Manual Servicio Jac j2

Maintenance Manual for J2 Sedan Foreword

Maintenance Manual for J2 Sedan

Foreword Master Table of Contents

General Description &

Maintenance

Engine

Chassis

Body Electrical & Structure

Circuit Troubleshooting

This manual is intended to help the

professional maintenance technicians

authorized by JAC Passenger Car Sales

Company provide effective and correct

maintenance and service for JAC J2

Sedan series models. The warm service

and proper operation from the

professional maintenance technicians of

JAC passenger cars are essential for

ensuring customer satisfaction to JAC

passenger car products. Therefore, the

maintenance technicians must

understand this manual fully. This

manual should be placed in a handy

place for your convenient reference.

All contents of this manual including

pictures and technical parameters are

latest. In case maintenance works are

affected due to product improvement,

JAC Passenger Car Sales Company will

provide technical bulletins or

supplementary volumes. Therefore, you

should use this manual and pay close

attention to obtaining latest update

relevant information.JAC Passenger Car

Sales Company reserves the rights to

change, add or improve designs of its

products.

No part of this manual is allowed to be

reproduced or modified in any form,

including but not limited to electronic

media, paper, sound and image, and

mechanical media, without written

authorization from JAC Passenger Car

Sales Company.

Use of non genuine spare parts for

JAC passenger cars or nonconforming

oils during maintenance and service

processes of JAC passenger car

products may cause vehicle damage.

Chapter I General Description

Chapter II Maintenance

Chapter I Engine mechanical system

Chapter II Engine electrical system

Chapter III engine electronic control

system

Chapter I Clutch & Manual

Transmission

Chapter II Traveling system

Chapter III Braking system

Chapter I Body Electrical

Chapter II Body Structure

Maintenance Manual for J2 Sedan Contents

Contents of Overview and Service

Chapter I Overview..........................................................................................................1

Section I General Instructions ...................................................................................................... 1

I. Summary .............................................................................................................................. 1

II. Operations ............................................................................................................................ 1

Section II Vehicle Information ..................................................................................................... 2

I. Identification Information Position ........................................................................................ 2

II. Nameplate ............................................................................................................................ 2

III. Vehicle Identification Number (VIN) ..................................................................................... 3

IV. Engine Number..................................................................................................................... 4

Section III Lifting, Protection and Towing of Vehicle.................................................................. 6

I. Lifting of Vehicle ................................................................................................................... 6

II. Protection of Vehicle............................................................................................................. 6

III. Towing of Vehicle ................................................................................................................. 7

Chapter II Service............................................................................................................8

Section I Service............................................................................................................................... 8

I. Prepara tools ........................................................................................................................ 8

II. General Service.................................................................................................................... 8

III. Regular Service .................................................................................................................... 9

IV. Recommended Oil and Lubricant....................................................................................... 10

V. Service of Engine ............................................................................................................... 11

VI. Service of Chassis and Body ............................................................................................. 19

VII. Maintenance Data .............................................................................................................. 27

Maintenance Manual for J2 Sedan Overview

1

Chapter I Overview

Section I General Instructioooons

I. Summary

This Manual provides the procedures required by service operations, including:

1. Structure and composition

2. Principles

3. Dismantlement and installation steps

4. Inspection methods

5. Adjustment & commissioning methods

6. Common trouble diagnosis procedures

7. Technical parameters

The simple operations that can be conducted through the observation of vehicle are left out in this Manual. No description is given for the necessary basic skills of maintenance technicians in this Manual.

II. How to use

This Manual comprises four parts, i.e. engine volume, chassis volume, electrical appliance & structure volume of vehicle body and electric circuit inspection volume. In front of each part is given a detailed content index, in which you can find the section you want quickly.

This Manual provides following information:

1. Working principles;

2. Component position

3. Inspection and service specifications

4. Component dismantlement & installation steps

5. Common troubles and repair procedures

Such information are in compliance with current model at time published.


2

Section II Vehicle Information

I. Identification Information Position

Position of vehicle ID

1- Name plate of vehicle 2- ID number of vehicle

II. Nameplate

1. Position of nameplate: at the firewall of engine compartment.

2. Instructions of nameplate

Example of Nameplate

Made by China Anhui Jianghuai Automobile Co., Ltd.

Ex-factory no. Ex-factory date Jan. 2010

Max. gross weight Fixed number 5 persons

Engine Model Rated power

Engine displacement Model

Brand: Jianghuai

1

2


3

III. Vehicle Identification Number (VIN)

1) VIN position: on the nameplate or at the left bottom of windshield.

2) Illustration of VIN

Part 1: Word Manufacturer Identification (WMI), consists of 3 numbers according to GB16737, which should be applied, approved and filed. WMI for JAC is LJ1, which applicable for freight truck, incomplete vehicle, bus, passenger car, tractor and special vehicle of JAC. Word Manufacturer Identification (WMI) is shown in table below.

Table Worldwide Manufacturer Identification

ID Manufacturer Applicable Models

LJ1 JAC Co., Ltd, ANHUI Freight truck, incomplete vehicle, bus, passenger car, tractor,

special vehicle

Part 2: vehicle description Code (VDS), as specified in GB 16737, this part should be made up with 6 digitals to presents basic features of vehicle model.

VDS making-up:

Inspection digit

Code of engine type and rated power

Max. gross weight

Body type

Vehicle type

Truck wheelbase / passenger cars, buses and chassis length

Geographical region

Country

Manufacturer

Vehicle Description Code

Check Character

Digitals

Order number

Assembled in

Model year

Representative letter or number

Representative number

Digitals


4

Vehicle type2 Means passenger cars

F: 3 chambers & 4 doors

Body type

G: 2 chambers & 5 doors

Max. Gross Weight: K: >1000-2000

Truck wheelbase / passenger cars, buses and chassis length: R> 2390 - 2600

1: gasoline 70Kw

Code of engine type and rated power 2: gasoline >70-90Kw

3: gasoline >90-110Kw

Part 3: indication of vehicle, 8 digitals

4:General Assembling Workshop of Passenger Car Manufacture Company

Factory assembled

7:General Assembling Workshop of Passenger Car Manufacture Company

8: 2008

Year 9: 2009

A: 2010

IV Engine Number

1. Position of engine number

Engine number is stamped on the exhaust side of cylinder block (See figure below).

Production SN

Factory assembled

Year

Digitals

Fig. 2.1.001


5

2. Meaning of Engine Number

3GB4.C Engine model: 1.0 3-cylinder gasoline engine

A3408769:

A the year of 2010

3 - engine type (petrol, local parts)

408769 Production SN

Fig. 2.1.002


6

Section III Lifting, Protection and Towing of Vehicle

I. Lifting of Vehicle

1. Vehicles Supporting Points

The positions of vehicles supporting points are shown in figure below.

Attention:

Dont lift the vehicle by using the point other than those specified; otherwise vehicle body may be damaged.

Positions of Vehicles Supporting Points

2. Operation of Lifter

The lifter should be operated strictly in accordance with the specifications of manufacturer.

Caution:

The operation against the specifications may cause damage of vehicle or personnel injury or even death.

II. Protection of Vehicle

1. Appearance Protection

Be sure to use the four protection appliances including seat cover, steering wheel cover, gearshift lever cover, and foot mat before any operation. A protective pad must be applied on the fenders when engine hood is opened for inspection.

2. Preventive Measures before Welding

Since electrical components are installed on the vehicle, the following procedures must be carried out in order to avoid too large current through such components in welding:

1) Turn ignition switch to OFF position;

2) Disconnect negative pole of battery;

3) Ground the welding equipment carefully at a point nearby the welding area;

4) Cover other exposed equipment around the welding area to prevent solders from splashing on.

Supporting point


7

III. Towing of Vehicle

If vehicle needs to be towed, please contact the local authorized after-sales service center or a special vehicle towing service company.

1. Towing with tractor

Caution:

No passenger allowed in the vehicle being towed;

Dont allow the traction speed over the safety speed or the stated speed limit;

Make sure the vehicle being towed are fixed firmly;

Operation against above-mentioned precautions may cause personnel injury.

2. Towing with wheel lifter

1) Turn ignition switch to ACC (accessory) position;

2) Turn on the hazard warning indicator flashing;

3) Shift to neutral position;

4) Release parking brake;

5) Make sure the front wheels are away from ground.

Attention:

If it is necessary to tow the vehicle from the back, the supporting wheel of traction device should be set under front wheels. Dont make front wheels in contact with ground in towing; otherwise the transmission may be seriously damaged.

3. Emergency towing

If no towing vehicle is available under emergency, a rope may be fixed to the emergency towing hole under the vehicle for temporary traction.

1) Front towing hole: It is under the front bumper. A driver is required in the vehicle for steering and braking purposes in towing. Such traction method is applicable only on hard pavement with towing distance and speed limited to certain extent. In addition, such parts as wheels, axles, drive system, steering system, and brakes must be in good conditions.

Caution:

The vehicle may be damaged when towed by rope.

In order to minimize such damage,

If no other towing equipment is available, the towing hole must be used;

Always tow the vehicle from its forehead;

Keep the towing rope away from the bumper;

Check the towing rope by pulling it to make sure both ends are fixed firmly on the towing hole.

2) Rear towing hook: It can used to tow another vehicle only under emergency (when a vehicle is trapped in a ditch, heavy snow or mud pit). When using the rear towing hook, always keep the rope or chain perpendicular to hook. Dont apply force to the towing hook from any ohter directions. Dont start towing sharply otherwise damage may be caused.

Maintenance Manual for J2 Sedan Service

8

Chapter II Service

Section I Service

I. Preparation

1. Maintenance Tools

List of Maintenance Tools

No. Tools Outside View Description

1 Power tool

For dismantlement and

installation of bolts and

nuts

2 Ignition plug

socket

For dismantlement and

installation of ignition

plug

II. General Service

General Service means the inspection and maintenance items which should be performed everyday during normal use of vehicles. These service items are very important, for normal operation performance of vehicle. The owners can perform these inspections by themselves, or go to a JAC franchised store for assistance. Followed is content of general service:

1. Exterior of Vehicle

The following inspection and maintenance items should be frequently conducted.

List of Items to be Frequently Inspected for the Exterior of Vehicle

Item Inspection

Tyre Use an air gauge to inspect the pressure of tyres (including spare tyre) in the service station regularly; adjust pressure in accordance with technical data if necessary. Check whether theres any damage, crack or excessive worn tear carefully.

Windshield Clean the windshield regularly. Check whether theres any crack or other damage of the windshield every six months or more frequently. Repair as required.

Windshield wiper blade

If the wiper doesnt work efficiently, check for worn or torn.

Door and engine hood

Check whether all of the doors, engine hood, boot cover and tail door can be normally opened and closed normally, whether all the door locks are locked closely. Lubricate as required. Moreover, If the vehicle often travels on the salt-spread roads or in the areas with corrosive substances, always inspect lubricating conditions.

Tyre exchange The tyre exchange should be conducted after each 8000 km traveling.


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Vehicle lamps Verify that headlamps, brake indicators, tail lamps, turning signal indicator and other lighting units work normally and have been stably fixed. Meanwhile, inspect focusing function of headlamp.

2. Interior of Vehicle

The following inspection and maintenance items should be performed regularly.

List of Items to be Regularly Inspected for Interior of Vehicle

Item Inspection

Alarm light and buzzer

Make sure all the alarm lights and buzzers are working normally.

Windshield wiper and washer

Check whether the wiper and cleaner are working normally; check whether there is any crack in the wiper.

Windshield defroster Check whether the air can be correctly bled from the air outlet of defroster, whether the heater or air conditioner can breathe enough air during operation of heater or air conditioner.

Steering wheel Check whether the free travel of steering wheel is in the standard range. Inspect changes of steering performance, such as the free travel beyond range, hard steering and abnormal noise etc.

Seat Belt Check whether all the components of seat belt system are flexible and working normally and fixed firmly and stably. Check seat belt for cracking, worn out or other damage.

Throttle pedal Check whether the pedal can be operated smoothly, make sure that the pedal would not be seized or loaded unevenly. Keep floor pad away from the pedal.

Brake pedal and booster

Check if the pedal can be operated smoothly; make sure the pedal still keeps an appropriate distance from the bottom plate when it is completely pressed down. Inspect the function of brake vacuum booster. Make sure that the bottom plate pad is away from the pedal.

Parking brake Check travel of handle.

3. Engine and Vehicle Chassis

The following inspection and maintenance items should be regularly performed.

List of Items to be Regularly Inspected for the Engine and Vehicle Chassis

Item Inspection

Cleaning liquid for windshield Check whether there is adequate cleaning liquid in reservior.

Level of engine coolant Check the coolant level when the engine is cold.

Engine oil level Stop the vehicle on a level ground and turn off engine; check oil level.

Levels of brake fluid and clutch fluid Make sure that the levels of brake fluid and clutch fluid are between the MAX line and MIN marks on reservoir.

Battery Inspect conditions of voltage and battery poles.

Liquid leakage After the vehicle has been stopped for a while, check for any leakage of fuel, engine oil, coolant or other liquid under the vehicle. Water drop from the air conditioner which has just been used is normal. In case of obvious leakage or petrol fume, find out the causes and repair immediately.

III. Regular Service

Each item is expressed in travel distance and time (months), whichever comes first (distance or time)

should be used as the basis for inspection.


10

Service operational code: I-examination; R-replacement; C-washing

Service cycle (odometer readings and the number of months, whichever comes first)

1000km 1 10 20 30 40 50 60 70 80 90 100 Item

Month 6 12 18 24 30 36 42 48 54 60

1 Driving belt I: every 10,000 km or 6 months

R: every 60,000 km or two years

2 Check oil and gas control systems of crankcase for normal working

I I

3 Spark plug I I R I I R I I R I

4 Change coolant R R R R R

General conditions of use C: every 5,000km R: 15,000km 5

Air filter element Harsh conditions of use C: every 3,000km R: 10,000km

General conditions of use R: every 5,000 km or 6 months 6

Oil and oil filter Harsh conditions of use R: every 3,000 km or 3 months

7 Carbon monoxide content with engine idling I I I I I I I I I I

8 Ignition timing I I I I I

9 Hose I I I I I I I I I I

10 Exhaust fittings leakage I I I I I I I I I I

11 Throttle body C C C C C

12 Injector C* C* C* C* C* C* C* C* C* C*

13 Valve clearance I I I I I I

Notes:

C *---For cleaning operation of fuel injector, it is recommended that dedicated fuel injector cleaning

analyzer is used; Check every 3 months or 5000km; if there are nozzle clogging or blockage failures and

they are non-product quality problems, they should be maintained at users expenses.

"Harsh conditions of use" specifications are only used in severe conditions of use of vehicles. Harsh

conditions of use include the following:

Driving in dusty areas or the vehicle is regularly exposed to salty air or sea water.

Driving on rugged road, road with water accumulation or on mountain roads.

Driving in cold areas.

In the cold season, the engine idles a long time or used frequently in short-distance traveling.

Frequent use of brakes, regular emergency braking. .

As tractor

As taxi or leasing

At temperatures above 32 , driving in urban heavy traffic for more than 50% of the total travel

time.


11

At a temperature below 30 , driving at 120km/h or higher speed limits for more than 50% of the

total travel time.

Overloaded traveling.

IV. Recommended Oil and Lubricant

Which listed below are the types of oil and lubricant recommended by JAC:

List of Recommended Oil and Lubricant

Item Capacity (L) Recommended oil / lubricant

Engine oil 3.8

Factory filled oil: SAE10W-30

Ambient temperature for use: -25 - 35

User must select the appropriate oil according to local ambient temperature

Quality level: SJ or above

Cooling system 5.5 High-quality HF-C anti-freezing solution

Manual transmission gear oil 2.0 API GL-4, SAE 75W/90

Brake fluid and clutch fluid 0.560.05 DOT4 (Great Wall)

AC refrigerant 60025g R134a

Wiper cleaning liquid 3 Water

AC compressor lubricating oil 0.12 PAG56

V. Service of Engine

1. Inspection of Driving Belt

Warnings

Be sure to operate only with engine stopped.

1) Check for belt aging, crack, wear and oil stain. Replace as required.

2) Check the belt tension at the mid-point between both pulleys.

Inspection should be conducted in the engine cold state or when it has been stopped after 30min.

Range of tension force Alternator belt: 50050N Please be noted that the experience equation for

tensioning force of reused belt is as below: Tensioning force for new belt * 1.2/1.5

If the belt tension is out of range, adjust.

Attention

For checking belt tension installation, firstly adjust to the specified value, then turn the crank

for more than two laps to re-adjust to the specified value in order to avoid tension between

pulleys changing.

2. Adjustment of Tension


12

Tension Adjustment Table

Part Adjusting Method

Generator belt Turn adjusting bolt of generator belt

Attention:

After replaced with new belt, adjust the belt tension so as to meet requirements.

During installation of belt, make sure that the belt is in correct engagement with the pulley

groove.

Dont spill any engine oil or engine coolant on the belt.

Do not over wind or bend belt; for used belt, be aware of mounting direction.

3. Change Coolant of Engine

Caution:

In order to avoid scald, never change coolant with engine hot.

Wrap the radiator cap with thick cloth and unscrew it carefully. Release the pressure inside

the radiator at first, and then completely unscrew it to open the radiator.

Be aware not to spill the engine coolant on the driving belt.

1) Drain engine coolant

Dismount the right deflector of engine. See Engine Deflector.

Open the water drain plug at the bottom of radiator, and then open the cap of radiator.

If necessary, please dismount coolant reservoir, drain the engine coolant, and reinstall it after cleaned.

Check if theres any foreign matter such as rust or any color change in the discharged engine coolant.

In case it is polluted, please wash the engine cooling system. See Washing the Cooling System please.

2) Refill engine coolant

Reinstall dismantled coolant reservoir and the drain plug of radiator.

Attention:

The drain screw plug must be cleaned, a new O-ring must be installed.

Make sure that all the hose clamps have been stably tightened.

Dismount the upper cover of air filter and the intake hose. Please refer to Air Filter Assembly.

Disconnect outlet tube of heater pipe. Please lift the hose as high as possible.

Fill coolant into radiator and coolant reservoir to specified level; the engine coolant must be filled slowly, such as to gradually bleed air from the system.

Attention:

Please mix the original JAC engine coolant or equivalent product with water. See Recommended Oil and Lubricant.


13

If coolant overflows from the heater outlet pipe, disconnect pipe and reconnect and then continue the filling of coolant.

Install air filter upper cover and intake hose. Please refer to Air Filter Assembly.

Install radiator cap.

Warm up the engine until the thermostat is switched on.

Examine if theres warm water flowing out by touching the lower hose of radiator, such as to check whether the thermostat has been switched on.

Attention:

Watch on engine temperature meter, such as to avoid overheating of engine.

Stop the engine, allow engine temperature drops.

The cooling time can be reduced by using fan.

Fill engine coolant in coolant until the MAX level reached.

Install radiator cap, and repeat steps - for more than two times until the level of engine coolant doesnt go down any more.

Start engine, check for any leakage in the cooling system.

3) Wash cooling system

Install water drain plug of radiator and coolant reservoir removed above.

Attention:

The drain screw plug must be cleaned, a new O-ring must be installed.

Dismount air filter upper cover and the intake hose. Refer to Air Filter Assembly.

Disconnect outlet tube of heater pipe. Please lift the hose as high as possible.

Fill engine coolant into the radiator and coolant reservoir, install cap of radiator.

If coolant overflows from the heater outlet pipe, disconnect pipe and reconnect and then continue

filling of coolant.

Install air filter upper cover and intake hose. Refer to Air Filter Assembly.

Start the engine, warm up it to normal working temperature.

Speed up the engine for several times without load.

Stop engine, and wait till engine cooled down.

Discharge coolant inside system. Refer to Draining Engine Coolant.

Repeat steps - until the radiator starts to discharge clear water.

4. Inspection of Cooling System

Caution:

Never open the radiator cap with engine hot. The high temperature and high pressure liquid

overflowing from the radiator may cause severe scald.

Wrap the radiator cap with thick cloth and unscrew it for 1/4 circle to release the pressure

inside radiator at first, and then completely unscrew it to open radiator.


14

1) Inspection of cooling system hose

Check the hose for incorrect installation, crack, damage, loose connection, worn or ageing.

Please repair or replace the damaged components as required.

2) Inspection of radiator cap

Check valve seat of radiator cap

Check whether the valve seat expands outward, i.e. when the plunger is vertically lifted from the top,

end of plunger is out of view.

Check valve seat for any dust or damage.

Pull out negative pressure valve to open it,

and upon the pressure is released, check

whether it can be completely closed.

Make sure there isnt any smudge or damage

on the valve seat.

Make sure that the valve seat can be normally

opened and closed.

Check the pressure released by radiator cap.

Standard: 78-98 KPa

Limit: 59 KPa

Connect the radiator cap to radiator leak

detector, paste engine coolant onto the

sealing face of cap.

If any failure is found in above-mentioned

three inspection items, replace radiator cap.

Attention:

For installation of radiator cap, please wipe the radiator filler carefully to clear away any

paraffin residue or foreign substance.

3) Inspection of radiator

Check for any mud or clogging situation in radiator. If any, clean with following method.

Be aware not to twist or damage the radiation fins.

In case of cleaning without dismounting the radiator, all accessories such as cooling fan, wind

collection hood and horn should be dismounted. Wrap connectors of wire harness with adhesive

tape for water proofing.

Wash back of radiator fins from the top to the bottom with water spraying normal to radiator.

Wash each surface of the radiator every other minute.

In case no dirt is washed away from the radiator, the washing work should be stopped.

Fig. 2.2.001

Fig. 2.2.002


15

Blow the back of radiation core with compressed air vertically from top to bottom. The pressure of

compressed air should be less than 490 KPa, and a distance of more than 30 cm should be kept.

Blow radiator core surface with compressed air every other minute until no water can be blown

away.

4) Check for leakage of cooling system

Check for leakage through applying pressure to the cooling system with a leakage detector of

radiator cap.

Test pressure: 157 KPa

Caution:

Never remove the radiator cap with engine hot;

otherwise the high temperature and high

pressure liquid overflowing from the radiator

may cause severe scald.

Attention:

A pressure exceeds the specified test

pressure may cause damage to the radiator.

In case the engine coolant is found decreased, please refill engine coolant into the radiator.

If any component is found damaged, repair or replace.

5. Inspection of Fuel Pipeline

Check the fuel pipeline, fuel filler cap and fuel tank for

incorrect installation, leakage, crack, damage, loose

connection, worn or aged.

Repair or replace damaged component as

required.

6. Replacement of Air Filter

1) Dismantlement

Unscrew lock bolt of air filter upper cover lift up the

cover.

Fig. 2.2.005

Fig. 2.2.004

Fig. 2.2.003

Engine Fuel pipeline

Fuel tank


16

Take off air filter element.

2) Inspection After Dismantlement

The air filter must be regularly cleaned or replaced

according to recommended schedule. Please

refer to Regular Service.

Blow back of air filter element with compressed air until nothing can be blown away.

3) Installation

Install with steps contrary to dismantlement.

7. Replacement of Engine Oil

Attention:

Be careful not to be scalded since oil temperature is high.

Long-time direct contact between skin and the used oil should be avoided. In case contacted,

wash with soap or detergent thoroughly as soon as possible.

1) Warm up the engine, and check for any oil leakage in the engine compartment. Refer to Leakage of

engine oil.

2) Stop engine and wait for ten minutes.

3) Loosen engine oil filler cap, and then remove the oil drain screw plug.

4) Discharge engine oil.

5) Install the oil drain screw plug with new gasket.

Attention:

Any dirt such as iron debris on oil drain screw plug must be cleaned, and new gaskets

should be installed.

Tightening torque of oil drain bolt: 34-44 Nm.

6) Refill new oil.

For specification and viscosity of engine oil, please refer to Recommended Oil and Lubricant.

Engine oil quantity: 3.8L

Attention:

During the filling of engine oil, please do not remove oil gage.

The filling amount of engine oil may vary according to oil temperature and oil drain time.

Quantity above is for reference only.

Fig. 2.2.006


17

Oil rule should be used all the way to check whether the filling amount of engine oil is

proper.

7) Warm up the engine, check areas around the oil drain screw plug and oil filter for leakage.

8) Stop engine and wait for ten minutes.

9) Inspect oil level. See also Engine oil level.

8. Change Oil Filter

1) Dismantlement

Use oil filter wrench to dismount the filter.

Attention:

JAC original engine oil or equivalent product should be used.

Be careful not to be scalded since engine and oil are hot.

During dismantlement, a cloth should be prepared to wipe up the leaked or splashed oil.

Please keep the driving belt free from engine oil.

Clean any oil splashed on engine and vehicle.

2) Installation

Clear any foreign substance on mounting

surface of oil filter.

Paste a film of engine oil onto the oil seal

surface of new filter.

Tighten.

Tightening torque: 10-12Nm

Attention:

The engine oil filter must be tightened with a filter wrench.

Manual tightening may cause oil leakage due to the inadequate tightening torque.

3) Post-installation inspection

Inspect oil level, and fill engine oil when it is inadequate. See also Engine Oil.

Start engine, check for any oil leakage.

Stop engine and wait for ten minutes.

Inspect oil level, and fill engine oil. See also Engine Oil.

9. Replacement of Ignition Plug

Fig. 2.2.007


18

1) Dismantlement

Dismount the engine hood. See also Intake manifold.

Disassemble the ignition coil. Please refer to Ignition Coil.

Dismount the ignition plug with plug socket.

Attention:

Be aware not to drop or shock the ignition plug.

2) Inspection after the dismantlement

Generally, the standard ignition plug should be used.

In the following conditions, if carbon deposition frequently occurs with standard ignition plug, the hot

ignition plug should be used:

Engine is frequently started.

Ambient temperature is low.

In the following conditions, in case ignition knock frequently occurs with standard ignition plug, the cold

ignition plug should be used:

Long-time traveling on the expressway;

Engine is frequently running with high speed.

Attention:

Be sure not to drop or shock the ignition plug.

Steel brush should not be used for cleaning.

If theres carbon deposition on ignition plug end, remove with ignition plug cleaner.

During the replacement interval, the ignition plug gap should be checked when it is

necessary.

Ignition plug gap: 0.7-0.8 mm

3) Installation

Install with steps contrary to dismantlement. Tightening torque of ignition plug: 25-30 Nm.

10. Replacement of Fuel Filter

1) Dismantlement

Caution:

Be sure to read the General Precautions before any handling of fuel system. See General

Precautions.

Open the fuel filler cap.


19

Release pressure inside fuel tank.

Remove the rear seat cushion. See Rear Seat.

Dismount the fuel tank service cap.

Dismount the fuel filter and fuel pipe.

For detailed information, please refer to Fuel Filter.

2) Installation

Be aware of following precautions to install with steps contrary to dismantlement.

Installation direction of fuel filter

Be aware of installation direction of fuel filter.

Towards inlet tube.

Installation of pipe fitting.

3) Post-installation inspection

Check for any fuel leakage with following steps.

Turn ignition switch to ON (with engine stopped), and then check for leakage at the joints of fuel

pipeline.

Start engine and run with increased speed, check again for fuel leakage at the joints of fuel pipeline.

11. Inspect the Evaporator passage of Fuel Evaporative Emission System (EVAP)

1) Visually check whether the installation position of EVAP evaporator pipeline is correct, and if it is

free from leakage, crack, damage, loose connection, scratching or ageing etc.

2) Check vacuum release valve of fuel tank cap for blockage or sticking etc. See Fuel Evaporative

Emission System.

VI. Service of Chassis and Body

1. Inspection of Exhaust System

Check for proper positions of exhaust pipe, muffler and fixed support, and anyleakage, crack, damage,

loose connection, worn or ageing.

Fig. 2.2.008


20

In case any component is found damaged,

repair or replace.

2. Inspection of Clutch Fluid Level and Leakage

If the fluid level is low, check clutch system for any leakage.

3. Inspection of Clutch System

Check for correct installation positions of liquid pipelines and operation cylinders, and any crack,

damage, loose connection, worn or ageing.

4. Inspection of Manual Transmission Gear Oil

Inspect oil level and whether there is any leakage. For detailed information, refer to Inspection of

Manual Transmission Oil.

5. Change Manual Transmission Gear Oil

1) Thoroughly drain oil from drain plug, and then refill with new gear oil. For detailed information, refer

to Change Manual Transmission Oil.

2) Inspect oil level. For detailed information, refer to Inspection of Manual Transmission Oil Level.

6. Wheel Balance

1) Dismantlement

Dismount the wheel(s) need to be adjusted.

Dismount the old balance blocks from both sides of the wheel, clear any foreign matters from treads

of tyre.

Note: for new tyre(s), the tape on the tyre should be removed.

Attention:

During dismantlement, be careful not to scratch the tyre.

2) Adjusting wheel balance

Take the center hole as guide to install the wheel on balancer. Start the balancer.

When unbalance values of both inner side and outer side of tyre have been indicated on the display

of wheel balancer, multiply the unbalance value of outer side with 5/3, so as to define the weight of

balance blocks which will be actually applied. Then, select the outer side balance block of which

Fig. 2.2.009


21

weight is nearest to the calculated value, and install it to the specified outer side position, or at the

specified angle relative to wheel.

Attention:

The balance block of outer side should be installed before inner side.

Prior to the installation of balance block, fitting surface on wheel must be thoroughly

cleaned.

a. Install the balance block to the position indicated in figure below.

b. As shown in the figure, during installation of

balance block on the wheel, the balance block

should be placed in the groove area on the

wheel inner wall, and fix with its center

towards the position (or angle) indicated by

the wheel balancer.

Attention:

The balance block should not be reused; it should be replaced every time.

At most three balance blocks are allowed to be installed.

The original balance blocks should be used any time.

c. In case the calculated weight of balance block

is more than 50 g, the two balance blocks

should be installed in a line.

Attention:

Never install a balance block on another

one.

Restart the wheel balancer.

At position (or angle) indicated by the wheel

balancer, knock in the balance block at the

inner side of wheel.

Attention:

At most two balance blocks are allowed to be installed.

Start the balancer. Make sure the residual unbalance value of both inner side and outer side is only

5 g or less.

In case the residual unbalance value of either side is more than 5 g, please repeat the installation

steps for balance block.

Fig. 2.2.010

Fig. 2.2.011

Stuck weight

Towards the groove

Position (or angle) indicated by the wheel balancer

Center of gravity

Position (or angle) indicated

by the wheel balancer


22

Allowable maximum unbalance:

7. Tyre Exchange

Tyre exchange should be performed every

8000 km.

Tyre exchange should also be performed when the

new tyre is put on.

Note: As shown in the figure is the recommend

method for tyre exchange.

8. Inspection for Brake Fluid Level and Leakage

If fluid level is low, please check brake system for

leakage.

9. Inspection of Brake System Pipeline and

Cable

Check for correct positions of brake pipeline and

parking brake cable, and any leakage, worn,

scratching or ageing etc.

10. Change Brake Fluid

Attention:

Refill brake fluid.

Discharged brake fluid must not be reused.

In order to keep the paintwork free from damage, be sure not to splash brake fluid onto the

paintwork. If the fluid is splashed onto the paintwork, please clean with water immediately.

Fig. 2.2.012

Fig. 2.2.014

Fig. 2.2.013

Highest line

Lowest line Norm

al


23

1) Insert the ethylene tube onto release valve.

2) Press on the brake pedal to loosen the

release valve, and then discharge brake fluid

slowly.

3) Wash the inner side of fluid reservoir and refill with new brake fluid.

4) Loosen the release valve, press down the

brake pedal slowly, and then release. Repeat this

operation every other 2 or 3 s until theres outflow

of new brake fluid, and then step on the brake

pedal to close the release valve. Repeat there

procedures for all wheels.

5) Bleed air. See also Air Bleeding of Brake Pipeline.

11. Inspection of Brake

1) Brake disc

Check for worn or damage.

List of Standard Specification of Brake Disc

Type Floating caliper type / ventilated disc

Brake disc diameter 241 mm

Brake disc thickness 19 mm

Friction block thickness 9 mm

Brake disc

Cylinder bore 51 mm

2) Brake drum

Check whether the inner diameter and circular runout of brake drum are in the scope of standard values.

If not, corresponding processing or replacement should be performed.

Fig. 2.2.015

Fig. 2.2.016


24

Standard Specification Table of Brake Drum

Type Leading trailing shoe brake

Brake drum diameter 204 mm

Cylinder bore of brake slave cylinder 17.46 mm

Clearance adjustment Automatically

Brake drum

Circular runout < 0.05 mm

3) Brake caliper

Check for any oil leakage.

4) Rear brake slave cylinder

Check for any leakage.

5) Front brake shoe

Check for worn or damaged conditions.

Standard thickness: 9 mm

Limit thickness: 2 mm

Fig. 2.2.017

Fig. 2.2.018

Fig. 2.1.019


25

6) Rear brake shoe

Check the brake shoe thickness and its contact

state with the brake drum. If it fails to meet the

requirement, replace.

Standard thickness of brake shoe (A): 5 mm

Allowable limiting thickness (A): 1 mm

12. Inspection of Steering Gear and Pull-rod

1) Steering gear

Check whether the steering gear housing and

dust boot are free from looseness, damage

and grease leakage.

Check whether its connection with the

steering column is loose.

2) Steering pull-rod

Check ball joint, dust boot and other components for loosening, worn, damage and grease leakage.

13. Check the pipeline.

Stop engine, check fluid level in reservior.

Attention:

Be sure not to fill steering fluid excessively.

Check for proper installation position of pipeline, and

any leakage, crack, damage, loose connection, worn

or ageing.

14. Axle and Suspension Components

Check for proper clearance between front/rear axles and suspension components and any crack,

damage, worn or other damages.

Fig. 2.2.020

Fig. 2.2.021

Fig. 2.2.022

Check the leakage of lubricating grease

Check the tightening torque


26

Rock each wheel to check for proper clearance.

Inspect operation conditions of wheel bearings.

Check axle, suspension nut and bolt for loosening.

Check shock absorber for oil leak or other damages.

Check the suspension ball joint for grease leakage;

check ball joint dust boot for crack or other damages.

15. Inspection of Drive Shaft

Check dust boot and drive shaft for any crack, worn,

damage or grease leakage.

16. Lubricating Door Lock, Hinge and Engine Hood Lock Pin

Lubricating Points of Door Lock, Hinge and Engine Hood Lock Pin

Fig. 2.2.023

Fig. 2.2.024

Fig. 2.2.025


27

17. Inspection of Seat belt, Tuckle and Pre-tensioner

Attention:

The seat belt assembly including retractor and other accessories (such as fixing bolt, guide

rail device) should be inspected every time after collision.

We suggest that you should replace seat belt assembly after collision, unless it is free of any damage

after slight impact.

And the seat belt assembly which is not used during the accident should also be checked, please

replace any damaged seat belt assembly.

In case a front collision which activates both driver and passengers airbags happens, the seat belt

pre-tensioner should be replaced, even though the seat belt is not used at all.

If any component of seat belt assembly has problems, please do not repair it, but replace the seat

belt assembly.

In case the seat belt is broken, worn or damaged, dont repair but replace the seat belt assembly.

Be sure not to lubricate the lock tongue and snap ring.

Use original seat belt assembly of JAC.

Check whether the anchorage is loose.

Check whether the seat belt is damaged.

Check whether the motion of retractor is flexible.

While the snap ring open, check whether the snap ring and lock tongue function normally.

VII. Maintenance Data

1. Tightening Torque of Standard Parts

Tightening Torque List of Standard Parts

Torque (Nm) Nominal Diameter of

Thread Pitch

Head mark 4 Head mark 7

M5 0.8 3-4 5-6

M6 1.0 5-6 9-11

M8 1.25 12-15 20-25

M10 1.25 25-30 30-50

M12 1.25 35-45 60-80

M14 1.5 75-85 120-140

M16 1.5 110-130 180-210

M18 1.5 160-180 260-300

M20 1.5 220-250 360-420

M22 1.5 290-330 480-550

M24 1.5 370-420 610-700


28

Attention:

Tightening torques listed above are the standard values which are applicable for following

conditions:

a. Steel, plating nuts and bolts.

b. Plated steel plain washers.

c. All the dry nuts, bolts and gaskets.

The torques listed above are not applicable for following conditions:

a. When the component is to be tightened with spring or tooth washer;

b. Tightening of the plastic parts.

c. Self-tapping screw or self-locking nut.

d. Oiled thread and surface.

In following conditions, the torques listed above should be correspondingly reduced:

a. if a spring washer is used, the torque should be reduced to 85%.

b. If bolt surface is coated with oil, the torque should be reduced to 85%.


Engine Volume

Chapter I Mechanical Part of Engine........................................................ 33

Section I Engine Body...............................................................................................33

I. General Precautions ................................................................................................. 33

II. Precautions on Sealant ............................................................................................ 34

III. Preparation ................................................................................................................ 36

IV. Engine Assembly ...................................................................................................... 39

V. Drive Belt.................................................................................................................... 43

VI. Air Filter and Air Duct ............................................................................................... 45

VII. Intake Manifold and Exhaust Manifold ................................................................... 47

VIII. Exhaust System......................................................................................................... 51

IX. Timing sprocket mechanism ................................................................................... 53

X. Camshaft and balance shaft assembly................................................................... 58

XI. Cylinder head............................................................................................................. 64

XII. Valves ......................................................................................................................... 68

XIII. Cylinder Body Assembly.......................................................................................... 72

XIV. Diagnosis of Common Troubles.............................................................................. 86

XV. Parameters for Maintenance.................................................................................... 88

Section II Engine Lubrication System .....................................................................92

I. Precautions................................................................................................................ 92

II. Preparation ................................................................................................................ 93

III. Engine Oil................................................................................................................... 94

IV. Oil Filter ...................................................................................................................... 96

V. Oil Pan and Engine Oil Pump .................................................................................. 98

Section III Cooling System of Engine..................................................................102

I. Cooling Circuit......................................................................................................... 102

II. Engine Coolant........................................................................................................ 103

III. Radiator.................................................................................................................... 105

IV. Radiator Cooling Fan.............................................................................................. 107

V. Water Pump ............................................................................................................. 107

VI. Thermostat Sub-assembly ..................................................................................... 109

VII. Water Piping Sub-assembly................................................................................... 111

VIII. Trouble Analysis ..................................................................................................... 112

IX. Parameters for Maintenance.................................................................................. 113


Section IV Fuel Supply System of Engine...........................................................114

I. General Precautions ............................................................................................... 114

II. Preparation .............................................................................................................. 115

III. Fuel System ............................................................................................................. 115

IV. Fuel Injector and Guide Rail .................................................................................. 116

V. Fuel Filter ................................................................................................................. 119

VI. Fuel Pump Assembly .............................................................................................. 122

VII. Fuel Tank Assembly ............................................................................................... 126

Section V Emission Control System of Engine ..................................................128

I. Fuel Evaporation Control System ......................................................................... 128

II. Forced Ventilating System of Crankcase ............................................................. 132

Chapter II Electrical Part of Engine...................................................... 135

Section I Ignition System......................................................................................135

I. Ignition coil .............................................................................................................. 135

II. Diagnosis of Common Troubles............................................................................ 137

III. Parameters for Maintenance.................................................................................. 137

Section II Starting and Charging System ............................................................138

I. Principle Diagram of Starting and Charging System .......................................... 138

II. Battery ...................................................................................................................... 138

III. Starting System ....................................................................................................... 141

IV. Charging System..................................................................................................... 149

Chapter III Electronic Control System of Engine ................................ 155

Section I Precautions............................................................................................155

I. Precautions of Supplemental Restraint System (SRS)....................................... 155

II. General Precautions ............................................................................................... 155

III. Precautions in Maintenance .................................................................................. 155

IV. Common tools for diagnose .................................................................................. 157

V Precautions for On-board diagnose (OBD) system of engine ........................... 160

Section II Structural Principle and Inspection of Engine Control System .......163

I. System Description................................................................................................. 163

II. Multiple-point Fuel Injection System .................................................................... 164

III. On-board Diagnosis System .................................................................................. 167

IV. Engine Trouble Diagnosis...................................................................................... 173


Section III Structural Principle and Inspection of Engine Electronic Components

..................................................................................................................................179

I. Intake Manifold Absolute Pressure (MAP/MAT) Sensor ..................................... 179

II. Engine Coolant Temperature (ECT) Sensor......................................................... 181

III. Throttle Position Sensor ........................................................................................ 183

IV. Crankshaft Position Sensor ................................................................................... 185

V. Camshaft phase sensor.......................................................................................... 188

VI. Oxygen sensor ........................................................................................................ 191

VII. Fuel Injector (INJ) .................................................................................................... 194

VIII. Knock sensor........................................................................................................... 195

IX. Air-conditioning switch and relay ......................................................................... 197

X. Canister solenoid valve .......................................................................................... 198

XI. Ignition coil .............................................................................................................. 199

XII. Electric Fuel Pump.................................................................................................. 201

XIII. Electronic Control Module (ECM) of Engine ........................................................ 203

Section IV Trouble Diagnosis Procedures for Engine Control System ............206

I. Diagnosis with DTC ................................................................................................ 206

II. Diagnosis by Trouble Phenomena ........................................................................ 226

Maintenance Manual for J2 Sedan Mechanical Part of Engine

33

Chapter I Mechanical Part of Engine

Section I Engine Body

I. General Precautions

1. Precautions on Discharging Engine Coolant

Discharge coolant after engine has cooled down.

2. Precautions on Disconnecting Fuel Pipeline

1) Before the operation, ensure that the operating area is free of objects which may cause combustion

or sparks.

2) Disconnect the piping, plug openings to prevent leakage of fuel.

3. Precautions on Dismantlement and Disassembly

1) Use special tools as required in Instruction. Always operate safely; any forcible operations and

operations other than that specified in Instructions are forbidden.

2) Take particular care not to damage the matching face or the sliding face.

3) Use the adhesive tape or equivalent to cover the opening of engine system so as to prevent the entry

of foreign bodies, if necessary.

4) For the purpose of troubleshooting and reassembly, methodically mark and neaten the disassembled

parts.

5) When loosening the bolts and nuts, follow this basic principle: outmost ones first, diagonal ones

second, and so on. Conduct the operation in compliance with the loosening sequence, if specified.

4. Precautions on Check, Repair and Replacement

Thoroughly check the parts before repair or replacement. Check the substitutive parts by the same

means, and then replace as required.

5. Precautions on Assembly and Installation

1) Use the torque spanner to tighten the nuts and bolts.

2) When tightening the nuts and bolts, follow this basic principle: screw up the central nuts and bolts

with the same torque in steps, and then carry out the same operation with the internal and external

diagonal ones. Perform the operation in accordance with the tightening sequence, if it is specified.

3) Replace gaskets, oil seal or O-ring with new ones.

4) Thoroughly rinse, clean and dry every part. Carefully check the engine oil pipeline or engine

coolant pipeline for obstruction.

5) Never damage the sliding face and the matching face. Completely eliminate the foreign bodies such

as cloth scraps or the dust. Before assembly, paste the sliding face with engine oil.

6) When refilling engine coolant after draining completely, release air from the pipes at first.

7) After repair, start the engine and run with high speed to check for any leakage of the engine coolant,

fuel, engine oil and exhaust gas.


34

6. Parts Needed to Be Tightened with Specified Angle

1) Use the angle spanner to finally screw up following engine parts:

- Cylinder head bolt

- Bolt of main bearing cap

- Connecting rod bolt

2) Please follow the specified tightening methods.

3) Make sure that the surfaces of threads and pedestal are clean and coated with engine oil.

II. Precautions on Sealant

1. Removal of Sealant

After dismounting fixing nuts and bolts, use the

scraper to detach the matching faces and remove

old sealant.

Attention:

Do not damage the matching faces.

Insert the scraper, and then knock its side

to slide it as shown in the figure.

For the positions where it is difficult to use

scraper, lightly knock the parts to dismount

them with a plastic hammer.

If you have no choice but to use the tools

such as a screwdriver, be careful not to

damage the matching faces.

2. Application Steps of Sealant

1) Remove the attached old sealant from the

application and matching faces of liner with

scraper.

Attention:

Thoroughly remove the old sealant from

the groove on surfaces, fixing bolts and bolt

holes where the sealant was applied.

2) Wipe sealant surface and matching surface clean with a special cleaner, remove water drops, grease

and foreign substances.

JAC-T1F017

Fig.1.1.001

Fig.1.1.002

Slide Knock

Scraper


35

3) Position sealant with the specified size.

Put the sealant into the groove for it (if any).

Generally, the sealant is put inside the bolt hole; however, it is occasionally put outside the bolt

hole.

Install the matching part in a certain period of time after applying sealant.

Eliminate any dirt from the sealant.

Do not re-tighten the bolts or nuts after installation in order to avoid failures of bolts or nuts.

Add engine oil and coolant 30min after the installation has been finished.

Attention:

Conduct the operation in accordance with the instructions specified in this manual.

Fig.1.1.003


36

III. Preparation

1. Tools for Maintenance

List of Special Tools

No. Tool Appearance Code Description

1 End forked clamp

Fix camshaft

timing

sprocket

2 Pin

JAC-T1D001

Used together

with the end

forked clamp

3 Locating tool for

piston pin

Used to

install and

dismantle the

piston pin

4 Guide sleeve

JAC-T1F005

Used together

with the

locating tool

for piston pin

5 Flywheel chock

JAC-T1F011 Used to fix

the flywheel

6 Valve spring

compressor

JAC-T1F012

Used to

compress the

valve spring

Install valve

cotter


37

7 Oxygen sensor

socket

JAC-T1F015

Used to install

and dismantle

the oxygen

sensor

8 Dismantlement

tool for oil pan

JAC-T1F017

Used to

dismantle the

oil pan

9 Installer for

valve oil seal

JAC-T3F001

Used to install

the valve oil

seal

11

Guide for front

oil seal of

crankshaft

JAC-T3F003

Functioning as

a guide during

the installation

of front oil seal

of crankshaft

12

Installer for front

oil seal of

crankshaft

JAC-T3F004

Used to install

the front oil

seal of engine

crankshaft

13

Installer for rear

oil seal of

crankshaft

JAC-T3F005

Used to install

the rear oil seal

of crankshaft


38

2. List of Auxiliary Materials for Assembling Engine

List of Auxiliary Materials for Assembling Engine

No. Name Application Specification and Grade

1 Engine

oil Used during filling and assembly

Factory filled oil: SAE10W-30

Ambient temperature: -25-35

User must select the appropriate oil

according to the local temperature

Quality level: SJ or above

2 Silica

gel

Engine oil pump, water pump, oil pan

and rear oil seal housing of crankshaft LT5699 or equivalent

3 Sealant Oil pressure switch, draining screw plug

and flywheel bolt LT243 or equivalent

4 Sealant Coolant temperature sensor and water

temperature alarm switch LT648 or equivalent

5 Petrol 93# unleaded petrol or above

6 Sealant Stud bolt LT271 or equivalent

3. List of Auxiliary Materials for Assembling Cylinder head

List of Auxiliary Materials for Assembling Cylinder head

No. Name Present Material and Model Assembly Position

1 Engine oil

5W-30 (winter) 15W-40

(summer),with SJ-class quality

level and above

Valve head, camshaft and camshaft oil seal

2 Sealant LT271 or equivalent Stud bolt

3 Sealant LT962T or equivalent Guide sleeve of spark plug, bowl patch of

cylinder body/cover, connecting pipe nozzle


39

IV. Engine Assembly

1. Precautions on Installation and Dismantlement

Caution:

Operation in violation of the following instructions may incur personal injury!

Park the vehicle on flat and firm ground.

Attention:

Always pay attention to safe operation, and do not conduct any forcible operations or

operations other than that specified in Instructions.

Do not start before the exhaust system and engine coolant have completely cooled down.

If the necessary items or operations are not mentioned in the sections of Engine, see relevant

chapters.

Use the specified lifting points all the time and select appropriate lifters according conditions.

2. Preparation for Dismounting Engine and Transmission Assembly

1) General

Dismount the engine and transmission assembly from the vehicle, and then detach the engine from

transmission.

2) Preparation

Discharge the engine coolant from the radiator. See Change Engine Coolant.

Discharge the engine oil, transmission oil and clutch oil. See "Engine Oil", Transmission Oil and

Clutch Pipeline.

Collect the refrigerant in AC pipeline.

Attention:

Perform this step after the engine has cooled down.

Do not spill engine cooling fluid or brake fluid to the drive belt.

Dismount the following parts:

Engine trimming cover. See Intake Manifold.

Front wheels and tyres. See Wheels and Tyres.

Engine deflectors (left and right).

Air duct and air filter assembly. See Air Duct.

Battery, battery base and base support. See Battery.

Radiator assembly and radiator fan. See Radiator.


40

3. Dismantlement of Related Elements in Engine Compartment

Disconnect the following pipelines and put them aside.

Attention:

Use plugs to prevent leakage when disconnecting the pipelines.

Inlet pipe of fuel injector. See Fuel Injector.

Vacuum hose of braking vacuum booster on engine side. See Braking Vacuum Booster.

PVC hose. See Fuel Evaporation Control System.

Oil inlet pipe joint of clutch. See Hydraulic Pipeline of Clutch.

Low and high-pressure pipes of air compressor. See Air Compressor.

Remove the brake fluid reservoir.

Remove the accelerator cable.

Disconnect the wire harness connectors and buckles of the following parts and then take them

away:

Oxygen sensor

Engine coolant temperature sensor

Crankshaft position sensor

Camshaft position sensor

Speed sensor

Throttle opening sensor

Absolute intake pressure sensor

Ignition coil

Fuel injector

Knock sensor

Generator

Starter

Air conditioner switch

4. Dismantlement of Components of Chassis

Dismount the front drive shaft. See Front Drive Shaft.

Remove the front exhaust pipe. Please refer to Exhaust System.

Dismount the engine supporting beam. See Engine Supporting Beam.

5. Dismantlement

Attach the lifting device hook to the hanging lug of the engine


41

Lift the engine and fix it in place.

Use the manual lifting stand or equivalent to firmly support the bottom of engine and transmission

assembly; adjust the lifting tension.

Attention:

A soft pad may be placed on the supporting surface so as to ensure a totally stable state.

Detach left, right, front and rear suspensions of engine. See Engine Suspension.

Carefully lower the engine and transmission assembly. Be aware of following items during

operation:

Make sure that the work will not affect the vehicle.

Make sure that all connecting parts have been disconnected.

In order to avoid falling due to changes of vehicle gravity, use the jack to support the rear lifting

point.

6. Detachment

Remove A/C compressor assembly from the engine and transmission assembly.

Dismount starter. See Starter.

Lift engine and transmission assembly with specified lifter, and then detach them.

Attention:

Before lifting, check whether each connection wiring harness has been disconnected.

7. Installation

Be aware of following items to install with steps contrary to dismantlement.

1) Do not damage the soft pad of engine suspension. Meantime, avoid spilling engine oil onto the soft

pad.

2) Make sure that all engine suspensions have been properly fixed. Then, tighten the nuts and bolts.

8. Check after Installation

1) Check for any leakage.

The steps for checking oil and fluid leakage, lubricating oil leakage and the exhaust leakage are as

follows:

Fig.1.1.004

Fig.1.1.005


42

Before starting engine, check oil and fluid levels (including engine oil and coolant). Refill to

specified level as required..

Check for fuel leakage with following steps

- With ignition switch turned to the ON position, check whether there is fuel leakage at the

connecting positions.

- With engine started, recheck whether there is fuel leakage at the connecting positions during engine

increasing.

During running of engine, check for any abnormal noise and/or vibration.

With engine warmed up, verify that there are no leakage of fuel, exhaust gas or other oil and liquid

(including engine coolant and oil).

Bleed air and replenish by using specified ports and hoses.

After engine cooled down, recheck oil and liquid levels (including engine oil and coolant). If

necessary, refill them to the specified levels.

2) General of Check Items

List of Leakage Check Items

Item Before Startup During Engine

Operation

After Engine

Stopped

Engine coolant Level Leakage Level

Engine oil Level Leakage Level

Transmission oil, brake fluid, and clutch fluid Level Leakage Level

Fuel Leakage Leakage Leakage

Exhaust Leakage


43

V. Drive Belt

1. Check Drive Belt

Warnings:

Be sure to operate only when engine stopped.

1) Check belt for aging, crack, wear and oil stain. Replace as required.

2) Check the belt tension at the mid-point between pulleys.

Inspection should be conducted with cold state of engine or when it has been stopped for at least

30min.

Tension range - Generator belt: 50050N. Please be noted that the experience equation for

tensioning force of reused belt is as below: Tensioning force for new belt * 1.2/1.5

Adjust if tension is out of range.

Attention:

When checking belt tension after installation, firstly to adjust tension to specified value. Then

revolve the crankshaft for more than two laps to re-adjust in order to avoid tension between

pulleys changes.

2. Adjustment of Tension

List of Tension Adjustment

Part Method

Generator belt Screw adjusting bolt of generator

Attention:

After replacing with the new belt, adjust the tension so as to meet the requirements

When installing the belt, ensure the proper engagement with the belt pulley groove.

Do not splash the engine oil or engine coolant onto the belt.

Do not over wind or bend belt; for worn belt, pay attention to mounting direction.


44

3. Generator Belt

1) Loosen the generator adjusting nuts and supporting nuts. Then adjust the tension by using the

adjusting bolt.

2) Tighten generator adjusting and supporting nuts.

Tightening torque: Generator adjusting nuts: 22.5 2.5 Nm

Generator supporting nuts: 475 N.m

4. Dismantlement of Drive Belt

1) Completely loosen the alternator belt as per the instructions in Tension Adjustment.

2) Remove the alternator belt.

5. Installation of Drive Belt

1) Mount the belt onto the pulley with steps contrary to dismantlement.

Attention:

Make sure that the belt has properly engaged with the groove of pulley.

Make sure that no engine oil or coolant splashed onto any belt or pulley groove.

2) Verify that the tension of every belt is within the standard range. See Inspection of Drive Belt.

Fig. 1.1.006 Fig. 1.1.007


45

VI. Air Filter and Air Duct

1. Parts

Diagram of Positions

2. Intake Pipe

1) Dismantlement

Remove the fastening bolts and clamps of

front intake pipe and remove the front intake

pipe assembly.

Tightening torque: 17-19 Nm

Loosen the lock clips from the air cleaner

upper cover.

Fig. 1.1.009

Fig. 1.1.008


46

Disconnect the locking clamp of intake hose, and then take off upper cover and intake hose.


Dismount the fixing bolt of air filter base, and

then take down the base.


2) Check after Dismantlement

Check whether there is any crack or wearing on the air duct assembly. If any, replace.

3) Installation


Attention:

Properly mount every joint and tighten the clamp.

3. Replacement of Air Filter element

1) Dismantlement

Loosen the lock clips of air cleaner upper

cover and lift the upper cover.

Fig. 1.1.012

Fig. 1.1.011

Fig. 1.1.013

Fig. 1.1.010


47

Dismount air filter element.


Periodically clean or replace the filter element with recommended period. See Periodical

Maintenance.

Blow the filter element from its back side with compressed air, till nothing is blown off.

3) Installation


VII. Intake Manifold and Exhaust Manifold

Decomposition Diagram of Intake and Exhaust Manifolds

1. Intake Manifold

1) Dismantlement

Caution:

Do not discharge the engine coolant when the engine is hot, otherwise you would be scalded.

Fig. 1.1.014


48

Discharge the engine coolant. See Engine Coolant.

Dismount the engine trimming cover.


Dismount the air filter assembly. See Air filter Assembly.

Disconnect the wire harness connectors of the following parts:

Absolute intake pressure sensor

Fuel injector

Throttle position sensor

Carbon canister control solenoid

Accelerator cable

Disconnect the following hose joints:

Water hose joint (insert a plug to prevent the engine coolant leakage)

PCV hose

Vacuum hose of braking vacuum booster on intake manifold side

Vacuum hose on carbon canister solenoid side

Small circulating water hose for throttle valve body

Remove the fastening bolts of throttle body and

remove the throttle body assembly.

Dismount the fuel injector assembly. See Fuel

Injector.

Tightening torque: 18.41.4 Nm

Fig. 1.1.015

Fig. 1.1.016


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Dismount the supporting bracket of intake manifold

and engine cylinder body.


Dismount the fixing bolt and nut of intake manifold.

Tightening torque: 181.0 Nm

Take off the intake manifold.


Check whether there is any crack or other damage on intake manifold and whether the matching face is

distorted. If this is the case, repair or replace the intake manifold. Check for any abnormal condition of

rubber rings.

3) Installation

Install with steps contrary to the dismantlement.

Attention:

Do not reuse the non-reusable parts.

Before starting the engine, check the level of engine coolant. If the level is lower, refill engine

coolant as specified.

Carry out the following steps to check whether fuel leakage is present.

With ignition switch turned to the ON position, check whether there is fuel leakage at the

connecting positions.

With engine started, recheck whether there is fuel leakage at the connecting positions during

engine increasing.

With engine warmed up, verify that there is no fuel and/or coolant leakage.

After engine cooled down, recheck the level of engine coolant. Refill to specified level as required.

2. Exhaust Manifold

1) Dismantlement

Fig. 1.1.017

Fig. 1.1.018


50

Caution:

Perform this operation after the exhaust system has completely cooled down.

Disconnect the wire harness connectors of front

oxygen sensor. Special tools should be used if

necessary.


Attention:

Do not damage the oxygen sensor.

It is forbidden to use any oxygen sensor which has dropped to the hard ground from a height

above 0.5m. Such an oxygen sensor should be replaced.

Unscrew the fixing bolt for heat shield of exhaust

manifold, and then take off heat shield.

Tightening torque: 9-11Nm

Unscrew bracket bolt to remove the exhaust manifold

bracket.


Unscrew fixing bolt to remove the exhaust manifold.

Tightening torque: M8 352 Nm

Fig. 1.1.020

Fig. 1.1.019

Fig. 1.1.021

Fig. 1.1.022


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Check whether the matching face of exhaust manifold is distorted.

3) Installation

Install with steps contrary to the dismantlement.

Attention:

Do not reuse the non-reusable parts.

Do not excessively tighten oxygen sensor, otherwise it may be damaged.

VIII. Exhaust System

1. Parts

Diagram of Exhaust System

1- Rear muffler; 2- Lug; 3- Front muffler; 4- Front exhaust pipe; 5-Three-element Catalytic Converter;

6- Bellow; 7-Rear oxygen sensor

2. Inspection of Exhaust System

Check whether the exhaust pipe, the three-way catalytic converter, the muffler and the fixing devices are

properly installed and whether there is any leakage, crack, damage or aging.

Repair or replace the damaged part as required.

3. Dismantlement and Installation

Attention:

Do not have you hand cut by the edge of heat shield.

Do use original exhaust system parts or equivalent products.

Perform the operation after the exhaust system has completely cooled down, for the temperature of

exhaust system remains hot when the engine has just stopped.

1) Dismantlement

Disconnect every joint and fixed part.

2

3

4

6

5

7

1


52

2) Installation



Replace the exhaust pipe gasket when reassembling the exhaust system each time.

Repair or replace the seriously distorted heat shield. Eliminate the accumulations from the heat

shield.

When install the heat shield, try to avoid wide clearance or blockage and intervention between the

heat shield and each exhaust pipe.

Eliminate the sediments from the sealed face of each joint. Such joints should be firmly connected

to avoid gas leakage.

Pre-tighten the fixing nuts and bolts on exhaust manifold side and those on vehicle side. Check

whether there is any intervention between parts, and then tighten the parts to specified torque.

When install the fixing rubber, avoid excessive upward/downward and leftward/rightward twist or

stretch.

3) Check after Installation

Verify clearance between rear muffler and rear bumper.

WIth engine running, check the connecting position of exhaust pipe for air leakage and abnormal

noise.

Ensure that the fixing support and the fixing rubber have been properly mounted. Do not subject

them to excessive force. Improper installation may result in considerable noise and shake.


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IX. Timing sprocket mechanism

1. Parts

Timing sprocket mechanism diagram

1 Timing chain 2 Movable rail bolt subassembly 4. Movable rail subassembly

5 Automatic tensioner bolt 5 Automatic tensioner 6 Bolt 7 Balance shaft front cover plate

8 Balance shaft chain wheel fastening bolt 9 Balance shaft chain wheel 10 Secondary chain

11 Balance shaft idler gear 12 Secondary tensioner 13 Secondary tensioner torsion spring

14 Fixed gauge subassembly 15 Fixed gauge bolt subassembly

2. Dismantlement and Installation of Timing

chain

1) Dismantlement

a) Remove the water pump pulley and tensioner

fastening bolts.

Tightening torque: Water pump pulley bolts:

7~8.2N.m

Tensioner bolts: 40~58N.m

Fig. 1.1.023

Balance shaft gear


54

Note: It is permissible to perform the

dismantlement by means of the friction force of

drive belt before drive belt is removed.

b) Dismantle drive belt to check whether the

drive belt has wearing, aging, cracking, etc.;

if any, replace drive belt.

c) Dismantle oil gauge assembly

Tightening torque: 7-8.2 Nm

d) Dismantle damping wheel


e) Remove the alternator bracket.

f) Dismantle oil pan and cylinder head cover

Attention: Only when oil pan and cylinder head

cover are disassembled can the oil pump

assembly be dismantled.

Remove the cylinder head shield as per the

illustrated sequence.

Fig. 1.1.024

Fig. 1.1.025

Fig. 1.1.026

Fig. 1.1.027

Tightening sequence for bolts of cylinder head shield


55

g) Dismantle oil pump assembly

h) Check timing

Check the timing point shown in the diagram for compliance.

Fig. 1.1.028

Timing mark of primary chain

Timing mark of secondary chain

Timing mark of secondary chain

Timing mark for crankshaft chain wheel

Timing mark for balance shaft chain wheel

Timing mark of primary chain

Timing mark for camshaft chain wheel


56

i) Dismantle tensioner and set/dynamic tracks of

the automatic timing chain. Check for any

abnormalities.

Tightening torque: Automatic tensi

Documents

Manual Servicio Jac j2