figure 148II. Fuel pipeline and Circuit Fault for Hard Engine StartingHard engine starting indicates that starter can crank but fail to start the engine, or it may take multiple
consecutive starting efforts or long time rotation to successfully start the engine. For hard start fault, make
sure whether it occurs at cold or hot status or regardless of the cold or hot status.
1. Symptom
When starting, engine cranks at normal speed, but it takes longer to start or fails to start although cranks.
2. Causes:
a. Air cleaner is clogged;
b. Intake temperature sensor fault;
c. Water temperature sensor fault; Engine can not start

Check the starting system Repair or replace the part if it is faulty

Check the high voltage spark
No high voltage spark or weak spark OK
Check the ignition system Is there any sign of cranking
No sign of cranking There is sign of cranking
Check the electric fuel pump for operation Check the air cleaner filter

Operative Inoperative OK Clogged
Check the injector Check the electric fuel Check the Replaced
pump and its control circuit spark clearance
Operative Inoperative
Measure the fuel pressure
Measure the fuel pressure Check the injector
Measure the vapor pressure,
water temperature and intake
Excessively low OK Check the control circuit air temperature sensor
Check the fuel Check thecylinder pressure Check the cylinder pressure
pressure regulator

69j. Poor intake and exhaust valve seal, failed piston ring, low compression pressure;
h. Too many carbon deposit in spark plug and combustion chamber;
k. Water temperature switch and thermostat fault;
l. Aging of Oxygon sensor;
m. Incorrect ignition timing;
n. Check valve fault.
Figure 149Engine is difficult to start


Check whether the air cleaner is clogged Clogged
Troubleshooting

OK
Check the idle control valve NG
Repair or replace
OK
Check the fuel pressure Excessivly low
Service the electric fuel pump,
fuel filter and fuel pressure regulator
OK
Check the vacuum pressure sensor NG
Replace
OK
Check the water temperature sensor and intake air temperature sensor NG
Replace
OK
Check the start switch signal No
Service the start signal wire
OK
Check the ignition timing Misaligned
Adjust
OK
Check the cylinder pressure NG
Disassemble the engine
OK
Replace the ECU to retry