Manual de Servicio Jac j2

Maintenance Manual for J2 Sedan

Foreword

Maintenance Manual for J2 Sedan Foreword 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.

Master Table of Contents General Description Maintenance

&

Chapter I General Description Chapter II Maintenance

Engine Chapter I Engine mechanical system Chapter II Engine electrical system Chapter III engine electronic control system

Chassis Chapter I Clutch & Manual Transmission Chapter II Traveling system Chapter III Braking system

Body Electrical & Structure Chapter I Body Electrical Chapter II Body Structure

Circuit Troubleshooting

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

Chapter I Overview Section I General Instructio ons 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.

1

Maintenance Manual for J2 Sedan Section II Vehicle Information I.

Identification Information Position

1 2

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 Made by China Anhui Jianghuai Automobile Co., Ltd.

Brand: Jianghuai

Model Engine Model Max. gross weight Ex-factory no.

Engine displacement

Rated power Fixed number Ex-factory date

Example of Nameplate

2

5 persons Jan. 2010

Overview

Maintenance Manual for J2 Sedan

Overview

III. Vehicle Identification Number (VIN) 1)

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

2)

Illustration of VIN

Digitals

Geographical region

Order number

Country

Assembled in

Vehicle Description Code Check Character

Manufacturer

Representative letter or number

Model year Representative number

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: Digitals

Inspection digit Code of engine type and rated power Truck wheelbase / passenger cars, buses and chassis length Max. gross weight Body type Vehicle type

3

Maintenance Manual for J2 Sedan

Overview

① Vehicle type：2 Means passenger cars F: 3 chambers & 4 doors ② Body type G: 2 chambers & 5 doors ③ Max. Gross Weight: K: >1000-2000 ④ Truck wheelbase / passenger cars, buses and chassis length: R> 2390 - 2600

1: gasoline ≤70Kw ⑤

Code of engine type and rated power

2: gasoline >70-90Kw 3: gasoline >90-110Kw

Part 3: indication of vehicle, 8 digitals Digitals

Production SN Factory assembled Year

4:General Assembling Workshop of Passenger Car Manufacture Company Factory assembled

7:General Assembling Workshop of Passenger Car Manufacture Company Year

8: 2008 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). Fig. 2.1.001

4

Maintenance Manual for J2 Sedan 2.

Meaning of Engine Number Fig. 2.1.002

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

5

Overview

Maintenance Manual for J2 Sedan

Overview

Section III Lifting, Protection and Towing of Vehicle I.

Lifting of Vehicle

1.

Vehicle’s Supporting Points The positions of vehicle’s supporting points are shown in figure below.

Attention:


Don’t lift the vehicle by using the point other than those specified; otherwise vehicle body may be damaged.

Supporting point

Positions of Vehicle’s 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.

6

Maintenance Manual for J2 Sedan

Overview

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;




Don’t 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. Don’t 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, ① If no other towing equipment is available, the towing hole must be used; ② Always tow the vehicle from its forehead; ③ Keep the towing rope away from the bumper; ④ 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. Don’t apply force to the towing hook from any ohter directions. Don’t start towing sharply otherwise damage may be caused.

7

Maintenance Manual for J2 Sedan

Service

Chapter II Service Section I Service I.

Preparation

1.

Maintenance Tools List of Maintenance Tools

II.

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

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 Tyre

Windshield Windshield wiper blade Door and engine hood

Tyre exchange

Inspection 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 there’s any damage, crack or excessive worn tear carefully. Clean the windshield regularly. Check whether there’s any crack or other damage of the windshield every six months or more frequently. Repair as required. If the wiper doesn’t work efficiently, check for worn or torn. 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. The tyre exchange should be conducted after each 8000 km traveling. 8

Maintenance Manual for J2 Sedan Vehicle lamps

2.

Service

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.

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 Alarm light and buzzer Windshield wiper and washer Windshield defroster

Steering wheel

Seat Belt Throttle pedal Brake pedal and booster Parking brake 3.

Inspection Make sure all the alarm lights and buzzers are working normally. Check whether the wiper and cleaner are working normally; check whether there is any crack in the wiper. 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. 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. 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. 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. 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. Check travel of handle.

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 Cleaning liquid for windshield Level of engine coolant Engine oil level Levels of brake fluid and clutch fluid Battery Liquid leakage

Inspection Check whether there is adequate cleaning liquid in reservior. Check the coolant level when the engine is cold. Stop the vehicle on a level ground and turn off engine; check oil level. Make sure that the levels of brake fluid and clutch fluid are between the “MAX” line and “MIN” marks on reservoir. Inspect conditions of voltage and battery poles. 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.

9

Maintenance Manual for J2 Sedan

Service

Service operational code: I-examination; R-replacement; C-washing Service cycle (odometer readings and the number of months, whichever comes first) Item

1000km

1

10

20

30

40

50

60

70

80

90

100

Month

—

6

12

18

24

30

36

42

48

54

60

R

I

I: every 10,000 km or 6 months

1

Driving belt

2

Check oil and gas control systems of crankcase for normal working

3

Spark plug

4

Change coolant

5

Air filter element

General conditions of use

C: every 5,000km R: 15,000km

Harsh conditions of use

C: every 3,000km R: 10,000km

Oil and oil filter

General conditions of use

R: every 5,000 km or 6 months

Harsh conditions of use

R: every 3,000 km or 3 months

6

R: every 60,000 km or two years I I

I

R

R

I

I

I

I

I

R

I

I

R

Ignition timing

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

12

Injector

13

Valve clearance

C

I

C* I

I

C C*

C* I

I

C*

I

I

C C*

I

R

8

I

I

R

Carbon monoxide content with engine idling

C*

I

I

7

I

I

R

I

C C*

I

C*

I

C C*

I

C* 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: ① Driving in dusty areas or the vehicle is regularly exposed to salty air or sea water. ② Driving on rugged road, road with water accumulation or on mountain roads. ③ Driving in cold areas. ④ In the cold season, the engine idles a long time or used frequently in short-distance traveling. ⑤ Frequent use of brakes, regular emergency braking. . ⑥ As tractor ⑦ As taxi or leasing ⑧ At temperatures above 32 ℃, driving in urban heavy traffic for more than 50% of the total travel time.

10

Maintenance Manual for J2 Sedan

Service

⑨ At a temperature below 30 ℃, driving at 120km/h or higher speed limits for more than 50% of the total travel time. ⑩ 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 Factory filled oil: SAE10W-30 Ambient temperature for use: -25 ℃ - 35 ℃

V.

Engine oil

3.8

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

0.56±0.05

DOT4 (Great Wall)

AC refrigerant

600±25g

R134a

Wiper cleaning liquid

3

Water

AC compressor lubricating oil

0.12

PAG56

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: 500±50N 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

11

Maintenance Manual for J2 Sedan

Service

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.

■

Don’t 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 ① Dismount the right deflector of engine. See “Engine Deflector”. ② Open the water drain plug at the bottom of radiator, and then open the cap of radiator. ③ If necessary, please dismount coolant reservoir, drain the engine coolant, and reinstall it after cleaned. ④ Check if there’s 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 ① 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.

② Make sure that all the hose clamps have been stably tightened. ③ Dismount the upper cover of air filter and the intake hose. Please refer to “Air Filter Assembly”. ④ Disconnect outlet tube of heater pipe. Please lift the hose as high as possible. ⑤ 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”. 12

Maintenance Manual for J2 Sedan ■

Service

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

⑥ Install air filter upper cover and intake hose. Please refer to “Air Filter Assembly”. ⑦ Install radiator cap. ⑧ Warm up the engine until the thermostat is switched on. ■

Examine if there’s 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.

⑨ Stop the engine, allow engine temperature drops. ■

The cooling time can be reduced by using fan.

⑩ Fill engine coolant in coolant until the MAX level reached.

⑪ Install radiator cap, and repeat steps ③-⑨ for more than two times until the level of engine coolant doesn’t go down any more.

⑫ Start engine, check for any leakage in the cooling system. 3) Wash cooling system ① 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.

② Dismount air filter upper cover and the intake hose. Refer to “Air Filter Assembly”. ③ Disconnect outlet tube of heater pipe. Please lift the hose as high as possible. ④ 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. ⑤ Install air filter upper cover and intake hose. Refer to “Air Filter Assembly”. ⑥ Start the engine, warm up it to normal working temperature. ⑦ Speed up the engine for several times without load. ⑧ Stop engine, and wait till engine cooled down. ⑨ Discharge coolant inside system. Refer to “Draining Engine Coolant”. ⑩ Repeat steps ①-⑨ 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. 13

Maintenance Manual for J2 Sedan

Service

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 ① 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.

② Pull out negative pressure valve to open it, and upon the pressure is released, check whether it can be completely closed. ■

Make sure there isn’t any smudge or damage on the valve seat.

■

Make sure that the valve seat can be normally opened and closed.

Fig. 2.2.001

③ Check the pressure released by radiator cap. Standard: 78-98 KPa Fig. 2.2.002

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.

① Wash back of radiator fins from the top to the bottom with water spraying normal to radiator. ② Wash each surface of the radiator every other minute. ③ In case no dirt is washed away from the radiator, the washing work should be stopped. 14

Maintenance Manual for J2 Sedan

Service

④ 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. ⑤ Blow radiator core surface with compressed air every other minute until no water can be blown away. 4) Check for leakage of cooling system ① Check for leakage through applying pressure to the cooling system with a leakage detector of radiator cap. ■ Test pressure: 157 KPa Caution: ■

Fig. 2.2.003

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.

② 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

Fig. 2.2.004

Engine

Fuel pipeline Fuel tank

Fig. 2.2.005

① Unscrew lock bolt of air filter upper cover lift up the cover.

15

Maintenance Manual for J2 Sedan

Service

Fig. 2.2.006

② 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 N·m.

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. 16

Maintenance Manual for J2 Sedan ■

Service

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

① 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

Fig. 2.2.007

① Clear any foreign substance on mounting surface of oil filter. ② Paste a film of engine oil onto the oil seal surface of new filter. ③ Tighten. ■

Tightening torque: 10-12N·m

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

① Inspect oil level, and fill engine oil when it is inadequate. See also “Engine Oil”. ② Start engine, check for any oil leakage. ③ Stop engine and wait for ten minutes. ④ Inspect oil level, and fill engine oil. See also “Engine Oil”. 9.

Replacement of Ignition Plug 17

Maintenance Manual for J2 Sedan 1)

Service

Dismantlement

① Dismount the engine hood. See also “Intake manifold”. ② Disassemble the ignition coil. Please refer to “Ignition Coil”. ③ 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 there’s 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 N·m.

10. Replacement of Fuel Filter 1)

Dismantlement

Caution: ■

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

① Open the fuel filler cap. 18

Maintenance Manual for J2 Sedan

Service

② Release pressure inside fuel tank. ③ Remove the rear seat cushion. See “Rear Seat”. ④ Dismount the fuel tank service cap. ⑤ 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. Fig. 2.2.008

① Installation direction of fuel filter ■

Be aware of installation direction of fuel filter. Towards inlet tube.

② Installation of pipe fitting. 3)

Post-installation inspection

Check for any fuel leakage with following steps. ① Turn ignition switch to “ON” (with engine stopped), and then check for leakage at the joints of fuel pipeline. ② 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.

19

Maintenance Manual for J2 Sedan

■

In case any component is found damaged, repair or replace.

2.

Inspection of Clutch Fluid Level and Leakage

Service

Fig. 2.2.009

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

① Dismount the wheel(s) need to be adjusted. ② 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

① Take the center hole as guide to install the wheel on balancer. Start the balancer. ② 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 20

Maintenance Manual for J2 Sedan

Service

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.

Fig. 2.2.010

Stuck weight Center of gravity

Towards the groove

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.

Fig. 2.2.011

Attention: ■

Never install a balance block on another one.

③ Restart the wheel balancer.

Position (or angle) indicated by the wheel balancer

④ 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.

⑤ 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. 21

Maintenance Manual for J2 Sedan ■

Allowable maximum unbalance:

7.

Tyre Exchange

■

Tyre exchange should be performed every 8000 km.

Service

Fig. 2.2.012

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.

Fig. 2.2.013

Inspection for Brake Fluid Level and Leakage

Highest line

If fluid level is low, please check brake system for leakage.

Lowest line Normal

Fig. 2.2.014

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.

22

Maintenance Manual for J2 Sedan Fig. 2.2.015

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. Fig. 2.2.016

4) Loosen the release valve, press down the brake pedal slowly, and then release. Repeat this operation every other 2 or 3 s until there’s outflow of new brake fluid, and then step on the brake pedal to close the release valve. Repeat there procedures for all wheels.

5)

Service

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

Brake disc

2)

Type

Floating caliper type / ventilated disc

Brake disc diameter

241 mm

Brake disc thickness

19 mm

Friction block thickness

9 mm

Cylinder bore

51 mm

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.

23

Maintenance Manual for J2 Sedan

Service

Standard Specification Table of Brake Drum

Brake drum

3)

Type

Leading trailing shoe brake

Brake drum diameter

204 mm

Cylinder bore of brake slave cylinder

17.46 mm

Clearance adjustment

Automatically

Circular runout

< 0.05 mm

Brake caliper

Fig. 2.2.017

Check for any oil leakage.

4)

Fig. 2.2.018

Rear brake slave cylinder

Check for any leakage.

5)

Fig. 2.1.019

Front brake shoe

Check for worn or damaged conditions. ■

Standard thickness: 9 mm

■

Limit thickness: 2 mm

24

Maintenance Manual for J2 Sedan

6)

Service

Fig. 2.2.020

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

Fig. 2.2.021

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 steering column is loose.

2)

Steering pull-rod

with

Check the leakage of lubricating grease Check the tightening torque

the

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: ■

Fig. 2.2.022

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.

25

Maintenance Manual for J2 Sedan

■ Rock each wheel to check for proper clearance.

Fig. 2.2.023

■ 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. Fig. 2.2.024

Fig. 2.2.025

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 26

Service

Maintenance Manual for J2 Sedan

Service

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 passenger’s 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, don’t 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

Nominal Diameter of Thread

Pitch

M5

Torque (N·m) Head mark 4

Head mark 7

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

27

Maintenance Manual for J2 Sedan

Service

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%.

28

Maintenance Manual for J2 Sedan

Contents

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

Maintenance Manual for J2 Sedan

Contents

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

Maintenance Manual for J2 Sedan

Contents

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

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.

33

Maintenance Manual for J2 Sedan 6.

Mechanical Part of Engine

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.

Fig.1.1.001

Removal of Sealant JAC-T1F017

After dismounting fixing nuts and bolts, use the scraper to detach the matching faces and remove old sealant. Knock

Slide

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

Fig.1.1.002 Scraper

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.

34

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

3) Position sealant with the specified size. Fig.1.1.003

■

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.

35

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

III. Preparation 1.

Tools for Maintenance No.

1

Tool

List of Special Tools Appearance

Code

Description

Fix camshaft timing sprocket

End forked clamp

JAC-T1D001

2

3

Pin

Used together with the end forked clamp

Locating tool for piston pin

Used to install and dismantle the piston pin JAC-T1F005

4

Guide sleeve

5

Flywheel chock

6

Used together with the locating tool for piston pin

Valve spring compressor

36

JAC-T1F011

Used to fix the flywheel

JAC-T1F012

Used to compress the valve spring Install valve cotter

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

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

JAC-T3F003

Functioning as a guide during the installation of front oil seal of crankshaft

JAC-T3F004

Used to install the front oil seal of engine crankshaft

JAC-T3F005

Used to install the rear oil seal of crankshaft

11

Guide for front oil seal of crankshaft

12

Installer for front oil seal of crankshaft

13

Installer for rear oil seal of crankshaft

37

Maintenance Manual for J2 Sedan 2.

Mechanical Part of Engine

List of Auxiliary Materials for Assembling Engine List of Auxiliary Materials for Assembling Engine

No.

Name

Application

1

Engine oil

Used during filling and assembly

2

Silica gel

3

Sealant

4

Sealant

5

Petrol Sealant

6

3.

Specification and Grade 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

Engine oil pump, water pump, oil pan and rear oil seal housing of crankshaft Oil pressure switch, draining screw plug and flywheel bolt Coolant temperature sensor and water temperature alarm switch

LT5699 or equivalent LT243 or equivalent LT648 or equivalent 93# unleaded petrol or above LT271 or equivalent

Stud bolt

List of Auxiliary Materials for Assembling Cylinder head List of Auxiliary Materials for Assembling Cylinder head

No.

Name

1

Engine oil

2

Sealant

Present Material and Model 5W-30 (winter) 15W-40 (summer),with SJ-class quality level and above LT271 or equivalent

3

Sealant

LT962T or equivalent

38

Assembly Position Valve head, camshaft and camshaft oil seal Stud bolt Guide sleeve of spark plug, bowl patch of cylinder body/cover, connecting pipe nozzle

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

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 ① Discharge the engine coolant from the radiator. See “Change Engine Coolant”. ② Discharge the engine oil, transmission oil and clutch oil. See "Engine Oil", “Transmission Oil” and “Clutch Pipeline”. ③ 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.

④ 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”.

39

Maintenance Manual for J2 Sedan 3.

Mechanical Part of Engine

Dismantlement of Related Elements in Engine Compartment

① 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”.

② Remove the brake fluid reservoir. ③ Remove the accelerator cable. ④ 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

① Dismount the front drive shaft. See “Front Drive Shaft”. ② Remove the front exhaust pipe. Please refer to “Exhaust System”. ③ Dismount the engine supporting beam. See “Engine Supporting Beam”. 5.

Dismantlement

① Attach the lifting device hook to the hanging lug of the engine

40

Maintenance Manual for J2 Sedan

Fig.1.1.004

Mechanical Part of Engine

Fig.1.1.005

② Lift the engine and fix it in place. ③ 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.

④ Detach left, right, front and rear suspensions of engine. See “Engine Suspension”. ⑤ 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

① Remove A/C compressor assembly from the engine and transmission assembly. ② Dismount starter. See “Starter”. ③ 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: 41

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

■

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

Engine coolant Engine oil Transmission oil, brake fluid, and clutch fluid Fuel Exhaust

Level Level Level Leakage —

42

During Engine Operation Leakage Leakage Leakage Leakage Leakage

After Engine Stopped Level Level Level Leakage —

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

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: 500±50N. 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 Generator belt

Method 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.

43

Maintenance Manual for J2 Sedan 3.

Mechanical Part of Engine

Generator Belt

1) Loosen the generator adjusting nuts and supporting nuts. Then adjust the tension by using the adjusting bolt. Fig. 1.1.007

Fig. 1.1.006

2) Tighten generator adjusting and supporting nuts. ■

Tightening torque: Generator adjusting nuts: 22.5 ± 2.5 Nm Generator supporting nuts: 47±5 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”.

44

Maintenance Manual for J2 Sedan VI. Air Filter and Air Duct 1.

Parts

Diagram of Positions 2.

Intake Pipe

Fig. 1.1.008

1) Dismantlement ① Remove the fastening bolts and clamps of front intake pipe and remove the front intake pipe assembly. ■

Tightening torque: 17-19 N·m

Fig. 1.1.009

② Loosen the lock clips from the air cleaner upper cover.

45

Mechanical Part of Engine

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

③ Disconnect the locking clamp of intake hose, and then take off upper cover and intake hose. ■

Tightening torque: 6-9 N·m Fig. 1.1.010

Fig. 1.1.011

④ Dismount the fixing bolt of air filter base, and then take down the base. ■

Fig. 1.1.012

Tightening torque: 8-12 N·m

2) Check after Dismantlement Check whether there is any crack or wearing on the air duct assembly. If any, replace. 3) Installation Install with steps contrary to dismantlement. Attention: ■

Properly mount every joint and tighten the clamp.

3.

Replacement of Air Filter element

1) Dismantlement

Fig. 1.1.013

① Loosen the lock clips of air cleaner upper cover and lift the upper cover.

46

Maintenance Manual for J2 Sedan

② Dismount air filter element.

Mechanical Part of Engine

Fig. 1.1.014

2) Check after Dismantlement ■

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 ■

Install with steps contrary to dismantlement.

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.

47

Maintenance Manual for J2 Sedan ① Discharge the engine coolant. See “Engine Coolant”. ②

Dismount the engine trimming cover.

■

Tightening torque: 8-12 N·m

③

Dismount the air filter assembly. See “Air filter Assembly”.

④ Disconnect the wire harness connectors of the following parts: ■

Absolute intake pressure sensor

■

Fuel injector

■

Throttle position sensor

■

Carbon canister control solenoid

■

Accelerator cable

⑤

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

⑥

Remove the fastening bolts of throttle body and remove the throttle body assembly.

Fig. 1.1.015

⑦

Dismount the fuel injector assembly. See “Fuel Injector”.

Fig. 1.1.016

■

Tightening torque: 18.4±1.4 N·m

48

Mechanical Part of Engine

Maintenance Manual for J2 Sedan

⑧

Dismount the supporting bracket of intake manifold and engine cylinder body.

■

Tightening torque: 10-20 N·m

⑨ Dismount the fixing bolt and nut of intake manifold. ■

Mechanical Part of Engine

Fig. 1.1.017

Fig. 1.1.018

Tightening torque: 18±1.0 N·m

⑩ Take off the intake manifold.

2) Check after Dismantlement 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 49

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

Caution: ■

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

①

Disconnect the wire harness connectors of front oxygen sensor. Special tools should be used if necessary.

■

Tightening torque: 30-40 N·m

Fig. 1.1.019

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.

②

Unscrew the fixing bolt for heat shield of exhaust manifold, and then take off heat shield.

■

Tightening torque: 9-11N·m

④

Unscrew bracket bolt to remove the exhaust manifold bracket.

■

Tightening torque: 20-25 N·m

⑤

Unscrew fixing bolt to remove the exhaust manifold.

■

Tightening torque: M8 35±2 N·m

50

Fig. 1.1.020

Fig. 1.1.021

Fig. 1.1.022

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

2) Check after Dismantlement 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. 1.

Exhaust System

Parts 2 4 7 5 1

3

6

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. 51

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

2) Installation ■

Install with steps contrary to dismantlement.

■

Tightening torque: 38-52 N·m

■

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.

52

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

IX. Timing sprocket mechanism 1.

Parts

Balance shaft gear

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

Fig. 1.1.023

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 53

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

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 N·m

Fig. 1.1.024

d) Dismantle damping wheel ■

Tightening torque: 160-170 N·m

e)

Remove the alternator bracket.

f)

Dismantle oil pan and cylinder head cover

Fig. 1.1.025

Fig. 1.1.026

Fig. 1.1.027

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. Tightening sequence for bolts of cylinder head shield

54

Maintenance Manual for J2 Sedan

g)

Dismantle oil pump assembly

Mechanical Part of Engine

Fig. 1.1.028

h) Check timing Check the timing point shown in the diagram for compliance. Timing mark of primary chain

Timing mark for camshaft chain wheel

Timing mark of secondary chain

Timing mark of primary chain

Timing mark for balance shaft chain wheel Timing mark of secondary chain Timing mark for crankshaft chain wheel

55

Maintenance Manual for J2 Sedan

i)

Dismantle tensioner and set/dynamic tracks of the automatic timing chain. Check for any abnormalities.

■

Tightening torque: Automatic tensioner: 9 11 N • m

Fig. 1.1.029

Set track: 10-12 N·m Dynamic track: 19-28 N·m j)

Dismantle exhaust camshaft sprocket bolt

■

Tightening torque: 88±10 N·m

Fig. 1.1.030

k) Remove t he bolts of intake cam chain wheel ■

Tightening torque: 88±10 N·m

l)

Remove the rear end cap of balance shaft and secure the anti-rotation device of balance shaft on the tail of the balance shaft.

■

Tightening torque for rear end cap of balance shaft: 7.6±0.6 N·m

Fig. 1.1.031

56

Mechanical Part of Engine

Maintenance Manual for J2 Sedan

m) Remove the bolts of secondary chain tensioner and remove the secondary chain tensioner. ■

Fig.1.1.033

Tightening torque: 10±2 N·m

n) Remove the bolts of balance shaft chain wheel and remove the balance shaft chain wheel. ■

Mechanical Part of Engine

Fig.1.1.034

Tightening torque: 45±5 N·m

2） Installation Reverse the above steps for installation. Be aware of timing and tightening torque during installation.

57

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

X. Camshaft and balance shaft assembly 1. Parts

Breakdown diagram for camshaft and balance shaft 1 – Intake camshaft subassembly 2 – Intake camshaft chain wheel 3 – Chain wheel bolts 4 – Exhaust camshaft chain wheel 5 – Exhaust camshaft subassembly 6 – Mechanical tappet 7 – Balance shaft retaining bolt 8 – Balance shaft gear 9 – Balance shaft 10 – Balance shaft rear end cap gasket 11 – Balance shaft rear end cap 12 – Balance shaft rear end cap bolts 2.

Disassembly and installation

1） Disassembly of camshaft ① Remove cylinder cover. See "Intake Manifold." ② Remove high-voltage ignition coil. See "Ignition Coil." ③ Disconnect PCV hose and air hose of respirator. ④ Remove the cylinder head cover from the cylinder head. ⑤ Remove camshaft timing sprocket. Seethe "timing sprocket body." ⑥ Remove camshaft position sensor from rear end of the cylinder head. Tightening torque: 9 - 11 N • m

58

Maintenance Manual for J2 Sedan Attention: ■

Handle with care to avoid collision or damage.

⑦ Remove the camshaft from cylinder head. 2） Disassembly of balance shaft

Fig.1.1.035

On the basis of above-mentioned disassembly procedure of camshaft, proceed as below: Remove the bolts of balance shaft front end cap and remove the balance shaft front end cap. ①■ Tightening torque for balance shaft front end cap: 7.6±0.5N.m

②

Remove the balance shaft idler gear, remove the bolts of balance shaft front gear, and remove the balance shaft gear.

■

Tightening torque for bolts of balance shaft front gear: 23.5±4.5N.m

③

Remove the bolts of exhaust bracket II and balance shaft side cover and remove the balance shaft.

■

Tightening torque 7.6±0.6N.m

for

bolts

of

Fig.1.1.036

Fig.1.1.037

cover:

Fastening bolts for exhaust pipe bracket II: 22.5±2.5N.m

59

Mechanical Part of Engine

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

Fig.1.1.038

3） Inspection after removal ① Camshaft Measuring camshaft base circle diameter and the maximum lifting strokes of intake and exhaust.

■

Base circle diameter: 36mm Maximum lifting stroke of intake：8.7054mm Maximum lifting 8.2836mm

stroke

of

exhaust ：

If specified value is exceeded, replace the camshaft. ② Mechanical tappet ■

Fig.1.1.039

Measure the top thickness of the mechanical tappet Measurement should be within: 2.70 ～ 2.30mm

4） Installation Assembly of camshaft machenism: All parts camshaft assembly should be assembled according to grouped drawings. ①

The mechanical tappet at the intake side will be grouped and assembled as per the following table to ensure the intake valve clearance.

Distance between intake camshaft base circle

Top end thickness of

Mechanical tappet

Valve clearance

and valve tappet L1

mechanical tappet

label

(mm)

2.91＜L1≤2.93

2.70

270

0.19-0.25

2.93＜L1≤2.95

2.72

272

0.19-0.25

2.95＜L1≤2.97

2.74

274

0.19-0.25

2.97＜L1≤2.99

2.76

276

0.19-0.25

2.99＜L1≤3.01

2.78

278

0.19-0.25

3.01＜L1≤3.03

2.80

280

0.19-0.25

3.03＜L1≤3.05

2.82

282

0.19-0.25

3.05＜L1≤3.07

2.84

284

0.19-0.25

3.07＜L1≤3.09

2.86

286

0.19-0.25

3.09＜L1≤3.11

2.88

288

0.19-0.25

3.11＜L1≤3.13

2.90

290

0.19-0.25

60

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

Distance between intake camshaft base circle

Top end thickness of

Mechanical tappet

Valve clearance

and valve tappet L1

mechanical tappet

label

(mm)

3.13＜L1≤3.15

2.92

292

0.19-0.25

3.15＜L1≤3.17

2.94

294

0.19-0.25

3.17＜L1≤3.19

2.96

296

0.19-0.25

3.19＜L1≤3.21

2.98

298

0.19-0.25

3.21＜L1≤3.23

3.00

300

0.19-0.25

3.23＜L1≤3.25

3.02

302

0.19-0.25

3.25＜L1≤3.27

3.04

304

0.19-0.25

3.27＜L1≤3.29

3.06

306

0.19-0.25

3.29＜L1≤3.31

3.08

308

0.19-0.25

3.31＜L1≤3.33

3.10

310

0.19-0.25

3.33＜L1≤3.35

3.12

312

0.19-0.25

3.35＜L1≤3.37

3.14

314

0.19-0.25

3.37＜L1≤3.39

3.16

316

0.19-0.25

3.39＜L1≤3.41

3.18

318

0.19-0.25

3.41＜L1≤3.43

3.20

320

0.19-0.25

3.43＜L1≤3.45

3.22

322

0.19-0.25

3.45＜L1≤3.47

3.24

324

0.19-0.25

3.47＜L1≤3.49

3.26

326

0.19-0.25

3.49＜L1≤3.51

3.28

328

0.19-0.25

3.51＜L1≤3.53

3.30

330

0.19-0.25

Table: Distance between intake camshaft base circle and top of valve tappet, top end thickness of the mechanical tappet grouping and assembly

61

Maintenance Manual for J2 Sedan ②

Mechanical Part of Engine

The mechanical tappet at the exhaust side will be grouped and assembled as per the following table to ensure the intake valve clearance.

Distance between exhaust camshaft base circle

Top end thickness of

Mechanical

Valve clearance

and valve tappet L2

mechanical tappet

tappet label

(mm)

2.99＜L2≤3.01

2.70

270

0.27-0.33

3.01＜L2≤3.03

2.72

272

0.27-0.33

3.03＜L2≤3.05

2.74

274

0.27-0.33

3.05＜L2≤3.07

2.76

276

0.27-0.33

3.07＜L2≤3.09

2.78

278

0.27-0.33

3.09＜L2≤3.11

2.80

280

0.27-0.33

3.11＜L2≤3.13

2.82

282

0.27-0.33

3.13＜L2≤3.15

2.84

284

0.27-0.33

3.15＜L2≤3.17

2.86

286

0.27-0.33

3.17＜L2≤3.19

2.88

288

0.27-0.33

3.19＜L2≤3.21

2.90

290

0.27-0.33

3.21＜L2≤3.23

2.92

292

0.27-0.33

3.23＜L2≤3.25

2.94

294

0.27-0.33

3.25＜L2≤3.27

2.96

296

0.27-0.33

3.27＜L2≤3.29

2.98

298

0.27-0.33

3.29＜L2≤3.31

3.00

300

0.27-0.33

3.31＜L2≤3.33

3.02

302

0.27-0.33

3.33＜L2≤3.35

3.04

304

0.27-0.33

3.35＜L2≤3.37

3.06

306

0.27-0.33

3.37＜L2≤3.39

3.08

308

0.27-0.33

3.39＜L2≤3.41

3.10

310

0.27-0.33

3.41＜L2≤3.43

3.12

312

0.27-0.33

3.43＜L2≤3.45

3.14

314

0.27-0.33

3.45＜L2≤3.47

3.16

316

0.27-0.33

3.47＜L2≤3.49

3.18

318

0.27-0.33

3.49＜L2≤3.51

3.20

320

0.27-0.33

3.51＜L2≤3.53

3.22

322

0.27-0.33

3.53＜L2≤3.55

3.24

324

0.27-0.33

3.55＜L2≤3.57

3.26

326

0.27-0.33

3.57＜L2≤3.59

3.28

328

0.27-0.33

3.59＜L2≤3.61

3.30

330

0.27-0.33

Table: Distance between the exhaust camshaft base circle and top of valve tappet, top end thickness of mechanical tappet assembly grouping and assembling

62

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

Installation precautions: ■

Mechanical tappet should be applied with proper amount of oil evenly; after the cylinder head is assembled, it should turn flexibly without sticking or other abnormalities.

■

Before assembling camshaft, proper amount of oil should be evenly applied on each contact surface; after the camshaft bearing bolt is tightened, the camshaft should turn flexibly without sticking or other abnormalities; axial clearance should be: 0.05 - 0.15mm. (Measurement location)

③ Install the camshaft position sensor. Attention: ■

Apply a film of sealant to the flange of rear end cover.

■

Tighten the fixing bolt after the support has been fully mounted.

④ Install camshaft timing sprocket ⑤

Install the timing chain wheel of balance shaft. During installation, notice to align the timing mark of balance shaft.

Fig.1.1.040

Backlash of balance shaft gear: 0.06-0.12mm Backlash of 0.08-0.14mm

balance

shaft

idler

gear:

Timing mark of balance shaft gear and idler gear

⑥ Be aware of following items to install with steps contrary to dismantlement. ■

Before installing cylinder head cover, clear any sealant on cylinder head.

■

Make sure that cylinder head cover gasket is put into the installation slot.

5) Check after Dismantlement ■

Check for proper position of all parts installed.

■

Check the level of engine oil before starting the engine. If the engine oil is less than the required volume, replenish to specified level.

■

With engine running, check for abnormal noise and vibration.

■

Be sure that there is no oil leakage after engine warmed-up thoroughly.

■

Recheck the level of engine oil with engine cooled down. Replenish the engine oil to the specified level as required.

63

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

XI. Cylinder head 1.

On-vehicle Maintenance

1) Inspect the cylinder pressure: ①

Thoroughly warm up the engine and then stop it.

②

Release the fuel pressure. See “Release of Fuel Pressure”.

③

Disconnect the fuse of fuel pump, otherwise the fuel may be sprayed out during measurement.

④

Use special ignition coil and spark plug removal tool. See "Ignition Coil" and the "Spark Plug."

⑤

Dismantle engine trimming cover. See “Intake manifold”.

⑥

Install a cylinder pressure gauge (with joint) on the spark plug hole.

⑦

Push the accelerator pedal to the end, then turn the ignition switch to the “START” position to start the engine. After the instrument finger appears stable, read compression pressure and engine speed. Perform these steps to check other cylinders.

■

Standard pressure: 1200±100 kPa

■

Tolerable pressure difference between cylinders: ≤98kPa

Attention: ■

It is required to obtain the specified engine speed always by the battery which is fully charged.

■

Inspect valve clearance and other relevant parts (such as valve, valve seat, piston, piston ring, cylinder bore, cylinder head and gasket) if the compression pressure is less than the minimum value. Repeat measurement of compression pressure after the check. If the pressures in some cylinders are low, add some engine oil to the spark plug holes of such cylinders and then inspect again.

■

The piston ring may be worn or damaged if the cylinder pressure rises after the engine oil is added. Check the piston ring and replace if necessary.

■

The valve may have faulty if the compression pressure is still low after the adding of engine oil. Check whether the valve is damaged. Replace the damaged valve or valve seat.

■

The cylinder gasket must be leaky if the compression pressures in two neighboring cylinders are low and even keep low after adding engine oil. Replace cylinder gasket.

⑧

After inspection, remount the dismounted parts.

⑨

Start engine, confirm that the engine runs smoothly.

64

Maintenance Manual for J2 Sedan 2.

Mechanical Part of Engine

Parts

Diagram of Cylinder head 3.

Dismantlement and Installation

1)

Dismantlement

①

Discharge engine coolant and oil. See “Change Engine Coolant” and “Change Engine Oil”.

Attention: ■

Perform these steps after engine cooled down.

■

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

② Dismount the following elements and the relevant parts: ■

Engine trimming cover. See “Intake Manifold”.

■

Drive belt. See “Drive Belt”.

■

Cylinder head cover. See "Camshaft Assembly."

■

Intake manifold. See “Intake Manifold”.

■

Exhaust manifold. See “Exhaust Manifold”.

■

Oil gauge tube.

■

Oil pump body assembly and timing mechanism. See the "Timing Sprocket Mechanism."

③ Loosen the cylinder head bolts with special tool. ④ Remove the cylinder gasket. 65

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

2) Check after Dismantlement ① Cylinder head Bolt Measure the length of cylinder head bolt. ■

Limit: 143.5±0.7mm. Replace the cylinder head bolt if this Limit is exceeded.

② Cylinder head ■

Check whether there are cracks or other damages on the cylinder head.

■

Check whether there is any blockage in the coolant gallery and oil passage. If any, clean the coolant gallery and oil passage.

■

Check planeness of cylinder head.

Note: Check the planeness of cylinder body as well when performing this check. a.

Wipe off the engine oil from the cylinder head, remove any sealant and the carbon deposit.

Attention: ■

Be careful to prevent impurities from falling into coolant gallery and oil passage of cylinder head.

b.

Measure the planeness in six directions at several positions on bottom surface of cylinder head.

Fig. 1.1.041

Standard value: below 0.03mm Height of cylinder head (new): 113±0.1mm If the the standard value is exceeded, grind or replace the cylinder head according to the specification. Attention: ■

The total grindable margin of matching surface between cylinder head and cylinder body should not be greater than 0.2mm.

3) Installation

Fig.1.1.042

① Install new cylinder gasket. ②

Follow the numerical order as shown in the diagram to tighten the cylinder head bolt and follow the given steps to install cylinder head.

A: Intake side B: Exhaust side : Front end of engine a.

Install washer.

66

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

b.

Apply a film of engine oil onto washer, which is at the threaded portion of bolt.

c.

Tighten cylinder head bolts in sequence, until each bolt torque is 24.5 ± 2 N • m.

d.

Fully unscrew bolts.

e.

Tighten the bolts until the torque of each bolt is 24.5 ± 2N • m.

f.

Paint marks on the bolt head and the cylinder head (see Fig.1.1.040).

g.

Screw each bolt for more 90° with to the tightening sequence.

h.

Re-tighten each bolt by 90°.

Fig.1.1.043

Attention:

Painting Mark

■

When the two tightening angles are below 180 °, tightening performance can not be assured; be sure to reach 180 ° when tightening.

■

When the two tightening angles are above 184 °, completely loosen the bolt and re-tighten per the initial sequence.

i.

If the old cylinder head bolts are replaced during the maintenance, operation should be performed in sequence from “a” to “h”.

j.

If the old cylinder head bolts are not replaced during the maintenance, operation should be performed in sequence “a, b, e, f, g and h”.

③

Then, perform the installation steps which are just contrary to dismantlement.

4) Check after Dismantlement The steps for checking oil leakage, lubricant leakage and tail gas leakage are as following: ■

Before starting the engine, check the engine oil/coolant level. If the level is lower, replenish the engine oil/coolant till the specified level is reached.

■

Perform the following steps to check whether the oil leakage occurs:

—

Turn the ignition switch to the “ON” position (when engine is stopped). With the oil pressure acting on the oil pipe, check whether there is fuel leakage at the joint.

—

Start the engine. With the engine accelerating, recheck whether there is fuel leakage at the joint.

■

Run the engine to check whether the abnormal noise or vibration appears.

■

With engine warmed up completely, verify that there is no fuel leakage, tail gas leakage or any oil/fluid (including engine oil and coolant) leakage.

■

After engine cooled down, recheck oil/fluid (including engine oil and engine coolant) level. Replenish the oil/fluid to the specified level as required.

67

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

XII. Valves 1.

Parts

Diagram of Valve parts 1 - cylinder head bolts 2 - cylinder head bolt washer 3 - cylinder head assembly 4 - Cylinder gasket 5 – intake valve cotter 6 - intake valve spring upper seat 7 - intake valve spring 8 - intake valve 9 - exhaust valve cotter 10 - exhaust valve spring upper seat 11 - exhaust valve spring 12 - exhaust valve 13 - intake valve oil seal 14 - intake valve spring lower seat 15 - exhaust valve seal 16 - exhaust valve spring lower seat 17 - intake valve guide 18 - exhaust valve guide 19 -intake valve seat 20 - exhaust valve seat 21 - cylinder head 2.

Disassembly and Assembly

Fig.1.1.044

1) Disassembly ①

Dismount the spark plug with the special socket.

②

Dismount the valve cotter, valve spring and spring seat.

■

Compress the valve spring with the special 68

JAC-T1F001

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

compressor. Attention: ■

Pay attention to the position of upper dead point of piston.

■

Label the dismounted valve, valve spring and other parts, and write down their corresponding cylinder numbers and positions

■

Store the parts reliably.

③

Dismount the valve oil seal.

④

See “Replacement of Valve Seat” to replace the valve seat, if required.

⑤

See “Valve Guide” to replace the valve guide, if required.

Fig.1.1.045

JAC-T1F012

Fig.1.1.046

2) Assembly ① Install valve guide if it has been dismounted. See “Valve Guide”. ② Install valve seat, if it has been dismounted. See “Valve Seat”. ③ Install valve oil seal. a.

Install the valve spring seat.

b.

Install the new valve oil seal with the special tool shown in Fig.1.1.044

Fig1.1.047 JAC-T3F001

Attention: ■

The valve oil seal should not be reused.

■

The valve oil seal must be installed with the proper special tool.

④ Install valve. ⑤ Install valve spring.

69

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

Note: The parts with paint mark should be installed upwards. ⑥ Install retaining seat for valve spring. ⑦ Install valve cotter. ■

Use the valve spring compressor during the installation.

■

After installation, lightly knock the edge of valve stem with a rubber hammer to check the mounting condition.

⑧ Install spark plug with the spark plug socket. 3) Check after Disassembly 1.

Valve

■

Check whether the contact between valve surfaces is proper. Renew the surface of valve seat if the contact is uneven or incomplete.

Fig.1.1.048

Good

Bad

■

Inspect thickness of valve edge. Replace the valve if the measurement is less than the specified value.

Fig.1.1.049 Contact (required to be at the center of surface)

For intake valve: 1.35-1.65mm， For exhaust valve: 1.85±0.15mm

■

Bad

Thickness of edge

Inspect the total length of valve. Replace the valve if the measurement is less than specified value. For intake valve: 89.51-90.01mm， For exhaust valve: 90.69-91.19mm

2.

Valve Spring

■

Check free height of valve spring. Replace the valve spring if the measurement is less than specified value.

■

Check perpendicularity of valve spring. Replace the valve spring if the measurement is out of limit. Standard value: 2° Limit: 4°

70

Maintenance Manual for J2 Sedan

3.

Valve guide

■

Check the gap between the valve guide and the valve stem. Replace the corresponding parts if the measurement is out of limit.

Mechanical Part of Engine

Fig.1.1.050

Valve guide

Valve guide Standard value: 0.020-0.036mm Outer Diameter of Valve Stem Inner Diameter of Valve Conduit

Limit: 0.10mm

■

Replacement of Valve guide

a.

Push out the valve guide towards the cylinder side by the press.

b.

Rebore mounting hole on the valve guide of cylinder head to make it match increased size of valve guide to be installed.

Attention: ■

Do not install the valve guides with the same sizes of old ones. Re-boring mounting hole on the valve guide of cylinder head

Outer diameter of valve guide:

Fig.1.1.051

For the hole with diameter of 10.655-10.665mm, extend the size of valve guide by 0.05mm. For the hole with diameter of 10.855-10.865mm, extend the size of valve guide by 0.25mm. For the hole with diameter of 11.105-11.115mm, extend the size of valve guide by 0.50mm. c.

Protrusion Height

Press the valve guide till its protrusion height reaches the specified value.

Standard value: 23.0mm Attention: ■

Use cold pressing method to install valve guide from upper side of cylinder head. Check whether there are cracks after press fitting.

■

After valve guide pressed in, insert a new valve to check for smooth sliding of valve.

4.

Valve Seat

■

Check the valve protrusion height between the end face of valve stem and the surface of valve spring seat. Replace the valve seat if the limit is exceeded.

71

Maintenance Manual for J2 Sedan

Standard values:

图 1.1.052

Mechanical Part of Engine

End Face of Valve Stem

For intake valve: 53.21mm Valve Protrusion Height

For exhaust valve: 54.10mm Limits:

Surface of Valve Spring Seat

For intake valve: 53.71mm For exhaust valve: 54.60mm ■

Renew valve seat.

a.

Before renewing the valve seat, check the clearance between valve guide and valve. Replace the valve guide if necessary.

b.

Resurfacing the valve seat by the proper special tool or the valve seat grinder till specified seat surface width and angle are met.

c.

After renewing the valve seat, grind the valve and the valve seat by the grinding cream. Then, check the protrusion height of valve stem (refer to the above mentioned check steps of valve seat)

■

Replacement of Valve Seat

a.

Cut away the replaced valve seat from its inner side in order to decrease the wall thickness. Then remove the valve seat.

Fig.1.1.053

Cut Away

b.

Rebore the valve seat hole on cylinder head till the hole matches the selected valve seat with a extended diameter. See “Parameters for Maintenance” for the detailed size.

c.

Do not have the cylinder head hole scratched by the valve seat cooled by the liquid nitrogen before it is pressed.

d.

Renew the valve seat till its width and angle meet the specifications (see the operation instruction of valve seat correction).

e.

leak testing must be conducted for disassembly of valve related components.

XIII.

Fig.1.1.054

Valve Seat Height

Inner Diameter of Extended Hole

Cylinder Body Assembly 72

Maintenance Manual for J2 Sedan 1.

Mechanical Part of Engine

Parts

Disassembly Diagram of Cylinder Body Assembly 2.

Disassembly and Assembly

1) Disassembly ①

Dismount the engine assembly from the vehicle, and then detach the transmission from engine. See “Engine Assembly” for detailed dismantlement steps.

③ Fix whole engine. ④ Discharge engine oil. See “Change Engine Oil”

⑤

Dismount following engine accessories. See relevant chapters for detailed dismantlement steps.

■

Drive belt

■

Alternator, compressor and relevant brackets

■

Intake and exhaust manifolds 73

Maintenance Manual for J2 Sedan ■

Water pump and its components

■

Ignition coil

■

Cylinder cover, damping wheel, oil pan

■

Engine timing sprocket mechanism

⑥ ■

Mechanical Part of Engine

Dismount the flywheel assembly. Fix the flywheel by the special tool to dismount the fixing bolt. Tightening torque:

For flywheel: 95-105N·m

Attention: ■

Fixing bolts should be loosened in the diagonal orders.

⑦ Disassemble knock sensor, crankshaft position sensor, oil pressure switch. ■

Tightening torque: Knock sensor: 16 - 24 N • m Crankshaft position sensor: 7.8 - 9 N • m Oil pressure switch: 8 - 12 N • m

Attention: ■

Do not drop or knock the sensor.

⑧ Remove crankshaft rear oil seal bracket ■

Tightening torque: 7.0-8.2N·m

■

Insert the screwdriver between the crankshaft and the rear oil seal housing to dismantle.

Attention: ■

Once dismounted, the rear oil seal must not be reused. It should be replaced by a new one.

⑨ Dismount the piston and connecting rod assembly: Before dismounting the piston and connecting rod assembly, check the gap at the big end of connecting rod. See “Check after Disassembly” below. a.

Rotate the crankshaft to place the journal side of crankshaft which is corresponding to the connecting rod to be dismounted at the center of bottom.

b.

Dismount the connecting rod cover.

■

Tightening torque: 13±1N·m + 90°-94°

Be aware that when tightening the "5Nm → 10Nm → 13Nm +45 ° +45 °" alternate methods should be followed to tighten. c.

Push out the piston and connecting rod assembly from the cylinder body by the rubber hammer or equivalent.

Attention: ■

Be careful not to damage the big bonnet and connecting rod fitting surface

■

Do not damage the cylinder wall and the crankshaft journal with the big end of the connecting 74

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

rod. ■

Maintain the connecting rod big end and the connecting rod body match sequentially and maintain the connecting rod big end serial number in consistency

⑩ Dismount bearing shell from the connecting rod and the connecting rod cover. Attention: ■

Identify their mounting positions, and properly place them to avoid confusion.

⑪ Dismount ring from the piston. Check the side clearance of piston ring before dismounting. See “Check after Disassembly” below. Attention: ■

Fig.1.1.055

Use the piston ring expander. Piston Ring Expander

⑫ Dismount the piston ring from the connecting rod with method below: a.

Insert the push rod (special tool) from the front side with a arrow mark, and then install the guide sleeve D.

b.

With the front mark of piston face upwards, install piston and connecting rod assembly on the mounting base of piston pin (special tool).

c.

Push out the piston ring by the press.

d.

Detach the connecting rod from piston.

Fig.1.1.056

Front Mark

Attention: ■

After dismounting piston pin, place it together with the piston pin and the connecting rod.

■

It is forbidden to place the pistons, piston pins and connecting rods of different cylinders together.

Push Rod

Guide Sleeve D Base

⑬ Dismount the crankshaft bearing cap. Before loosening the crankshaft bearing cap, measure axial clearance of crankshaft. See “Check after Disassembly” below.

75

Maintenance Manual for J2 Sedan

Loosen the bolts of crankshaft bearing cap in the following sequence. ■

Mechanical Part of Engine

Fig.1.1.057

Tightening torque: 35±2 N·m＋60°～64° Be aware of the number and forward mark of bearing cap.

During the dismantlement, it is allowable to jiggle the crankshaft bearing cap forwards and backwards by the bolts of crankshaft bearing cap. See Fig.1.1.055.

Fig.1.1.058

⑭ Dismount the crankshaft.

Fig.1.1.059

2) Check after Disassembly ① Axial clearance of Crankshaft Detection methods are as shown in the figure Standard value: 0.09-0.27mm

If measurement is not within the standard range, replace the thrust washer and repeat measurement. If it is still over limit, replace the crankshaft. ② Big End Clearance of Connecting Rod Measure the gap between the connecting rod and the crankshaft by using feeler gauge.

Fig.1.1.060

Standard value: 0.10-0.3mm Limit: 0.4mm If the limit is exceeded, replace the connecting rod and measure again. Replace the crankshaft if measurement is still out of the limit.

76

Maintenance Manual for J2 Sedan

③ Side clearance of Piston Ring

Mechanical Part of Engine

Fig.1.1.061 Bad

Measure the side clearance between piston ring and piston ring groove top land by the feeler gauge. Feeler Gauge

Standard values:

Good

st

For 1 piston ring, 0.03～0.07mm For 2nd piston ring, 0.04～0.06mm

Feeler Gauge Piston Ring

Limits: For 1st piston ring, 0.1mm For 2nd piston ring, 0.1mm If the measurement exceeds the limit, replace the piston ring, and then remeasure the gap. Replace the piston if the measurement is still out of the limit. ④ End Gap of Piston Ring Ensure that the inner diameter of cylinder stays within the specified range.

Piston Pressed and Fixed

Fig.1.1.062 Feeler Gauge Piston Ring

See "Cylindricality of Cylinder" Lubricate the piston and the piston ring with new engine oil, then insert the piston ring till the piston reaches the middle part of cylinder, measure end gap of piston ring by the feeler gauge.

Piston Ring Measured Point

Standard values: For 1st piston ring, 0.15-0.30mm For 2nd piston ring, 0.30-0.50mm Limits: For 1st piston ring, 0.8mm For 2nd piston ring, 0.8mm If the measurement exceeds the limit, replace the piston ring, and then measure again. Extend cylinder bore through grinding and use the corresponding piston and piston ring if the measurement is still over the limit. ⑤ Planeness of Cylinder Body Remove any gasket material and eliminate the engine oil, sediment, carbon or other contaminants on surface of cylinder body.

77

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

Attention: ■

Be careful to prevent gasket materials from falling into the engine oil or coolant.

Measure planeness of cylinder body in different directions at six positions using ruler and feeler gauge.

Ruler

Fig.1.1.063

Standard values: below 0.05mm Limits: below 0.1mm If the limit is exceeded, replace cylinder body. Feeler Gauge

⑥ Cylindricality of Cylinder Measure the cylinder degree at 6 different points per cylinder by using micrometer. Standard values: For cylinder bore: 75.0mm For cylindricality: below 0.07mm ⑦ Diameter of Piston Skirt

Fig.1.1.064

Use outside micrometer to check whether the piston skirt is distorted. Standard values:74.973mm

Dial Indicator

⑧ Clearance between Piston and Cylinder Bore Calculate per the actual measurement of piston skirt and cylinder bore. (Gap) ＝ (inner diameter of cylinder) － (diameter of piston skirt) Standard value: 0.02-0.04mm If the calculated value exceeds the limit, replace piston and piston ring assembly. ⑨ Boring Cylinder a.

The piston with extended size to be used should be determined in accordance with the cylinder which has the highest bore.

Pistons of the following extended sizes, i.e. 0.25mm, 0.50mm, 0.75mm and 1.00mm, are applicable. b.

Measure the diameter of piston to be used.

After boring cylinder, clearance between piston and cylinder bore must be within standard range. The 78

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

piston diameter should be measured at the position shown in Figure. c.

Calculate the boring size based on the piston diameter.

[Boring size] ＝ [outer diameter of piston] ＋ [clearance between piston and cylinder (0.02-0.04mm)] － [grinding margin (0.02mm)] d.

Boring each cylinder till it obtains the calculated boring size.

Attention: ■

To avoid the distortion due to heat during the boring course, bore the cylinders in following sequence: Cylinder 2 → Cylinder 4 → Cylinder 1 → Cylinder 3

e.

Grind the cylinder till it meets the final processing size (outer diameter of piston ＋ clearance between piston and cylinder)

⑩ Diameter of Main Crankshaft Journal Measure the main crankshaft journal by the outside micrometer. Standard value: 48.0mm If it exceeds the standard, please follow the rules of selection to replace.

⑪ Diameter of Main Journal of Connecting Rod Measure the diameter of main journal of connecting rod by using outside micrometer. Standard values:43.0mm Replace the connecting rod bearing shell if measurement exceeds standard value.

Fig.1.1.065

Dial Indicator

⑫ Gap of Connecting Rod Bearing Shell Note: Use the plastic divider to perform the measurement. a. Clean any engine oil from the connecting rod journal and connecting rod bearing shell. b.

c.

Put the plastic divider on the connecting rod journal, and asset it to a length equal to bearing shell width. The plastic divider must be placed at the center of connecting rod journal and be parallel with the axial line of connecting rod. Lightly put the connecting rod cover to specified place, and screw the bolt to specified torque.

Fig.1.1.066

d.

Dismount the bolt, then take off the connecting rod cover slowly.

e.

Measure the pressed portion of plastic divider at the widest point by the scale which is printed on the plastic divider bag.

79

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

Standard value: 0.02 - 0.04mm + (0.01mm) expansion Limit:0.1mm

⑬ Roundness and Cylindricality of Crankshaft Measure sizes of each main crankshaft journal and main connecting rod journal at four different positions as shown in the figure. ■

The difference between “X” and “Y” of “A” and “B” represents the roundness.

■

The difference between “A” and “B” of “X” and “Y” represents the cylindricality.

Fig.1.1.067

Limits: For roundness: equal to or less than 0.05mm For cylindricality: equal to or less than 0.05mm Calibrate or replace the crankshaft if the measurements exceed the limits.

⑭ Clearance of Crankshaft a.

Wipe off oil from the crankshaft journal and the inner surface of bearing shell.

b.

Mount the bearing shell.

c.

Set the plastic divicer till its width equals to the width of bearing shell. Then put them on the journal along the axial line of journal.

d.

Lightly mount the crankshaft bearing shell cover, and screw the bolt till to specified torque.

e.

Dismount the bolt and lightly take off the crankshaft bearing shell cover.

f.

Measure the pressed portion of plastic divider at the widest point by the scale which is printed on the plastic wire gauge bag.

Plastic Wire Gauge

Fig.1.1.068

Standard values: 0.02-0.04mm Limit:0.1mm

Attention: ■ The connecting rod journal and main journal of crankshaft should be rolled but needn't to be machined to the reduced size.

Fig.1.1.069 Round-angle Rolling Area

80

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

⑮ Flywheel Check whether the flywheel and the signal disk are distorted or cracked. Attention: ■ Do not disassemble the flywheel. 16 Crankshaft signal wheel ○

Fig.1.1.070

Check whether the crank signal wheel has distortions, cracks and other anomalies. Check whether the bolts are loose

3) Assembly ①

Blow away any oil and coolant from the cylinder body, the cylinder bore and the crankcase. Remove any foreign bodies.

Attention: ■

Use goggles to protect your eyes.

② Install the upper and lower main bearings shells. Attention: ■

Select the bearing shells by using the identification marks of crankshaft (See the table below). If the crankshaft can not be identified, measure the diameter of crankshaft, and then select the corresponding bearing shell to match the crankshaft.

Crankshaft group marking Main bearing 1 2 3 4 Hole group marking Black／Black Black／Yellow Black／Red Black／White 0 (up / down) Yellow／Black Yellow／ Yellow／Red Yellow／ 1 (up / down) Yellow White Red／Black Red／Yellow Red／Red 2(up / down) Red／White

5 Black／Purple Yellow／Purple Red／Purple

a.

Remove any dust, dirt and oil from the matching surfaces of cylinder body and main bearing cap.

b.

Install intermediate and upper bearing shells on the cylinder body

c.

Be aware of direction of bearing shell during the installation.

■

Bearings shells with oil holes and slots should be installed at block side; other shells should be installed at the main bearing cap side.

■

For installation of bearings, clean before installation. Please apply engine oil to the bearing surface. Do not use oil on the back, but to thoroughly clean it.

■

During installation, align the extrusion on bearing shell with the cut of cylinder body and main bearing cap.

81

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

③ Add oil to bearing surface Install crankshaft on cylinder block. When rotating the crankshaft by hand, check whether the rotation of crankshaft is smooth. ④ Install main bearing cap.

Fig.1.1.071

■

The main bearing cap can be identified through mark.

■

Install the main bearing cap starting from the front of the engine according to the ordering numbers.

■

Arrow must point to engine front.

⑤

Tighten the bolts of main bearing cap to standard torque.

a.

Apply new engine oil onto the thread and fixing surface of bolts of main bearing cap.

b.

Tighten bolts for main bearing cap in steps.

■

Tightening torque: 35±2N·m Screw all bearing cap bolts by 60-64° clockwise.

■

After installation of bolts of main bearing cap, verify that the crankshaft can be rotated smoothly by hand.

■

Check the axial clearance of crankshaft. See “Axial clearance of Crankshaft”.

⑥

Install piston onto the connecting rod with following instructions.

a.

Fig.1.1.072

Measure the following lengths (See right Figure). Piston

B： Distance from piston flange to piston flange inside

Connecting Rod Piston Pin

A： Distance from piston flange to piston flange outside

C： Length of piston pin. D： Thickness of small end of connecting rod. b.

Introduce the measurements into following formula:

L = [(A-C)-(B-D)]／2 c.

Insert push rod (special tool) into the piston pin, and then install guide sleeve.

d.

When mounting the piston and the connecting rod, keep the front marks at same side.

e.

Apply the engine oil onto the outer circle of piston pin.

f.

Starting from the guide sleeve, press the guide sleeve, piston pin and push rod into the piston front 82

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

mark side. g.

Screw in the guide sleeves, clearance between the two sleeves should be 3mm plus the calculated L in Step 2.

h.

With the front mark facing downwards, install piston and connecting rod on mounting base of piston pin.

i.

Install piston pin by the press.

Fig.1.1.073

Guide Sleeve B

Guide Sleeve A

Attention: ■

If the pressing load exceeds specified value, replace the piston pin and piston assembly and/or the connecting rod.

Standard value: 108±54N·m ⑦ Install piston pin. Attention: ■

When mounting the piston ring, do not damage the piston.

■

Do not damage the piston ring due to the excessive expansion.

a.

Install oil ring

a)

Install oil ring lining ring into the piston ring groove. Then install the upper and lower blades.

Attention: ■

Lining ring and blade can be installed in two directions。 。 There is no difference between upper and lower blades.

■

Lining ring and blade size coloring scheme. Table of lining ring and blade size coloring scheme

b)

Size

Color

Standard

Colorless

Extended by 0.50mm

Blue

Extended by 1.00mm

Yellow

To install the blade, install one end of blade into the groove (as shown in the diagram) before pressing the other areas to place.

Attention: ■

Do install blades by using piston ring expander, otherwise, they may break.

c)

After installation of the blades, check whether they can move smoothly in both directions.

Fig.1.1.074

Piston Ring Expander

83

Maintenance Manual for J2 Sedan

b.

Mechanical Part of Engine

Install first and second piston rings.

Install first and second piston rings with the identification marks facing upwards (on the piston top side) by using expander. Notes: Piston ring opening direction Schematic Diagram for Piston Ring Location Opening direction of first gas ring

Opening direction of combined oil ring lower blade

Opening direction of lining ring of combined oil ring

Opening direction of second gas ring

Opening direction of combined oil ring upper blade Engine front-end

⑧ Install bearing shell onto the connecting rod and the connecting rod cover. ■

Apply engine oil onto bearing surface of shells before installation. Do not use engine oil on the back but to thoroughly clean it.

⑨ ■

Install piston and connecting rod assembly onto the crankshaft. Place the crankshaft journal which is corresponding to the connecting rod to be mounted at the just center of bottom. Apply sufficient engine oil onto cylinder bore, piston and crankshaft journal. Align air ring opening with oil ring opening. See Fig.1.1.097.

■ ■

Schematic Diagram for Piston Ring Location Opening direction of first gas ring

Opening direction of combined oil ring lower blade

Opening direction of lining ring of combined oil ring

Opening direction of second gas ring Opening direction of combined oil ring upper blade Engine front-end

■

Install piston rod assembly in corresponding cylinder according to marks on connecting rod.

■

Make sure that the front mark on piston top faces to timing belt, and then press the piston and connecting rod assembly into the cylinder from the cylinder upside.

84

Maintenance Manual for J2 Sedan ■

Make the piston ring with front mark facing the front end of engine by the piston ring compressor or other suitable tool, then install piston ring onto piston head.

Mechanical Part of Engine

Fig.1.1.075

Attention: ■

Do not damage cylinder wall or crankshaft journal by the big end of connecting rod.

■

Do not to damage big bonnet and connecting rod fitting surface

⑩ Install connecting rod cover.

During installation, first use high pressure gas for blowing the expansion sections.

Fig.1.1.076

When tightening connecting rod bolt, the order of “5Nm→10Nm→13Nm+45°+45°”alternate methods should be followed. After piston connecting rod assembly is installed, verify that clearance for the connecting rod big end is 0.10 0.30mm. Attention: ■

Connecting rod bolts can only be used once..

■ Before installing nut, apply engine oil on its thread and seat.

⑪ Install rear oil seal housing of crankshaft with rear oil seal assemble to the cylinder block. ⑫ Installation of knock sensor, Hall sensors, oil pressure switch. Attention: ■

Do not screw the nut when grasping the joint.

■

If the knock sensor is shocked, replace with a new one.

Note: Be sure that there is no foreign body at the matching surface of cylinder body or the back side of knock sensor.

⑬ Be aware of following to install with steps contrary to dismantlement. ■

Flywheel

Alternately tighten bolts to specified torque.

85

Maintenance Manual for J2 Sedan XIV.

Mechanical Part of Engine

Diagnosis of Common Troubles Diagnosis List of Common Troubles Trouble

Possible Cause

Resolution

The cylinder gasket is leaky.

Replace cylinder gasket.

The piston ring is damaged or worn.

Replace the piston ring.

The cylinder or the piston is worn.

Repair or replace the piston or the cylinder body.

The valve seat is worn or damaged.

Repair or replace the valve seat.

The volume of engine oil is insufficient.

Check oil level.

The engine oil pressure sensor failed.

Replace sensor.

The engine oil filter is blocked.

Replace filter.

Oil pump rotor or cover damaged

Replace.

The viscosity of engine oil is low.

Check. Change oil as required.

The plunger of engine oil pressure switch is constantly open.

Repair.

The bearing gap is high.

Replace.

The plunger of engine oil pressure switch is constantly closed.

Repair.

The engine supporting bolt loosened

Tighten

The transmission mounting support loosened.

Tighten

The engine support loosened

Tighten

The heat shield for engine is damaged.

Replace.

The engine support heat shield is damaged.

Replace.

The heat shield for transmission is damaged.

Replace

The engine oil is thin (low oil pressure).

Change oil.

The valve or the valve guide is damaged or worn.

Replace.

The oil is insufficient.

Check the level of engine oil.

The engine oil is thin (the oil pressure is low).

Change oil.

The bearing gap is wide.

Check and then determine the cause.

The radiator or the radiating pipe is leaky.

Repair or replace.

The water tank cover is not sealed.

Tighten or replace the cover.

The thermostat is leaky.

Replace the thermostat pad.

The radiator is leaky.

Repair or replace.

The water pump is leaky.

Replace.

Jam in radiator

The coolant contains the impurities.

Replace the coolant.

High temperature of coolant

The water tank cover is not strictly sealed.

Replace.

The cooling system is jammed.

Rinse or replace.

The thermostat is at fault.

Replace.

Low cylinder pressure

Low oil pressure

High engine oil pressure

Engine quiver

Noise of valve Noise from connecting rod bearing shell and the main bearing shell

Poor cooling performance

86

Maintenance Manual for J2 Sedan Trouble

Low temperature of coolant Ineffective fan

Exhaust system leaks

Abnormal noise

Mechanical Part of Engine

Possible Cause

Resolution

The belt skids.

Adjust or replace.

The water pump is at fault.

Replace.

The sensor is at fault.

Repair or replace.

The fan is at fault.

Repair or replace.

The coolant is insufficient.

Replenish

The thermostat is at fault.

Replace.

The sensor or the wire harness is at fault.

Repair or replace.

The sensor or the starter is at fault.

Repair or replace.

The fan relay or the wire harness is damaged.

Repair or replace.

The joint loosened.

Tighten it

The exhaust pipe or the muffler is damaged.

Repair or replace.

Exhaust pipe gasket damaged

Replace.

The muffler loosened

Tighten it

The rubber pad cut off

Replace.

The exhaust pipe or muffler contacts vehicle body.

Correct

The exhaust pipe or the muffler is damaged.

Repair or replace.

87

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

XV. Parameters for Maintenance 1.

List for Technical Parameters of Engine Technical Parameters list of Engine Item

Standard Value

Limits

Camshaft base circle diameter (mm)

36

—

Diameter of camshaft journal (mm)

32.033-32.082

—

Planeness of cylinder gasket surface (mm)

＜0.03

0.1

Total height of cylinder head (mm)

112.9-113.1

—

Intake valve

1.35

0.85

Exhaust valve

1.85

1.35

Φ5

—

Camshaft

Cylinder head and valve

Thickness of valve edge (mm)

Diameter of valve stem (mm) Clearance between valve stem and

Intake valve

0.020-0.036

0.10

valve guide (mm)

Exhaust valve

0.030-0.045

0.15

45°-45.5°

—

Intake valve

89.61

89.51

Exhaust valve

90.91

90.41

43.1

—

152/33.4

—

310/25.2

—

Perpendicularity of valve spring

＜2°

4°

Contact width of valve seat (mm)

0.9-1.3

—

Inner diameter of valve guide (mm)

φ5.5

—

23.0

—

φ10.605-10.615

—

φ10.805-10.815

—

φ11.055-11.065

—

φ28.425-28.445

—

φ28.725-28.745

—

φ26.725-26.745

—

φ26.725-26.745

—

Conical angle of valve Total length of valve (mm)

Free height of valve spring (mm) Load / mounting height of valve spring (N)/(mm)

Protrusion of valve guide (mm)

Diameter of size-extended valve guide on cylinder head (mm)

Intake Diameter of size-extended valve seat ring hole (mm) Exhaust

Extended by 0.05mm Extended by 0.25mm Extended by 0.50mm Extended by 0.3mm Extended by 0.6mm Extended by 0.3mm Extended by 0.6mm

88

Maintenance Manual for J2 Sedan Item

Mechanical Part of Engine

Standard Value

Limits

Addendum gap of oil pump

0.06-0.18

—

Side clearance of oil pump(mm)

0.04-0.11

—

Clearance of oil pump housing

0.10-0.18

0.35

75.0

—

Oil pump and oil pan

Piston and connecting rod Reference outer diameter of piston (mm) 1st piston ring

0.03-0.07

0.1

nd

0.02-0.06

0.1

st

1 piston ring

0.15-0.30

0.8

2nd piston ring

0.30-0.50

0.8

Oil ring

0.20-0.50

1.0

Outer diameter of piston pin (mm)

18.0

—

Pressing load on piston pin (under room temperature) (N)

4900-14700

—

Oil gap of crankshaft pin (clearance of connecting rod journal) (mm)

0.02-0.04

0.1

Side clearance of big end of connecting rod (mm)

0.10-0.25

0.4

Axial clearance of crankshaft (mm)

0.09-0.27

0.25

Diameter of main journal of crankshaft (mm)

48.0

—

Diameter of connecting rod journal (mm)

42.0

—

Clearance of main journal of crankshaft (mm)

0.02-0.04

0.1

Plainness of surface of cylinder body gasket (mm)

8mm

113

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

Section IV Fuel Supply System of Engine I.

General Precautions

Caution: The following rules should be complied with during the replacement of parts of fuel pipeline. ■

Set the mark “Attention: combustive” in workshop.

■

Be sure to operate in the well-ventilated area, and prepare C02 fire extinguisher in the operation workshop.

■

Do not smoke during the fuel system servicing. No fire in working area.

■

Hold the discharged fuel in the container and cover it. Put the container in safe area.

When disassembling the fuel pipe components, note the following: ■

Disconnect negative pole of battery.

■

Replace with new clips all the time.

■

Do not distort the fuel pipe during installation.

■

Please operate on level ground.

■

Connect the fuel pipe joint and make sure the joint has been fixed. Make sure the joint and resin pipe don’t contact any adjacent parts.

■

Do not excessively tighten the hose clips to prevent damage of hose.

■

Check each connection for fuel leakage according to following steps after installation of fuel pipe.

-

Set the ignition switch at “ON” position to apply fuel pressure on fuel pipeline (do not start the engine). Then check each connection for fuel leakage.

-

Start the engine, increase its speed and check each connection for fuel leakage.

■

Only the original fuel filler cap provided by JAC can be used.

■

Please refer to “Fuel Evaporative Emission System” for maintenance of parts of the system.

114

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

II. Preparation The special tools are listed in the table below: List of Special Tools S.N.

Tool

1

Fuel pressure gauge

Outline Diagram

No.

Explanation

JAC－T1F018

Measure fuel pressure

III. Fuel System 1.

Check Fuel Pipe

Check the fuel pipeline, fuel filler cap and fuel tank for proper installation, leakage, crack, damage, loose connection, worn and aging. 2.

Inspect Fuel Pressure

Attention: ■

Always keep the joints of fuel hose sealed with O-ring.

■

Do not operate electrical system during inspection.

■

Prepare a container under the fuel pipe to be disconnect to avoid fuel splash.

1) Fully release fuel pressure. Please refer to “Release Fuel Pressure”. 2) Dismount the nut for fuel pressure inspection door on fuel injector guide rail. 3) Connect fuel pressure gauge. 4) Set ignition switch at “ON” position and check for fuel leakage. 5) Start engine and check if there is fuel leakage. 6) Obtain the reading shown in fuel pressure gauge. ■

Fuel pressure: 350KPa

Attention: ■

Do not check fuel pressure during system operation.

■

During the Inspection of fuel pressure, please always check the fuel piping for leakage.

7) If the check result is not good, turn to the next step. 115

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

8) Check for the following matters. -

Blockage of fuel hose and fuel pipe.

-

Blockage of fuel filter.

-

Fuel pump and its control circuit.

IV. Fuel Injector and Guide Rail 1.

Dismantlement

Caution: ■

Do read the “General Precautions” before dealing with fuel system. Please refer to “General Precautions”.

1)

Disconnect the PCV hose joint at intake manifold side.

Fig. 1.4.001

2)

Disconnect connector

Fig. 1.4.002

3)

Disconnect the joint of fuel hose on fuel guide rail.

the

injector

wiring

harness

116

Fig. 1.4.003

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

Attention: ■

Please prepare the container and cleaning cloth in advance as fuel leakage may take place.

■

Avoid the naked flame and spark.

■

Please keep any parts away from heat source. Special attention must be paid when welding around them.

■

Do not expose the parts to the electrolyte of battery or other fluid.

■

Keep the connection clean and prevent damage and foreign substance, and properly cover the connection with plastic bag or equivalent.

4) Dismount the fixing bolt for fuel guide rail.

5)

Fig. 1.4.004

Take off the fuel guide rail with injector from intake manifold.

Attention: ■

Avoid interference with fuel injector during removal.

■

Absorb the fuel leaked from fuel pipe with cleaning cloth.

6) Dismount the fuel injector from fuel guide rail with following steps: a.

Pry and dismount the snap-in.

b.

Straightly pull out the fuel injector from fuel pipe.

Attention: ■

Pay attention to the leakage of residual fuel in fuel pipe.

■

Do not damage the nozzle of fuel injector.

■

Do not make it fall off or knock it.

■

Do not disassemble it.

2.

Check after Dismantlement

1) Fuel Injector ■

Check the upper and lower seal rings of fuel injector for crack, aging and breakage. If any, please replace.

117

Maintenance Manual for J2 Sedan ■

Mechanical Part of Engine

Check the injection hole of fuel injector for blockage. If any, please wash or replace by using special instrument.

2) Fuel Guide Rail ■

Check the fuel inspection hole for damage and jamming. If any, please replace.

■

Check if there is residuum in guide rail. If any, please clean.

3.

Installation

1)

Be aware of following precautions when mounting new O-ring on fuel injector.

■

As the upper and lower O-rings are different, do not confound them. Fuel pipe side: thick one Nozzle side: thin one

■

Please mount the O-ring by your hands.

■

Lubricate the O-ring with petrol.

■

Do not wash O-ring with solvent.

■

Verify that there is no foreign substance on O-ring and its matching part.

■

Make sure the O-ring will not be scraped by tool or fingernail, and it is not distorted or stretched during installation.

■

Insert new O-ring into fuel injector straightly. Do not deflect or distort it.

2)

Mount fuel injector ④ on fuel pipe ①with following steps.

Fig. 1.4.005

③ : thick one ⑤ : thin one a.

Insert the snap ② into the fixing groove on fuel injector. Insert the snap slice D into raised position F of fuel injector.

Attention: ■

Replace with the new snap every time.

■

Make sure there is no interference between the snap and O-ring.

b.

Insert fuel injector into fuel pipe where snap has been mounted.

Attention: ■

Make sure the direction of insertion aligns with the axis.

118

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

■

Insert the snap slice C into the raised position B of fuel pipe.

■

Make sure the flange A of fuel pipe is properly mounted in the fixing groove on snap flange.

c.

Make sure the fuel injector will not move or fall off. Installation is completed.

3) Install fuel pipe guide rail and fuel injector assembly inside intake manifold. Attention: ■

Be careful not to make fuel injector nozzle contact with other parts.

4) For the following steps, install with steps contrary to dismantlement. 4. Check after Installation Check for fuel leakage with following steps. 1) Set the ignition switch at “ON” position (when the engine stops), and then check the connection of fuel pipe for leakage. 2) Start the engine, increase its speed and recheck the connection of fuel pipe for leakage. V. Fuel Filter 1.

Dismantlement

Caution: ■

Do read the “General Precautions” before dealing with fuel system. Please refer to “General Precautions”.

Attention: ■

The fuel filter should be periodically replaced in accordance with the maintenance instruction specified in “User’s Manual”.

1) Open the fuel filler cap.

Fig. 1.4.006

2) Release the pressure in fuel tank. 3)

Dismount the rear seat cushion. Please refer to “Rear Seat”.

4) Dismount the service lid for fuel tank. ■

Directly prize it up with flat end screwdriver.

119

Maintenance Manual for J2 Sedan

5)

Disconnect the fuel pipe joint 1 (at fuel pump side), joint 2 (at fuel filter side) and grounding end 3 of fuel filter.

Mechanical Part of Engine

Fig. 1.4.007

Attention: 1

The fuel filter should be wrapped up with towel or equivalent, so as to avoid injection of residual fuel. Disconnect joint with following methods: ■

■

Hold the side edge of joint and press the raised position of joint to pull out the fuel pipe.

Fig. 1.4.008 3

If the joint attaches to the resin pipe, push and pull the joint for several times until it moves, and then pull out the joint.

Attention: 2

■

The joint can not be disconnected when the raised position is fully pressed down. Do not excessively distort the joint.

■

Do not disconnect the joint with any tool.

■

Prevent the resin pipe from being heated. Special attention must be paid when welding around the resin pipe.

■

Prevent the resin pipe from contacting acidic fluid such as electrolyte of battery.

■

Do not bend or distort the resin pipe during installation and dismantlement.

■

To keep the connection clean and prevent from damage and foreign substance, please fully cover them with plastic bag or equivalent.

6) Take off the fuel filter and fuel pipe.

2.

Fig. 1.4.009

Installation

Be aware of following precautions to install with steps contrary to dismantlement. 120

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

1) Fuel filter ■

Be aware of correct installation direction of fuel filter.

Fig. 1.4.010

towards fuel inlet pipe side

2) Connector Connect the connector of fuel supply hose according to following methods: ① Check the connection for foreign substance or damage. ② Make the connector align with the resin pipe and insert the connector straightly until “click” is heard. ③ Check whether the connector is connected properly with following methods after connection. ■

Visually inspect that 2 raised positions have been connected to the connectors.

■

Stretch the resin pipe and its connector hard to verify that they have been firmly connected.

3.

Check after Installation

Fig. 1.4.011

Check whether there is fuel leakage with following steps. 1) Set ignition switch at “ON” position (when engine stopped), and then check the connection of fuel pipe for leakage. 2) Start engine, increase its speed and recheck the connection of fuel pipe for leakage.

121

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

VI. Fuel Pump Assembly

Figure of fuel pump assembly 1.

Dismantlement

Caution: ■

Do read the “General Precautions” before dealing with fuel system. See “General Precautions”.

1) Check fuel level indicated on fuel meter. If the meter indicates “full” or “to be full”, discharge the fuel from tank until the meter indicates that the fuel level is lower than position “E”. Attention: If fuel level exceeds mounting surface of fuel level sensor, the fuel may overflow during the dismantlement of fuel level sensor. 2) Open the fuel filler cap. 3) Release the pressure in fuel tank. 4) Dismount the rear seat cushion. Please refer to “Rear Seat”. 5) Dismount the service lid for fuel tank. ■

Directly prize it up with flat end screwdriver.

122

Fig. 1.4.012

Maintenance Manual for J2 Sedan 6)

Disconnect the harness connector of fuel pump and fuel pipe joint.

Mechanical Part of Engine

Fig. 1.4.013

① Fuel pipe joint of fuel pump

1 2

② Harness connector of fuel harness

Disconnect the joint with following methods: ■

Hold the side edge of joint and press the raised position of joint to pull out the pipe.

■

If the joint sticks on the resin pipe, push and pull the joint for several times until it moves, and then pull out the joint.

Attention: ■

The joint can not be disconnected until the raised position is fully pressed down. Do not excessively distort the joint.

■

Do not disconnect the joint with any tool.

■

Prevent the resin pipe from being heated. Special attention must be paid when welding around the resin pipe.

■

Prevent the resin pipe from contacting with acidic fluid such as electrolyte of battery.

■

Do not bend or distort the resin pipe during installation and dismantlement.

■

To keep the connection clean and prevent damage and foreign substance, please fully cover them with plastic bag or equivalent.

7) Loose and take off the locknut with special tool. ■

Tightening torque: 70-80N·m

123

Fig. 1.4.014

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

Fig. 1.4.015

8) Take off the Y-ring. Attention: ■

Tilt the fuel pump when it is taken out, so as to avoid broken of fuel level sensor.

■

To avoid residual fuel from being polluted, wrap the Y-ring with cloth to pull it out straightly.

9)

Take off the fuel pump.

2.

Check after Dismantlement

Fig. 1.4.016

1) Fuel pump ① Visual Inspection ■

Check for broken or fuel impurity. If any, please replace or wash it.

② Inspect Fuel Pump Operation ■ Actuate the fuel pump with 12V regulated power supply directly and check if the operation is normal. Attention: ■

Do not make the fuel pump operation for a long time, so as to avoid damage of pump plunger.

2) Y-ring ■

Check it for material loss and broken.

3) Locknut ■

Check for deformation, crack, material loss, broken, and damage at mounting thread.

4) Fuel Level Sensor ■

Check the fuel float for interference and oxidation of its surface.

3.

Installation

Be aware of following precautions and install with steps contrary to dismantlement. 1) Fuel pump assembly 124

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

■

The Y-ring must fully fit with fuel tank during installation.

■

Tilt the fuel pump to facilitate its installation and pay attention to its direction.

■

There should be no turn-up on Y-ring during the installation.

■

Pre-tighten the locknut during its installation, and then tighten it horizontally.

2) Connector Insert the connector of fuel supply hose with following methods: ① Check the connection for any foreign substance and damage. ② Make the connector align with the resin pipe and insert the connector straightly until “click” is heard. ③ Check whether the connector is properly connected with following methods after connected. ■

Visually check whether the 2 raised positions have been connected to the connectors.

■

Stretch the resin pipe and its connector hard and make sure they have been firmly connected.

4.

Check after Installation

Check for fuel leakage with following steps. 1) Set ignition switch at “ON” position (when engine stops), and then check the connection of fuel pipe for leakage. 2) Start the engine, increase its speed and recheck the connection of fuel pipe for leakage.

125

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

VII. Fuel Tank Assembly

Breakdown diagram of fuel tank assembly 1-Filler cap 2-Filler tube 3-Fuel tank 4-Fastening band of fuel tank 5-Service lid 6-Locknut 7-Y-ring 8-Fuel pump 9-Fuel filter 10-Thermal baffle 1.

Dismantlement and Installation

1） Dismantlement Caution: ■

Do read the “General Precautions” before dealing with fuel system. See “General Precautions”.

■

Discharge fuel tank if necessary. Please refer to “Fuel Pump”.

■

Please operate on level ground.

① Carry out the dismantlement steps 1-6 of fuel pump. Please refer to “Fuel Pump”. ② Disconnect fuel supply hose and vent hose. ③ Disconnect EVAP hose. ④ Support the fuel tank with special jack. Attention: ■ The fastening band of fuel tank should not be blocked in supporting position. ⑤

Dismount the clamping bands of filler tube and fuel tank, and then disconnect the filler tube and fuel tank.

⑥ Dismount fastening band of fuel tank. 126

Maintenance Manual for J2 Sedan

■

Tightening torque: 30-40N·m

⑦

Manually support the tank and carefully lower the jack to dismount fuel tank.

Mechanical Part of Engine

Fig. 1.4.017

Attention: ■

Make sure all connections have been disconnected.

■

Make sure there is no interference with vehicle.

2) Check after dismantlement ① Fuel tank ■

Check for impurity of fuel. If any, clean it with hot water.

■

Capacity of fuel tank: 45L

② EVAP hose and clips ■

Check the hose for blockage, corrugation, deformation and breakage.

■

Check the clips for damage or breakage.

③ Reinforced plate and its backing plate ■

Check the surface of reinforced plate for scratch and deformation.

■

Check the backing plate for crack, material loss, deformation and breakage.

3) Installation Be aware of following precautions to install with steps contrary to dismantlement. ■

Firmly hold fuel supply hose to insert it.

■

Do not set the hose clamp in expansion area of fuel pipe.

■

Please refer to “Fuel Pipe Joint” for precautions of fuel pipe joint connection.

2.

Check after Installation

Check for leakage with following steps. ① Set ignition switch at “ON” position (when engine stops), and then check the connection of fuel pipeline for leakage. ② Start the engine, increase its speed and recheck the connection between piping and fuel pipe of fuel system for leakage.

127

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

Section V Emission Control System of Engine I.

Fuel Evaporation Control System

1.

Description Intake manifold Air cleaner

EVAP carbon canister solenoid valve

Fuel evaporation EVAP carbon canister

Fuel tank

Air

Schematic diagram of fuel evaporation system The fuel evaporation system is used to reduce hydrocarbon compositions emitted into ambient air from fuel system. Reduction of hydrocarbon is achieved by using active carbon in EVAP carbon canister. When the engine is stopped or fuel is filled, the fuel evaporation from sealed fuel tank will be introduced into EVAP carbon canister with active carbon and stored there. During operation of engine, the fuel evaporation in EVAP carbon canister will be introduced into intake manifold through clean passage. EVAP carbon canister is controlled by ECM. With engine running, evaporation flow controlled by EVAP canister solenoid is adjusted with direct proportion of increased air flow. During deceleration and idling, the evaporation passage may be cut off by EVAP carbon canister solenoid.

128

Maintenance Manual for J2 Sedan 2.

Mechanical Part of Engine

Diagram of Fuel Evaporative Emission Pipeline

2 4

5

1 6

3

Diagram of fuel evaporative emission pipeline 1-Carbon canister assembly

2-Fuel inlet hose of engine

3-Pipe connecting carbon canister with solenoid valve

4-Hose connecting carbon canister with solenoid valve

Note:

6-Fuel filter

Fig. 1.5.001

Do not use soap water or any other detergent when installing vacuum pipe or cleaning pipeline. 3.

5-Fuel inlet pipe of engine

2 1

3

Inspection of parts

1) EVAP carbon canister ①

Check EVAP carbon canister with following methods:

a.

Plug port 1, blow at port 3, make sure the air flows out from port 2 freely.

b.

Plug port 3, blow at port 1, make sure the air flows out from port 2 freely.

② Dismount the vacuum hose Loose the clamps between carbon canister and fuel tank and carbon canister solenoid valve with slip-joint pliers, pull out the vacuum hose. 129

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

③ Dismount the carbon canister Lift the carbon canister and dismount it from the bracket on inner lining of left fender.

Fig. 1.5.002

Left front frame 左前车架

2) EVAP carbon canister solenoid valve The air flow rate is controlled by the opening of evaporation by-pass passage in EVAP carbon canister solenoid valve. The solenoid valve will repeat the operations of “ON” and “OFF” with signal from ECM to actuate the variation of valve opening, so as to optimize engine control. The optimum value memorized in ECM lies on the state of engine. When the engine operates, flow rate of fuel evaporation from EVAP carbon canister is adjusted along with the variation of air flow. ① Instruction of parts Flow rate of fuel evaporation from EVAP carbon canister is controlled by duty cycle of ON/OFF of the solenoid valve. The solenoid valve is actuated by ON/OFF duty cycle signal from ECM. The wider the pulse width in “ON” condition is, the more fuel evaporation will flow through the valve. ② Dismantlement a.

Fig. 1.5.003

Disconnect the vacuum hose of EVAP carbon canister solenoid valve.

130

Maintenance Manual for J2 Sedan

b.

Disconnect the harness connector of EVAP carbon canister solenoid valve.

Fig. 1.5.004

c.

Remove the EVAP electromagnetic valve.

Fig. 1.5.005

carbon

canister

Mechanical Part of Engine

3) Filler cap Vacuum relief valve is mounted at the filler cap. When the pressure in fuel tank is high (more fuel evaporation), the vacuum relief will be closed, so as to avoid emission of fuel evaporation to ambient air. When the pressure in fuel tank is low (negative pressure), the vacuum relief valve will be opened, so as to enable the outside air to get into fuel tank.

131

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

II. Forced Ventilating System of Crankcase 1.

System Illustration

The forced ventilating system of crankcase is used to bring the cylinder blow-by gas in crankcase back to intake manifold. It is the forced ventilating valve (PCV) which brings the cylinder blow-by gas in crankcase back to intake manifold. With throttle partially opening, the intake manifold sucks blow-by gas of crankcase through PCV valve. In normal conditions, the ventilation volume of PCV valve is sufficient to suck all blow-by gas of crankcase and a little air. The vent air is brought into crankshaft through air intake pipe. Ventilation hose inhales fresh air from the rear end of the air filter to the crankcase to keep the crankcase pressure at a certain range. When the air throttle is fully open, the vacuum degree is not sufficient to open PCV valve and thus unable to suck blow-by gas of crankcase. The air flows through connecting hose in reversed direction. In vehicles with severe blow-by gas, PCV valve can not meet the requirements because part of air may get into the air intake pipe at any time during operation.

132

Maintenance Manual for J2 Sedan 2.

Mechanical Part of Engine

Inspection of Element

Check the PCV (forced ventilation of crankcase) valve as shown below: 1) Operation principle Operation principle list of PAV valve

High vacuum

No vacuum

Valve chamber cover side

Valve chamber cover side

Operating state of engine

Out of work

Operating state of engine

Idling or deceleration

PCV valve

Out of work

PCV valve

Fully open

Variation of vacuum

Limited

Variation of vacuum

Slight

No

Moderate

Valve chamber cover side

Valve chamber cover side Improper acceleration and

Operating state of engine

Normal operation

Operating state of engine

PCV valve

Normal operation

PCV valve

Retardant operation

Variation of vacuum

Large

Variation of vacuum

Extremely large

133

high speed

Maintenance Manual for J2 Sedan

Mechanical Part of Engine

2) Dismantlement and Installation ① Dismantlement a.

Disconnect the PCV valve hose from cylinder cover.

b. Remove the PCV valve from cylinder

cover.

Fig. 1.5.006

Fig. 1.5.007

3) Check after Dismantlement ① PCV valve: Hissing may be produced during normal working of valve with air flows through. When finger touches the valve at the entrance, you can immediately feel a strong vacuum pressure.

Fig. 1.5.008 P.C.V valve

② Vent hose of PCV valve a.

Check the hose and joint for leakage.

b.

Disconnect all hoses and clean with compressed air. If the blockage in hose can not be cleared, replace.

134

Maintenance Manual for J2 Sedan

Chapter II

Electrical Part of Engine

Section I I.

Ignition coil

1.

Parts

Ignition System

Ignition coil 2.

Dismantlement & Installation

1) Dismantlement Attention:

Fig. 3.1.001

■

Be sure that the ignition switch is in the “OFF” position.

①

Dismount the trimming cover of engine. Refer to “Intake Manifold” section.

②

Disconnect the wiring harness connectors of the ignition coil from high voltage ignition coil.

135

Electrical Part of Engine

Maintenance Manual for J2 Sedan

③

Remove high-voltage ignition coil bolt to remove coil.

■

Tightening torque: 6-8N·m

④

Dismount the spark plug with special socket.

Electrical Part of Engine

Fig. 3.1.002

Tightening torque: 25-30N·m Attention: ■

Please do not drop or shake it.

2) Check after dismantlement ① High-voltage ignition coil ■

Check the primary coil resistance between both terminals. Primary coil resistance: 0.77-0.95 Ω

■

Check the resistance of secondary coil Secondary coil resistance: 7.75-10.23 KΩ

Attention: ■

The ignition coil harness connector must be disconnected for secondary coil resistance measurement.

② Spark plug Check the spark plug: ■

Check insulator of spark plug for damage and broken.

■

Check spark plug for carbon deposit. See the following table for causes of carbon deposit. Causes of Carbon Deposit Phenomenon Reason

Black charcoal Impurity in the fuel or high fuel-air ratio.

■

Check spark plug electrodes for damage.

■

Inspect clearance of spark plug. 136

Hard charcoal Impurities in the fuel; wrong ignition timing, or untight spark plug.

Maintenance Manual for J2 Sedan

Electrical Part of Engine

Inspect clearance of spark plug by using feeler. Standard value: 0.7-0.8 mm If the clearance is beyond the standard value, replace. ■

Check sparking ability of spark plug.

a.

Connect spark plug to high voltage circuit.

b.

Keep the distance between edge of spark plug and the grounding metal at about 14 mm.

c.

Start the engine for about 3s, check whether there are sparks produced between the edge of spark plug and the grounding metal.

Attention: ■

During check, be careful not to get an electric shock.

■

If the clearance is less than 14 mm, the sparks may also be produced even though the high voltage wire has trouble.

■

If there are no sparks, replace spark plug.

3) Installation Install with steps contrary to dismantlement. II. Diagnosis of Common Troubles Diagnosis Common Troubles Symptom The engine can’t or is difficult to start.

Unstable idle speed

Engine surge or poor acceleration Poor. fuel economy

Possible causes Solution Trouble of ignition coil or ignition Check or replace the ignition coil or the switch ignition switch Trouble of spark plug Check or replace spark plug Disconnected high voltage wire Check the high voltage wire Trouble of high voltage wire or spark Check the high voltage wire or check or plug Replace spark plug Trouble of ignition coil Check or replace the ignition coil Trouble of high voltage wire. Check the high voltage wire Trouble of spark plug Check or replace spark plug Trouble of spark plug Check or replace spark plug

III. Parameters for Maintenance Maintenance Specification of Ignition System High voltage Ignition coil Spark plug

Primary coil resistance Secondary coil resistance Spark plug clearance

137

0.77-0.95Ω 8.7±0.87 KΩ 0.7-0.8mm

Maintenance Manual for J2 Sedan

Section II I.

Electrical Part of Engine

Starting and Charging System

Principle Diagram of Starting and Charging System 120 A 中央电器盒 box 熔断片 fuse link 120A Central

熔断片 30A

30 A fuse link

electric

熔断片 20A

20 A fuse link

Battery

蓄电池

LOCK

Ignition switch START 点火开关

ACC ON O/S Combined Charging 组合仪表 充电指示灯 alarm light device - +

Anti-theft relay

Starting relay

防盗继电器

起动继电器

B

S

L

Electric generator

发电机

R2 整流器 Rectifier

Magnetic field磁场绕组 winding

ETACS－low level effective

ETACS-低电平有效

Df

R1

R3

接地 Grounding ZD

起动机 Starter 定子绕组 Stator winding ENG 电动机 单向离合器

Electric motor

R4

Tr1 Tr2

Solenoid 电磁开关 switch

One-way clutch

E

Principle Diagram of Starting and Charging System II. Battery 1.

How to use battery

Attention: ■

If the engine is necessary to be started with auxiliary battery and jumper wire, 12 V auxiliary battery should be used.

■

When jumper wires are connected with battery, make sure that the jumper wires are clamped to the terminals of battery and have good contact.

2.

Methods to prevent excessive discharging of battery

The following precautions should be particularly emphasized to prevent excessive discharging of battery. ■

Always keep surface of battery (esp. the top) clean and dry.

■

The connecting part of the terminals should be clean and tightened.

138

Maintenance Manual for J2 Sedan

Electrical Part of Engine

■

If the vehicle is not used for a long time, the cathode terminal of battery should be disconnected.

■

Check charging condition of battery.

3.

Check

1) Visual inspect ■

Check terminals of battery for damage and electrolyte leakage. If any, replace.

2)

Voltage inspection: Inspect batter for proper voltage. (The following parameters is for reference only)

① If U>13.2V, inspect the electrical system. ② If 12.5V