Chapter II Service
VII. Maintenance Data
1. Tightening Torque of Standard Parts
Tightening Torque List of Standard Parts
Torque (N·m)
28 Attention:
■ Tightening torques listed above are the standard values which are applicable for following conditions:
a. Steel, plating nuts and bolts.
b. Plated steel plain washers.
c. All the dry nuts, bolts and gaskets.
■ The torques listed above are not applicable for following conditions:
a. When the component is to be tightened with spring or tooth washer;
b. Tightening of the plastic parts.
c. Self-tapping screw or self-locking nut.
d. Oiled thread and surface.
■ In following conditions, the torques listed above should be correspondingly reduced:
a. if a spring washer is used, the torque should be reduced to 85%.
b. If bolt surface is coated with oil, the torque should be reduced to 85%.
Engine Volume
Chapter I Mechanical Part of Engine ... 33
Section I Engine Body...33 I. General Precautions ... 33 II. Precautions on Sealant ... 34 III. Preparation ... 36 IV. Engine Assembly ... 39 V. Drive Belt... 43 VI. Air Filter and Air Duct ... 45 VII. Intake Manifold and Exhaust Manifold ... 47 VIII. Exhaust System... 51 IX. Timing sprocket mechanism ... 53 X. Camshaft and balance shaft assembly... 58 XI. Cylinder head... 64 XII. Valves ... 68 XIII. Cylinder Body Assembly... 72 XIV. Diagnosis of Common Troubles... 86 XV. Parameters for Maintenance... 88 Section II Engine Lubrication System ...92
I. Precautions... 92 II. Preparation ... 93 III. Engine Oil... 94 IV. Oil Filter ... 96 V. Oil Pan and Engine Oil Pump ... 98 Section III Cooling System of Engine ...102
I. Cooling Circuit... 102 II. Engine Coolant ... 103 III. Radiator... 105 IV. Radiator Cooling Fan... 107 V. Water Pump ... 107
Section IV Fuel Supply System of Engine... 114 I. General Precautions ... 114 II. Preparation ... 115 III. Fuel System ... 115 IV. Fuel Injector and Guide Rail ... 116 V. Fuel Filter ... 119 VI. Fuel Pump Assembly... 122 VII. Fuel Tank Assembly ... 126 Section V Emission Control System of Engine ...128
I. Fuel Evaporation Control System ... 128 II. Forced Ventilating System of Crankcase ... 132
Chapter II Electrical Part of Engine ... 135
Section I Ignition System...135 I. Ignition coil ... 135 II. Diagnosis of Common Troubles... 137 III. Parameters for Maintenance... 137 Section II Starting and Charging System ...138
I. Principle Diagram of Starting and Charging System ... 138 II. Battery ... 138 III. Starting System ... 141 IV. Charging System... 149
Chapter III Electronic Control System of Engine ... 155
Section I Precautions...155 I. Precautions of Supplemental Restraint System (SRS)... 155 II. General Precautions ... 155 III. Precautions in Maintenance ... 155 IV. Common tools for diagnose ... 157 V Precautions for On-board diagnose (OBD) system of engine ... 160 Section II Structural Principle and Inspection of Engine Control System ...163
I. System Description... 163 II. Multiple-point Fuel Injection System ... 164 III. On-board Diagnosis System... 167 IV. Engine Trouble Diagnosis... 173
Section III Structural Principle and Inspection of Engine Electronic Components ...179 I. Intake Manifold Absolute Pressure (MAP/MAT) Sensor ... 179 II. Engine Coolant Temperature (ECT) Sensor... 181 III. Throttle Position Sensor ... 183 IV. Crankshaft Position Sensor... 185 V. Camshaft phase sensor... 188 VI. Oxygen sensor ... 191 VII. Fuel Injector (INJ)... 194 VIII. Knock sensor... 195 IX. Air-conditioning switch and relay ... 197 X. Canister solenoid valve ... 198 XI. Ignition coil ... 199 XII. Electric Fuel Pump... 201 XIII. Electronic Control Module (ECM) of Engine ... 203 Section IV Trouble Diagnosis Procedures for Engine Control System ...206
I. Diagnosis with DTC ... 206 II. Diagnosis by Trouble Phenomena ... 226
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.
6. Parts Needed to Be Tightened with Specified Angle
1) Use the angle spanner to finally screw up following engine parts:
- Cylinder head bolt - Bolt of main bearing cap - Connecting rod bolt
2) Please follow the specified tightening methods.
3) Make sure that the surfaces of threads and pedestal are clean and coated with engine oil.
II. Precautions on Sealant 1. Removal of Sealant
After dismounting fixing nuts and bolts, use the scraper to detach the matching faces and remove old sealant.
Attention:
■ Do not damage the matching faces.
■ Insert the scraper, and then knock its side to slide it as shown in the figure.
■ For the positions where it is difficult to use scraper, lightly knock the parts to dismount them with a plastic hammer.
■ If you have no choice but to use the tools such as a screwdriver, be careful not to damage the matching faces.
2. Application Steps of Sealant
1) Remove the attached old sealant from the application and matching faces of liner with scraper.
Attention:
■ Thoroughly remove the old sealant from the groove on surfaces, fixing bolts and bolt holes where the sealant was applied.
2) Wipe sealant surface and matching surface clean with a special cleaner, remove water drops, grease
JAC-T1F017
3) Position sealant with the specified size.
■ Put the sealant into the groove for it (if any).
■ Generally, the sealant is put inside the bolt hole; however, it is occasionally put outside the bolt hole.
■ Install the matching part in a certain period of time after applying sealant.
■ Eliminate any dirt from the sealant.
■ Do not re-tighten the bolts or nuts after installation in order to avoid failures of bolts or nuts.
■ Add engine oil and coolant 30min after the installation has been finished.
Attention:
■ Conduct the operation in accordance with the instructions specified in this manual.
Fig.1.1.003
III. Preparation
1. Tools for Maintenance
List of Special Tools
No. Tool Appearance Code Description
1 End forked clamp
Fix camshaft
5 Flywheel chock JAC-T1F011 Used to fix
the flywheel
7 Oxygen sensor
tool for oil pan JAC-T1F017
Used to dismantle the
oil pan
9 Installer for
valve oil seal JAC-T3F001
Used to install
2. List of Auxiliary Materials for Assembling Engine
List of Auxiliary Materials for Assembling Engine
No. Name Application Specification and Grade
1 Engine
oil Used during filling and assembly
Factory filled oil: SAE10W-30 Ambient temperature: -25℃-35℃
User must select the appropriate oil according to the local temperature
Quality level: SJ or above
2 Silica gel
Engine oil pump, water pump, oil pan
and rear oil seal housing of crankshaft LT5699 or equivalent
3 Sealant Oil pressure switch, draining screw plug
and flywheel bolt LT243 or equivalent
4 Sealant Coolant temperature sensor and water
temperature alarm switch LT648 or equivalent
5 Petrol 93# unleaded petrol or above
6 Sealant Stud bolt LT271 or equivalent
3. List of Auxiliary Materials for Assembling Cylinder head
List of Auxiliary Materials for Assembling Cylinder head
No. Name Present Material and Model Assembly Position
1 Engine oil
5W-30 (winter) 15W-40 (summer),with SJ-class quality
level and above
Valve head, camshaft and camshaft oil seal
2 Sealant LT271 or equivalent Stud bolt
3 Sealant LT962T or equivalent Guide sleeve of spark plug, bowl patch of cylinder body/cover, connecting pipe nozzle
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”.
3. 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”.
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:
Fig.1.1.004 Fig.1.1.005
■ Before starting engine, check oil and fluid levels (including engine oil and coolant). Refill to specified level as required..
■ Check for fuel leakage with following steps：
- With ignition switch turned to the “ON” position, check whether there is fuel leakage at the connecting positions.
- With engine started, recheck whether there is fuel leakage at the connecting positions during engine increasing.
■ During running of engine, check for any abnormal noise and/or vibration.
■ With engine warmed up, verify that there are no leakage of fuel, exhaust gas or other oil and liquid (including engine coolant and oil).
■ Bleed air and replenish by using specified ports and hoses.
■ After engine cooled down, recheck oil and liquid levels (including engine oil and coolant). If necessary, refill them to the specified levels.
2) General of Check Items
List of Leakage Check Items
Item Before Startup During Engine
Operation
After Engine Stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission oil, brake fluid, and clutch fluid Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust — Leakage —
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 Method
Generator belt Screw adjusting bolt of generator
Attention:
■ After replacing with the new belt, adjust the tension so as to meet the requirements
■ When installing the belt, ensure the proper engagement with the belt pulley groove.
■ Do not splash the engine oil or engine coolant onto the belt.
■ Do not over wind or bend belt; for worn belt, pay attention to mounting direction.
3. Generator Belt
1) Loosen the generator adjusting nuts and supporting nuts. Then adjust the tension by using the adjusting bolt.
2) Tighten generator adjusting and supporting nuts.
■ Tightening torque: Generator adjusting nuts: 22.5 ± 2.5 Nm Generator supporting nuts: 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”.
Fig. 1.1.006 Fig. 1.1.007
VI. Air Filter and Air Duct 1. Parts
Diagram of Positions 2. Intake Pipe
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
② Loosen the lock clips from the air cleaner upper cover.
Fig. 1.1.009 Fig. 1.1.008
③ Disconnect the locking clamp of intake hose, and then take off upper cover and intake hose.
■ Tightening torque: 6-9 N·m
④ Dismount the fixing bolt of air filter base, and then take down the base.
■ 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
① Loosen the lock clips of air cleaner upper cover and lift the upper cover.
Fig. 1.1.012 Fig. 1.1.011
Fig. 1.1.013 Fig. 1.1.010
② Dismount air filter element.
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.
Fig. 1.1.014
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.
⑦ Dismount the fuel injector assembly. See “Fuel Injector”.
■ Tightening torque: 18.4±1.4 N·m
Fig. 1.1.015
Fig. 1.1.016
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.
■ 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 engine warmed up, verify that there is no fuel and/or coolant leakage.
■ After engine cooled down, recheck the level of engine coolant. Refill to specified level as required.
2. Exhaust Manifold 1) Dismantlement
Fig. 1.1.017
Fig. 1.1.018
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
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
Fig. 1.1.020 Fig. 1.1.019
Fig. 1.1.021
Fig. 1.1.022
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. Exhaust System 1. Parts
Diagram of Exhaust System
Diagram of Exhaust System