Maintenance Manual for J2 Sedan
Foreword
Master Table of Contents
General
Description
&
Maintenance
Engine
Chassis
Body Electrical & Structure
Circuit Troubleshooting
This manual is intended to help theprofessional 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
Chapter I General Description
Chapter II Maintenance
Chapter I Engine mechanical system
Chapter II Engine electrical system
Chapter III engine electronic control
system
Chapter I Clutch & Manual Transmission
Chapter II Traveling system
Chapter III Braking system
Chapter I Body Electrical
Chapter II Body Structure
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
Chapter I Overview
Section I General Instructioooons I. Summary
This Manual provides the procedures required by service operations, including: 1. Structure and composition
2. Principles
3. Dismantlement and installation steps 4. Inspection methods
5. Adjustment & commissioning methods 6. Common trouble diagnosis procedures 7. Technical parameters
The simple operations that can be conducted through the observation of vehicle are left out in this Manual. No description is given for the necessary basic skills of maintenance technicians in this Manual.
II. How to use
This Manual comprises four parts, i.e. engine volume, chassis volume, electrical appliance & structure volume of vehicle body and electric circuit inspection volume. In front of each part is given a detailed content index, in which you can find the section you want quickly.
This Manual provides following information: 1. Working principles;
2. Component position
3. Inspection and service specifications
4. Component dismantlement & installation steps 5. Common troubles and repair procedures
Section II Vehicle Information I. Identification Information Position
Position of vehicle ID
1- Name plate of vehicle 2- ID number of vehicle II. Nameplate
1. Position of nameplate: at the firewall of engine compartment. 2. Instructions of nameplate
Example of Nameplate
Made by China Anhui Jianghuai Automobile Co., Ltd.
Ex-factory no. Ex-factory date Jan. 2010
Max. gross weight
Fixed number 5 persons
Engine Model Rated power
Engine displacement Model
Brand: Jianghuai
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III. Vehicle Identification Number (VIN)
1) VIN position: on the nameplate or at the left bottom of windshield. 2) Illustration of VIN
Part 1: Word Manufacturer Identification (WMI), consists of 3 numbers according to GB16737, which should be applied, approved and filed. WMI for JAC is LJ1, which applicable for freight truck, incomplete vehicle, bus, passenger car, tractor and special vehicle of JAC. Word Manufacturer Identification (WMI) is shown in table below.
Table Worldwide Manufacturer Identification
ID Manufacturer Applicable Models
LJ1 JAC Co., Ltd, ANHUI Freight truck, incomplete vehicle, bus, passenger car, tractor, special vehicle
Part 2: vehicle description Code (VDS), as specified in GB 16737, this part should be made up with 6 digitals to presents basic features of vehicle model.
VDS making-up:
Inspection digit
Code of engine type and rated power Truck wheelbase / passenger cars, buses and chassis length
Geographical region Country Manufacturer Vehicle Description Code Check Character Digitals Order number Assembled in Model year Representative letter
or number Representative number
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
4:General Assembling Workshop of Passenger Car Manufacture Company Factory assembled
7:General Assembling Workshop of Passenger Car Manufacture Company 8: 2008
Year 9: 2009 A: 2010
IV Engine Number
1. Position of engine number
Engine number is stamped on the exhaust side of cylinder block (See figure below).
Production SN Factory assembled
Year
Digitals
2. Meaning of Engine Number
3GB4.C – Engine model: 1.0 3-cylinder gasoline engine ☆A3408769☆:
A – the year of 2010
3 - engine type (petrol, local parts) 408769– Production SN
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.
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.
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
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Chapter II Service
Section I Service I. Preparation
1. Maintenance Tools
List of Maintenance Tools
No. Tools Outside View Description
1 Power tool
For dismantlement and installation of bolts and
nuts
2 Ignition plug socket
For dismantlement and installation of ignition
plug
II. General Service
General Service means the inspection and maintenance items which should be performed everyday during normal use of vehicles. These service items are very important, for normal operation performance of vehicle. The owners can perform these inspections by themselves, or go to a JAC franchised store for assistance. Followed is content of general service:
1. Exterior of Vehicle
The following inspection and maintenance items should be frequently conducted. List of Items to be Frequently Inspected for the Exterior of Vehicle
Item Inspection
Tyre Use an air gauge to inspect the pressure of tyres (including spare tyre) in the service station regularly; adjust pressure in accordance with technical data if necessary. Check whether there’s any damage, crack or excessive worn tear carefully.
Windshield 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.
Windshield
wiper blade If the wiper doesn’t work efficiently, check for worn or torn. Door and
engine hood
Check whether all of the doors, engine hood, boot cover and tail door can be normally opened and closed normally, whether all the door locks are locked closely. Lubricate as required. Moreover, If the vehicle often travels on the salt-spread roads or in the areas with corrosive substances, always inspect lubricating conditions.
Vehicle lamps Verify that headlamps, brake indicators, tail lamps, turning signal indicator and other lighting units work normally and have been stably fixed. Meanwhile, inspect focusing function of headlamp.
2. Interior of Vehicle
The following inspection and maintenance items should be performed regularly. List of Items to be Regularly Inspected for Interior of Vehicle
Item Inspection
Alarm light and buzzer
Make sure all the alarm lights and buzzers are working normally. Windshield wiper
and washer
Check whether the wiper and cleaner are working normally; check whether there is any crack in the wiper.
Windshield defroster
Check whether the air can be correctly bled from the air outlet of defroster, whether the heater or air conditioner can breathe enough air during operation of heater or air conditioner.
Steering wheel
Check whether the free travel of steering wheel is in the standard range. Inspect changes of steering performance, such as the free travel beyond range, hard steering and abnormal noise etc.
Seat Belt
Check whether all the components of seat belt system are flexible and working normally and fixed firmly and stably. Check seat belt for cracking, worn out or other damage.
Throttle pedal Check whether the pedal can be operated smoothly, make sure that the pedal would not be seized or loaded unevenly. Keep floor pad away from the pedal. Brake pedal and
booster
Check if the pedal can be operated smoothly; make sure the pedal still keeps an appropriate distance from the bottom plate when it is completely pressed down. Inspect the function of brake vacuum booster. Make sure that the bottom plate pad is away from the pedal.
Parking brake Check travel of handle. 3. Engine and Vehicle Chassis
The following inspection and maintenance items should be regularly performed.
List of Items to be Regularly Inspected for the Engine and Vehicle Chassis
Item Inspection
Cleaning liquid for windshield Check whether there is adequate cleaning liquid in reservior. Level of engine coolant Check the coolant level when the engine is cold.
Engine oil level Stop the vehicle on a level ground and turn off engine; check oil level.
Levels of brake fluid and clutch fluid Make sure that the levels of brake fluid and clutch fluid are between the “MAX” line and “MIN” marks on reservoir.
Battery Inspect conditions of voltage and battery poles.
Liquid leakage After the vehicle has been stopped for a while, check for any leakage of fuel, engine oil, coolant or other liquid under the vehicle. Water drop from the air conditioner which has just been used is normal. In case of obvious leakage or petrol fume, find out the causes and repair immediately.
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Service operational code: I-examination; R-replacement; C-washing
Service cycle (odometer readings and the number of months, whichever comes first)
1000km 1 10 20 30 40 50 60 70 80 90 100
Item
Month — 6 12 18 24 30 36 42 48 54 60
1 Driving belt I: every 10,000 km or 6 months
R: every 60,000 km or two years 2 Check oil and gas control systems of
crankcase for normal working I I
3 Spark plug I I R I I R I I R I
4 Change coolant R R R R R
General conditions of use C: every 5,000km R: 15,000km 5 Air filter element
Harsh conditions of use C: every 3,000km R: 10,000km General conditions of use R: every 5,000 km or 6 months 6 Oil and oil
filter Harsh conditions of use R: every 3,000 km or 3 months
7 Carbon monoxide content with engine idling I I I I I I I I I I
8 Ignition timing I I I I I
9 Hose I I I I I I I I I I
10 Exhaust fittings leakage I I I I I I I I I I
11 Throttle body C C C C C
12 Injector C* C* C* C* C* C* C* C* C* C*
13 Valve clearance I I I I I I
Notes:
C *---For cleaning operation of fuel injector, it is recommended that dedicated fuel injector cleaning analyzer is used; Check every 3 months or 5000km; if there are nozzle clogging or blockage failures and they are non-product quality problems, they should be maintained at users’ expenses.
"Harsh conditions of use" specifications are only used in severe conditions of use of vehicles. Harsh conditions of use include the following:
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.
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
Engine oil 3.8
Factory filled oil: SAE10W-30
Ambient temperature for use: -25 ℃ - 35 ℃
User must select the appropriate oil according to local ambient temperature
Quality level: SJ or above
Cooling system 5.5 High-quality HF-C anti-freezing solution
Manual transmission gear oil 2.0 API GL-4, SAE 75W/90
Brake fluid and clutch fluid 0.56±0.05 DOT4 (Great Wall)
AC refrigerant 600±25g R134a
Wiper cleaning liquid 3 Water
AC compressor lubricating oil 0.12 PAG56
V. Service of Engine 1. Inspection of Driving Belt Warnings
■ Be sure to operate only with engine stopped.
1) Check for belt aging, crack, wear and oil stain. Replace as required. 2) Check the belt tension at the mid-point between both pulleys.
■ Inspection should be conducted in the engine cold state or when it has been stopped after 30min. ■ Range of tension force – Alternator belt: 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
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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”.
■ 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
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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.
③ Check the pressure released by radiator cap. Standard: 78-98 KPa
Limit: 59 KPa
— Connect the radiator cap to radiator leak detector, paste engine coolant onto the sealing face of cap.
■ If any failure is found in above-mentioned three inspection items, replace radiator cap.
Attention:
■ For installation of radiator cap, please wipe the radiator filler carefully to clear away any paraffin residue or foreign substance.
3) Inspection of radiator
Check for any mud or clogging situation in radiator. If any, clean with following method. ■ Be aware not to twist or damage the radiation fins.
■ In case of cleaning without dismounting the radiator, all accessories such as cooling fan, wind collection hood and horn should be dismounted. Wrap connectors of wire harness with adhesive tape for water proofing.
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.
Fig. 2.2.001
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:
■ 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
① Unscrew lock bolt of air filter upper cover lift up the cover.
Fig. 2.2.005 Fig. 2.2.004 Fig. 2.2.003
Engine Fuel pipeline
16
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.
■ 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
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.
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1) 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”.
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. 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.
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■ In case any component is found damaged, repair or replace.
2. Inspection of Clutch Fluid Level and Leakage
If the fluid level is low, check clutch system for any leakage. 3. Inspection of Clutch System
Check for correct installation positions of liquid pipelines and operation cylinders, and any crack, damage, loose connection, worn or ageing.
4. Inspection of Manual Transmission Gear Oil
Inspect oil level and whether there is any leakage. For detailed information, refer to “Inspection of Manual Transmission Oil”.
5. Change Manual Transmission Gear Oil
1) Thoroughly drain oil from drain plug, and then refill with new gear oil. For detailed information, refer to “Change Manual Transmission Oil”.
2) Inspect oil level. For detailed information, refer to “Inspection of Manual Transmission Oil Level”. 6. Wheel Balance
1) Dismantlement
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
weight is nearest to the calculated value, and install it to the specified outer side position, or at the specified angle relative to wheel.
Attention:
■ The balance block of outer side should be installed before inner side.
■ Prior to the installation of balance block, fitting surface on wheel must be thoroughly cleaned.
a. Install the balance block to the position indicated in figure below. b. As shown in the figure, during installation of
balance block on the wheel, the balance block should be placed in the groove area on the wheel inner wall, and fix with its center towards the position (or angle) indicated by the wheel balancer.
Attention:
■ The balance block should not be reused; it should be replaced every time. ■ At most three balance blocks are allowed to be installed.
■ The original balance blocks should be used any time. c. In case the calculated weight of balance block
is more than 50 g, the two balance blocks should be installed in a line.
Attention:
■ Never install a balance block on another one.
③ Restart 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.
Fig. 2.2.010
Fig. 2.2.011
Stuck weight
Towards the groove
Position (or angle) indicated by the wheel balancer
Center of gravity
Position (or angle) indicated by the wheel balancer
22
■ Allowable maximum unbalance: 7. Tyre Exchange
■ Tyre exchange should be performed every 8000 km.
Tyre exchange should also be performed when the new tyre is put on.
Note: As shown in the figure is the recommend method for tyre exchange.
8. Inspection for Brake Fluid Level and Leakage If fluid level is low, please check brake system for leakage.
9. Inspection of Brake System Pipeline and Cable
Check for correct positions of brake pipeline and parking brake cable, and any leakage, worn, scratching or ageing etc.
10. Change Brake Fluid Attention:
■ Refill brake fluid.
■ Discharged brake fluid must not be reused.
■ In order to keep the paintwork free from damage, be sure not to splash brake fluid onto the paintwork. If the fluid is splashed onto the paintwork, please clean with water immediately.
Fig. 2.2.012 Fig. 2.2.014 Fig. 2.2.013 Highest line Lowest line No rm a l
1) Insert the ethylene tube onto release valve. 2) Press on the brake pedal to loosen the
release valve, and then discharge brake fluid slowly.
3) Wash the inner side of fluid reservoir and refill with new brake fluid. 4) Loosen the release valve, press down the
brake pedal slowly, and then release. Repeat this operation every other 2 or 3 s until 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) Bleed air. See also “Air Bleeding of Brake Pipeline”. 11. Inspection of Brake
1) Brake disc
Check for worn or damage.
List of Standard Specification of Brake Disc
Type Floating caliper type / ventilated disc
Brake disc diameter 241 mm
Brake disc thickness 19 mm
Friction block thickness 9 mm
Brake disc
Cylinder bore 51 mm
2) Brake drum
Check whether the inner diameter and circular runout of brake drum are in the scope of standard values. If not, corresponding processing or replacement should be performed.
Fig. 2.2.015
24
Standard Specification Table of Brake Drum
Type Leading trailing shoe brake
Brake drum diameter 204 mm
Cylinder bore of brake slave cylinder 17.46 mm
Clearance adjustment Automatically
Brake drum
Circular runout < 0.05 mm
3) Brake caliper
Check for any oil leakage.
4) Rear brake slave cylinder Check for any leakage.
5) Front brake shoe
Check for worn or damaged conditions. ■ Standard thickness: 9 mm
■ Limit thickness: 2 mm
Fig. 2.2.017
Fig. 2.2.018
6) Rear brake shoe
Check the brake shoe thickness and its contact state with the brake drum. If it fails to meet the requirement, replace.
■ Standard thickness of brake shoe (A): 5 mm ■ Allowable limiting thickness (A): 1 mm
12. Inspection of Steering Gear and Pull-rod 1) Steering gear
■ Check whether the steering gear housing and dust boot are free from looseness, damage and grease leakage.
■ Check whether its connection with the steering column is loose.
2) Steering pull-rod
Check ball joint, dust boot and other components for loosening, worn, damage and grease leakage. 13. Check the pipeline.
Stop engine, check fluid level in reservior. Attention:
■ Be sure not to fill steering fluid excessively.
■ Check for proper installation position of pipeline, and any leakage, crack, damage, loose connection, worn or ageing.
14. Axle and Suspension Components
Check for proper clearance between front/rear axles and suspension components and any crack,
Fig. 2.2.020
Fig. 2.2.021
Fig. 2.2.022
Check the leakage of lubricating grease
26
■ Rock each wheel to check for proper clearance. ■ Inspect operation conditions of wheel bearings. ■ Check axle, suspension nut and bolt for loosening. ■ Check shock absorber for oil leak or other damages. ■ Check the suspension ball joint for grease leakage;
check ball joint dust boot for crack or other damages.
15. Inspection of Drive Shaft
Check dust boot and drive shaft for any crack, worn, damage or grease leakage.
16. Lubricating Door Lock, Hinge and Engine Hood Lock Pin
Lubricating Points of Door Lock, Hinge and Engine Hood Lock Pin
Fig. 2.2.023
Fig. 2.2.024
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
Torque (N·m) Nominal Diameter of
Thread Pitch Head mark 4 Head mark 7
M5 0.8 3-4 5-6 M6 1.0 5-6 9-11 M8 1.25 12-15 20-25 M10 1.25 25-30 30-50 M12 1.25 35-45 60-80 M14 1.5 75-85 120-140 M16 1.5 110-130 180-210
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%.
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 Fig.1.1.001 Fig.1.1.002 Slide Knock Scraper
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 timing sprocket 2 Pin JAC-T1D001 Used together with the end forked clamp
3 Locating tool for
piston pin Used to install and dismantle the piston pin 4 Guide sleeve JAC-T1F005 Used together with the locating tool for piston pin
5 Flywheel chock JAC-T1F011 Used to fix
the flywheel
6 Valve spring JAC-T1F012
Used to compress the
7 Oxygen sensor socket JAC-T1F015 Used to install and dismantle the oxygen sensor 8 Dismantlement
tool for oil pan JAC-T1F017
Used to dismantle the
oil pan
9 Installer for
valve oil seal JAC-T3F001
Used to install the valve oil
seal
11
Guide for front oil seal of crankshaft JAC-T3F003 Functioning as a guide during the installation of front oil seal
of crankshaft
12
Installer for front oil seal of crankshaft
JAC-T3F004
Used to install the front oil seal of engine
crankshaft
13
Installer for rear oil seal of crankshaft
JAC-T3F005
Used to install the rear oil seal
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
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 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:
■ 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
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.
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”.
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
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 ignition switch turned to the “ON” position, check whether there is fuel leakage at the connecting positions.
— — —
— With engine started, recheck whether there is fuel leakage at the connecting positions during engine increasing.
■ With engine warmed up, verify that there is no fuel and/or coolant leakage.
■ After engine cooled down, recheck the level of engine coolant. Refill to specified level as required. 2. Exhaust Manifold
1) Dismantlement
Fig. 1.1.017
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
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
1- Rear muffler; 2- Lug; 3- Front muffler; 4- Front exhaust pipe; 5-Three-element Catalytic Converter; 6- Bellow; 7-Rear oxygen sensor
2. Inspection of Exhaust System
Check whether the exhaust pipe, the three-way catalytic converter, the muffler and the fixing devices are properly installed and whether there is any leakage, crack, damage or aging.
■ Repair or replace the damaged part as required. 3. Dismantlement and Installation
Attention:
■ Do not have you hand cut by the edge of heat shield.
■ Do use original exhaust system parts or equivalent products.
■ Perform the operation after the exhaust system has completely cooled down, for the temperature of exhaust system remains hot when the engine has just stopped.
1) Dismantlement
Disconnect every joint and fixed part. 2 3 4 6 5 7 1
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.
