Service MANUAL

J4 (5MT) Model

EQUIPED WITH HFC4GB2.3D ENGINE AND MF70B 5MT TRANSSIMISSION

JAC INTERNATIONAL

2014.02

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General Information and Maintenance

GI General Information

Precautions

Description:

Please read the following precautions to ensure personal safety and proper servicing.

Precautions for supplemental restraint system (SRS) “air bag” and (SB) “seat belt pre-tensioner”:

The supplemental restraint system (SRS) “air bag” and (SB) “seat belt pre-tensioner”, used along with a seat belt, help reduce the risk or severity of injury to the driver and front passenger in the event of a vehicle collision. The information necessary to service the system safely is included in the SRS section and SB section of this Service Manual.

Warning:

To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision, all maintenance operations must be performed by an authorized JAC dealer.

Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury or death caused by unintentional activation of the system.

Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this manual. SRS wiring harnesses can be identified by yellow and orange harnesses or harness connectors.

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Replace inner and outer races of tapered roller bearings and needle bearings as a set.

Arrange the removed parts in accordance with their assembled locations and sequence.

Please do not touch the ports of electronic components which use microcomputers (such as ECM). Static electricity may damage internal electronic

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components.

After disconnecting vacuum or air tubes, attach a tag to indicate the proper connection.

Use only the oils and lubricants recommended in this manual.

Use approved bonding agents, sealants or their equivalents when needed.

Use hand tools, power tools (for disassembly only) and special tools correctly for safe and efficient repairs.

When the ongoing repairs relate to the fuel, oil, water, vacuum or exhaust system, check all affected lines for leaks.

Fender pad

Warning:

To prevent ECM from storing the diagnostic trouble codes incorrectly, do not carelessly disconnect the harness connectors which are related to the engine control system. Operate only according to the work flow of trouble diagnoses in EC section.

Precautions for three way catalyst:

If a large amount of unburned fuel flows into the three way catalyst, the catalyst temperature will rise sharply. To avoid this, follow the instructions below:

Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.

When performing spark plug tests or measuring cylinder pressure, do the jobs quickly and only when necessary.

Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to the three way catalyst.

Please do not park the vehicle on inflammable materials. Keep inflammable materials away from the exhaust pipe and the three way catalyst.

Precautions for fuel:

The 4GB2.3D engine uses unleaded gasoline with an octane rating of number 93 or above

Please do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel other than that specified could adversely affect the

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emission control equipment and system, and could also affect the warranty coverage validity.

Precautions for multiport fuel injection system or engine control system:

Before connecting or disconnecting any harness connector for the multiport fuel injection system or ECM:

①Turn ignition switch to “OFF” position.

②Disconnect negative battery terminal. Otherwise, there may be damage to ECM.

Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure.

Be careful not to shake components such as ECM and sensors.

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Precautions for engine oil:

Prolonged and repeated contact with used engine oil may cause skin cancer. Therefore, avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or cleanser as soon as possible.

Health protection precautions:

Avoid prolonged and repeated contact with engine oil, particularly used engine oil.

Wear protective clothing. Please use impervious gloves where practicable.

Please do not put oily rags in pockets.

Please do not contaminate clothes, particularly underwear, with oil.

Heavily soiled clothing and oil impregnated footwear should not be worn. Overalls should be cleaned regularly.

First aid treatment should be obtained immediately for skin cuts and other body wounds.

Apply barrier cream to skin before starting each work in order to help the removal of oil from the skin.

Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Use lanolin in replace of the natural skin oils which have been removed.

Please do not use gasoline, kerosene, diesel oil, gas oil, thinners or solvents for cleaning skin.

If skin disorders develop, take medical measures without delay.

Where practical, degrease components prior to use.

Where there is a risk of eye contact, goggles or face shields should be worn; in addition, an eye wash facility should be provided.

Environmental protection precautions:

Dispose of waste oil and oil filters through officially approved waste disposal contractors to licensed waste disposal sites, or to the waste oil reclamation enterprises. If you have any question on disposal of waste substances, contact the local authority.

It is illegal to pour used oil on to the ground, down sewers or drain ditches, or into

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water sources; the laws and regulations concerning pollution vary between regions.

Precautions for air conditioning:

Use an approved refrigerant recovery unit any time the refrigerant in the A/C system must be discharged. Refer to corresponding items in AC section for specific instructions.

How to Use This Manual

Description:

This manual explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diagnoses”.

Terms:

The captions WARNING and CAUTION warn staffs of steps that must be followed to prevent personal injury or damage to some parts of the vehicle.

WARNING indicates the possibility of personal injury if instructions are not followed.

CAUTION indicates the possibility of component damage if instructions are not followed.

BOLD TYPED STATEMENTS besides WARNING and CAUTION also give you helpful information.

Standard value: Tolerance at inspection and adjustment.

Limit value: The maximum or minimum limit value that should not be exceeded at inspection and adjustment.

Units:

The UNITS of measurement used in this manual are primarily expressed as the SI UNIT (International System of Unit).

Example: Outer Socket Lock Nut: 59-78 N·m

Contents:

THE CONTENTS are listed on the first page of each section.

THE TITLE is indicated on the upper portion of each page and shows the parts or systems involved in this page.

THE PAGE NUMBER of each section consists of two or three letters which designate the particular system and a number (e.g. “GI-6”).

THE SMALL ILLUSTRATIONS show inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations.

Special tools:

Tools marked with JAC special tool numbers are special tools provided by JAC. Tools not marked or general-purpose tools are commercially available in the

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mark.

How to follow trouble diagnoses:

Description:

Trouble diagnoses indicate work procedures required to diagnose problems effectively. Read the following instructions before diagnosing.

1.Before performing trouble diagnoses, read the “Preliminary Check”, the “Symptom Chart” or the “Work Flow” first.

2.After repairs, recheck that the problem has been completely eliminated.

3.Refer to Component Parts and Harness Connector Location for the Systems described in each section for identification/location of components and harness connectors.

4.Refer to the Circuit Diagram Volume.

If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring Diagram and Harness Layout in each individual section for identification of harness connectors.

5.When checking circuit continuity, ignition switch should be set to OFF position.

6.Before checking voltage at electrical components, check battery voltage first.

7.After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were.

Model Identification Information

Vehicle type:

Body number	Engine model	Manual transmission number
J4	HFC4GB2.3D	MF70B10

Vehicle identification number (VIN):

1)Vehicle identification number (VIN) location: On name plate or at lower left corner of windshield.

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2)Vehicle identification number description

Digit capacity

Geographic region

Serial number

Country

Vehicle feature code

Assembly plant

Maker

Check digit

Year

A letter or number

A number

①The first section: World Manufacturer Identifier (WMI) composed of 3 digits according to GB16737. This code must be subject to application, approval and filing. The code for JAC is LJ1 which applies to trucks, non-complete vehicles, buses, passenger vehicles, tractors and special purpose vehicles manufactured by our company. See the following table for the world manufacturer identifier (WMI).

Table World Manufacturer Identifier (WMI)

	Code	Name of maker	Applicable vehicle types
	LJ1	Anhui Jianghuai Automobile Co., Ltd.	Trucks, non-complete vehicles, buses, passenger
			vehicles, tractors, special purpose vehicles

②The second section: Vehicle Descriptive Section (VDS) code composed of 6 digits according to GB16737. It can reflect basic features of a vehicle type adequately.

VDS composition:

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Digit capacity

Check digit

Engine type/rated power

Wheel base of truck/length of passenger vehicle, bus and chassis

Maximum total mass

Body type

Vehicle type

①Vehicle type: 2 represents passenger vehicle.

F:3-box 4-door

②Body type

G:2-box 5-door

③Maximum total mass: K: >1000~2000

④Wheel base of truck/length of passenger vehicle, bus and chassis: R>2390~2600

1:Gasoline ≤70Kw

⑤ Engine type/rated power

2: Gasoline >70~90Kw

3:Gasoline >90~110Kw

3)The third section: Vehicle Indicator Section (VIS) composed of 8 digits.

Digit capacity

Production SN

Name of assembly plant

Year

4:Passenger vehicle manufacturer/car plant/general assembly shop/assembly plant

Assembly plant

7:Commercial vehicle manufacturer/general assembly shop of commercial vehicles

B: 2011

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Year

C: 2012

D: 2013

Engine model:

Location of HFC4GB2.3D engine model is shown in the figure:

Engine Type

Engine Sequence

Number

Manufacture Plant

Gasoline Engine

Manufacture Year

Manual transmission model:

Location of MF70B10 transmission model is shown in the figure.

the Location Transmission print Plate Number

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Vehicle parameters:

List of Vehicle Parameters

Overall body size

	Overall length (mm)		4435
	Overall width (mm)		1725
	Overall height (mm)		1505
	Front tread (mm)		1470
	Rear tread (mm)		1460
	Wheel base (mm)		2560
	Front overhang (mm)		880
	Rear overhang (mm)		995
		Mass parameters
	No. of seats (occupants)		5
		Vehicle	1110
	Kerb mass (kg)
		Fore axle	680
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	Back axle	430
	Vehicle	1485
Gross mass (kg)	Fore axle	775
	Back axle	710

	Wheels
Size		15×5 1/2J
	Tires
Regular		185/65R15 88H

Lifting Points

Service tools:

Board on attachment

Safety stand attachment

Caution:

Make sure vehicle is empty when lifting.

Since the vehicle’s center of gravity changes when removing main parts on the nose (e.g. engine, transmission, suspension etc.), be sure to support a jack up point on the rear side garage jack with a transmission jack or equivalent.

Since the vehicle’s center of gravity changes when removing main parts on the tail (e.g. rear axle, suspension, etc.), support a jack up point on the front side garage jack with a transmission jack or equivalent.

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Be careful not to smash any circuit or do anything that would affect the piping.

Garage jack and safety stand:

Warning:

Park the vehicle on a level road before using the jack. In addition, make sure to avoid damaging important parts such as pipes etc. under the vehicle.

Never get under the vehicle while it is supported only by the jack. Use safety stands to support the vehicle when you have to get under it.

Place wheel chocks at both front and back of the wheels on the ground.

2-pole lift:

Warning:

When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced.

When setting the lift arm, do not allow it to contact the brake lines, brake cable, fuel lines and sill spoiler.

Board-on lift:

Caution:

Make sure vehicle is empty when lifting.

The board-on lift attachment set at front end of vehicle should be set on the front of the sill under the front door opening.

Position attachments at front and rear ends of board-on lift.

When towing, make sure that the transmission, steering system and power train are in good order. If any unit is damaged, dollies must be used. It is recommended that the vehicle be towed with the driving (front) wheels off the ground as shown in the above figure.

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	J4 Service Manual	General Information and
		Maintenance

Vehicle recovery (freeing a stuck vehicle):

Pull the cable straight out from the front or rear of the vehicle. Never pull on the hook at an angle.

When towing a vehicle forward, remove front spoiler. Otherwise front spoiler may be damaged by the towing equipment.

Pulling devices such as ropes or canvas straps are not recommended for use in vehicle towing or recovery.

Use towing hook only and not other components of the vehicle. Otherwise, the vehicle body will be damaged.

Use towing hook to free a vehicle stuck in sand, snow, mud, etc. only. Please do not perform long-distance towing using towing hook only.

When used for freeing a stuck vehicle, the towing hook will be subjected to a large force.

Keep away from a stuck vehicle.

Tightening Torques of Standard Bolts

Tightening Torque Table

					Tightening torque (without lubricant)
			Bolt diameter	Pitch
	Grade	Bolt size			Hexagon head bolt	Hexagon flange bolt
			mm	mm
					N·m	N·m
		M6	6.0	1.0	5.5	7
		M8	8.0	1.25	13.5	17
				1.0	13.8	17
	4T	M10	10.0	1.5	28	35
				1.25	28	35
		M12	12.0	1.75	45	55
				1.25	45	65
		M14	14.0	1.5	80	100
		M6	6.0	1.0	9	11
		M8	8.0	1.25	22	28
	7T			1.0	22	28
		M10	10.0	1.5	45	55
				1.25	45	55
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		M12	12.0	1.75	90	100
				1.25	90	100
		M14	14.0	1.5	190	170
		M6	6.0	1.0	11	13.5
		M8	8.0	1.25	28	35
				1.0	28	35
	9T	M10	10.0	1.5	55	80
				1.25	55	80
		M12	12.0	1.75	100	130
				1.25	100	130
		M14	14.0	1.5	170	210

*: Nominal diameter

1.Special parts are excluded.

2.This standard is also applicable to bolts having the following marks embossed on the bolt head.

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Nominal diameter of bolt threads (unit: mm)

Metric screw threads

Terminology

See the following chart for notes of the terms that appear in this manual:

	Terminology List
DG	Speed sensor
TF-W	Coolant temperature sensor
ZSK	Ignition coil
FPM	Accelerator pedal
ECU	Electronic control unit (commonly referred to as Computer)
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EKP	Fuel pump
EMS	Engine management system
EV	Injector
LSH	Heated oxygen sensor
KS	Knock sensor
KSZ	Fuel rail assembly
KVS	Fuel rail
PG	Phase sensor
RUV	Distributorless ignition system
TEE	Fuel pump bracket assembly
TEV	Canister control valve

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MA Maintenance

Preparation

List of Commercial Service Tools

Tool name	Description
Radiator cap tester adapter
	Connecting radiator cap tester
	to radiator cap and radiator
	filler port
	a: 28 (1.10) dia.
	b: 31.4 (1.236) dia.
	c: 41.3 (1.626) dia.
	Unit: mm
Oil filter wrench
	Removing and installing oil
	filter
Radiator cap tester
	Checking radiator and radiator
	cap
Spark plug wrench
	Removing and installing spark
	plugs

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General Maintenance

General maintenance includes those items which should be checked during the normal day-to-day operation of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform these checks themselves or have their JAC dealers do them.

Outside the vehicle:

The maintenance items listed here should be performed from time to time, unless otherwise specified.

		Item
		Check tire pressure (including spare tire) with a pressure gauge at a service station
	Tires	regularly. Adjust to the specified pressure if necessary. Check tires carefully for
		damage, cracking or excessive wear.
	Windshield	Clean the windshield on a regular basis. Check the windshield at least every six
		months for cracks or other damage. Please repair or replace as necessary.
	Windshield	Check for fracture or wear if they do not wipe properly.
	wiper blades
		Check that all doors as well as the engine hood and tail gate can be opened and
		closed normally. Also make sure that all latches lock securely. Lubricate if
	Doors and	necessary. Make sure that the secondary latch keeps the hood from opening when
		the primary latch of the engine hood is released.
	engine hood
		When always driving in areas using road salt or other corrosive materials, check
		lubrication frequently too.
	Tire rotation	Tires should be rotated every 8,000 km.
		Make sure that the headlights, fog lights, stop lights, taillights, turn signal lights,
	Lamps	and other lighting are all operating properly and fixed securely. Also check
		headlight aim.

Inside the vehicle:

		Item
	Warning lights	Make sure that all warning lights and buzzers are operating properly.
	and buzzers
	Windshield,	Check that the wipers and washer operate properly and that the wipers do not
	wipers and washer	streak.
	Windshield	Check that the air comes out of the defroster outlets properly and that air is
	defroster	sucked in sufficient quantity when operating the heater or air conditioner.
	Steering wheel	Check that it has the specified free play (<35 mm); check it for hard steering or
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		abnormal noise.
		Check that buckles, anchor bolts, adjusters and retractors of seat belts operate
	Seat belts	properly and smartly and are installed securely; check seat belts for cracking,
		fraying, wear or damage.
		Check the pedal for smooth operation and make sure it does not catch or
	Accelerator pedal	require uneven effort.
		Keep the undercover mat away from the pedal.
	Brake pedal and	Check the pedal for smooth operation and make sure it has the proper distance
		from the undercover when depressed fully. Check the brake booster function.
	booster
		Keep the undercover mat away from the pedal.

Under the hood and vehicle:

The maintenance items listed here should be checked periodically, e.g. each time you check the engine oil or refuel.

Item

	Windshield	Check that there is adequate fluid in the reservoir tank.
	washer fluid
	Engine coolant	Check the coolant level when the engine is cold.
	level
	Engine oil level	Check the level after parking the vehicle on a level ground with the engine shut
		down.
	Brake fluid level	Make sure that the brake fluid level is between the “MAX” and “MIN” lines on
		the reservoir.
	Battery	Check battery terminal condition.
		Check under the vehicle for fuel, oil, water or other fluid leaks after the vehicle
		has been parked for a while. Water dripping from the air conditioner after use is
	Fluid leaks	normal.
		If you should notice any leaks or gasoline fumes are evident, check for the cause
		and repair it immediately.

Periodic Maintenance

The periodic maintenance section lists the minimum maintenance items required to ensure trouble free operation of the vehicle roughly. Some additional maintenance items may be required depending on areas and climates. For more detailed information, please refer to your Warranty Manual.

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Recommended Oils and Lubricants

Table of Oils and Lubricants

				Recommended oils/lubricants
	Name
			L
		With oil filter	3.5		SAE 5W-30 (winter in northern areas)
		change
Engine oil
					SAE 15W-40 (year round in southern areas
drain and refill
		Without oil			and summer in northern areas), SJ quality
			3
					grade above
		filter change
		With reservoir	7.5		ELQ-L3 long life antifreeze
Cooling		tank
system
		Reservoir tank	1.9		ELQ-L3 long life antifreeze
			2.1 (Top off to		Hypoid gear oil SAE 75W~85W
Manual transmission fluid			lower edge of		API GL-4 grade above compliant
			filler)
Power steering fluid			1.1		ATF-III
Brake fluid			Just enough		DOT4
Multi-purpose grease			Just enough		No. 2 general purpose lithium base grease

*1: For detailed instructions, please refer to “SAE Viscosity Numbers”.

*2: Please use original engine coolant for JAC B-Class MPV or products of equal quality so as to avoid aluminum metal corrosion in engine cooling system caused by use of false and inferior engine coolant.

Please note that the engine cooling system damage caused by use of false and inferior engine coolant is not covered by the JAC warranty even within warranty period.

SAE viscosity number (gasoline engine):

SJ quality grade above SAE 5W-30 (winter in northern areas) and SAE 15W-40 (year round in southern areas and summer in northern areas). If 5W-30 is not available, please select the viscosity suitable for outside temperature range from the table.

Ambient temperature

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Specific gravity of engine coolant:

The engine cooling system is filled at the factory with a high-quality long life antifreeze coolant. The coolant contains special corrosion and freeze inhibitors. Therefore, additional cooling system additives are not necessary.

Caution:

When adding or replacing coolant, be sure to use only original JAC engine coolant or products of equal quality with the proper mixture ratio. Refer to the examples in the following table.

Coolant Composition Table

Outside temperature down to		Composition
℃	℉	Engine coolant (concentrate)	Distilled or demineralized water
-15	5	30﹪	70﹪
-35	-30	50﹪	50﹪

Use of other types of engine coolant solutions may damage your engine cooling system.

When checking the engine coolant mixture ratio by the coolant hydrometer, use the chart below to correct your hydrometer reading (specific gravity) according to coolant temperature.

Coolant Specific Gravity Comparison Table

			Coolant temperature ℃ (℉)
	Engine coolant mixture ratio
		15 (59)	25 (77)	35 (95)	45 (113)
	30﹪	1.046-1.050	1.042-1.046	1.038-1.042	1.033-1.038
	50﹪	1.076-1.080	1.070-1.076	1.065-1.071	1.059-1.065

Warning:

Never open the radiator cap when the engine is hot. Serious burns could be caused by high pressure fluid escaping from the radiator. Wait and do not operate until the engine and radiator cool down.

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Engine Maintenance

Checking drive belts:

Be sure to perform the following when engine is stopped.

① Check belts for cracks, wear and oil trace.	MA001
If necessary, please replace.

②Check drive belt deflection at a point on belt midway between pulleys.

Inspection should be done only when engine is cold, or over 30 minutes after engine is stopped.

When measuring the deflection, apply 100 N at the marked point.

Adjust if the belt deflection exceeds the limit.

Specified value of belt deflection: 8.3~10.4mm.

⑥Detect drive belt’s flinch degree. If there is a need, adjust it.

Specification:

Detect time
When install new belt	When check
Detect method

	Alternator drive
	belt’s flinch	5.6～6.7(mm)	8.3～10.4(mm)
	degree(Under 100N
	force)
	Alternator drive	785～981(N)	392～588(N)
	belt’s tension

Engine coolant:

The semitransparent coolant expansion tank is installed in the engine compartment. Keep the coolant level in this expansion tank between the “MIN” and “MAX” lines. Be sure to check coolant level when engine is cold.

Precautions:

When coolant of other brand is to be used, be sure to drain original coolant and clean. Hybrid use of coolants of different brands will cause damage to such components as engine and radiator.

Coolants are harmful to human health! The coolant should be kept properly in its original container and particularly out of reach of children.

Note that the expansion tank cap can not be opened during operation when engine is hot. A certain pressure exists in cooling system of a hot engine. Serious burns will be caused when hot coolant ejects.

Do not spill fluid when filling coolant. Otherwise wipe up the spillage with a cloth immediately.

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The coolant contains harmful corrosion inhibitors. Therefore, flush clean with clear water immediately if the fluid spills on your body inadvertently.

Never open radiator cap before engine cools down completely. Serious burns could be caused by high-pressure fluid spilling from radiator.

Wrap a thick cloth around radiator cap. First turn radiator cap 1/4 turn to release built-up pressure in radiator, and then screw off radiator cap all the way.

1.Changing engine coolant

Hybrid use of coolants of different brands is not allowed. When changing to a different coolant, you need to drain the original antifreeze coolant in the engine radiator and engine completely as follows:

①Remove radiator cap.

②Remove radiator drain valve (from lower left part of radiator), and drain coolant in radiator and engine water jacket.

③Remove expansion kettle and drain coolant in it.

④Loosen radiator inlet pipe clamp and pull out the pipe. Clean engine coolant lines by pouring clear water through radiator inlet until clean water is drained. Then install radiator inlet pipe and clamp it.

⑤Tighten radiator drain valve firmly.

⑥Pour coolant designated by JAC Motors in radiator slowly until it is topped off. Start engine and then liquid level in radiator should drop. Wait until radiator is filled with coolant, and then install radiator cap.

⑦Fill expansion tank with coolant until liquid level reaches line “MAX” (full).

⑧Install expansion tank cap.

⑨Start engine and warm it up until thermostat opening.

⑩After thermostat opening, run engine at full speed for several times and then shut it down; wait until engine cools down, and then fill expansion tank with engine coolant until liquid level reaches line “MAX” (full).

2.Coolant

The engine coolant contains corrosion inhibitor-ethylene glycol. The cylinder head and water pump are aluminum alloy die castings. To prevent these components from corrosion, be sure to change engine coolant regularly.

The coolant contains corrosion inhibitors, so do not replace it by light water even in summer.

Content of the required coolant varies with ambient temperature used:

Contrast Table of Coolant Content and Ambient Temperature

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3.In cold seasons

When the air temperature in the location of your vehicle drops to below 0℃, the coolant in the engine or radiator may have the risk of freezing causing serious damage to them. To prevent coolant from freezing, add sufficient quantity of coolant in it. The engine coolant filled at delivery of the vehicle has an antifreeze effect even at a low temperature of around -35℃. Before start of each cold season, check coolant content and add coolant to the system in time when necessary.

Flushing cooling system:

①Install reservoir tank and radiator drain plug if removed.

Caution:

Be sure to clean drain plug and install with new O-ring.

If water drain plugs on cylinder block are removed, please install and tighten them.

②Remove air duct component.

③Disconnect heater hose.

Raise heater hose as high as possible.

④Fill radiator and reservoir tank with water, and install radiator cap.

Disconnect when engine coolant overflows heater hose, and then reconnect heater hose and continue filling engine coolant.

⑤Install air duct component.

⑥Run engine and warm it up to normal operating temperature.

⑦Rev engine 2 or 3 times under no-load.

⑧Stop engine and wait until it cools down.

⑨Drain water from the system.

⑩Repeat steps 1~9 until clear water begins to drain from radiator.

Checking cooling system:

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When connecting radiator cap to the radiator cap tester (commercial service tool) and the radiator cap tester adapter, apply engine coolant to the cap sealing surface.

Please replace radiator cap if negative-pressure valve operates abnormally or relief pressure drops to below the limit.

3.Checking radiator

Check radiator for mud or clogging. If necessary, clean radiator as follows.

Be careful not to bend or damage radiator fins.

When radiator is cleaned without removal, please remove all surrounding parts such as cooling fan, cowl and horns. Then tape harness and electrical connectors to prevent water from entering.

①Apply water by hose to flush the back side of the radiator core vertically downward.

②Apply water to flush all radiator core surfaces once per minute.

③Stop washing if any dirt no longer flows out from radiator.

④Blow compressed air into the back side of radiator core vertically downward.

Use compressed air lower than 490 kPa and keep distance more than 30cm.

⑤Blow compressed air into all the radiator core surfaces once per minute until no water sprays out.

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Higher test pressure than specified may cause radiator damage. In a case that engine coolant decreases, replenish radiator with engine coolant.

Maximum test pressure: 157 kPa.

If any part is found damaged, repair or replace.

Checking fuel lines

Check fuel lines, filler cap and tank for improper attachment, leaks, cracks, damage, loose connections, wear or aging. If necessary, please repair or replace damaged parts.

Changing engine oil:

Warning!

Be careful not to burn yourself, as engine oil may be hot.

Prolonged and repeated contact with used engine oil may cause skin cancer; therefore, avoid direct skin contact with used engine oil. If skin contact is made, wash thoroughly with soap or cleanser as soon as possible.

①Warm up the engine, and check for oil leakage from engine room.

②Stop the engine and wait for 10 minutes.

③Loosen filler cap, and then remove drain plug.

④Drain engine oil.

⑤Install drain plug with new washer.

Caution:

Be sure to clean drain plug and install with new washer.

⑥Refill with fresh engine oil.

Caution:

When filling engine oil, do not pull out oil level gauge.

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The refill capacity depends on the engine oil temperature and drain time.

Always use oil level gauge to check for proper engine oil refill capacity.

⑦Pull out the engine oil dipstick from the engine. Check whether the engine oil level is at MAX and MIN.

⑧Warm up the engine and check area around drain plug and oil filter for engine oil leakage.

⑨Check if the oil level is within the normal range.

⑩Stop the engine and wait for 10 minutes. Check whether the engine oil level is normal.

Chassis and body maintenance

Checking exhaust system:

Check exhaust pipes, muffler and mounting brackets for improper positions, cracks, damage, loose connections or wear; if any part is found damaged, please repair or replace.

Transmission:

Both poor lubricant quality and lubricant excess or lack will affect normal operation and service life of the manual transmission. Use gear oil SAE 75W~85W as the manual transmission fluid. Check oil volume as follows:

①Check oil volume after vehicle driving with transmission still hot.

②When checking, be sure to park your vehicle on a flat, level and good ground and set parking brake. Do not proceed with the next operation until making sure the vehicle has come to a full stop.

③Set shift lever to neutral position.

④Screw off filler plug at left side of transmission and wipe up filler with a clean cotton cloth. Check that the fluid level is within the range from lower edge of filler to not lower than 5mm from the lower edge.

⑤If the fluid is found dilute, gumming or too dirty, change immediately.

Caution:

Do not spill fluid when filling. Otherwise wipe clean the spillage immediately.

■Hybrid use of gear oils of different brands will damage transmission. Be sure to use the designated hypoid gear oil SAE 75W~85W (API GL-4 grade above compliant).

Brake system:

Check brake fluid level in reservoir tank. The level must be between the “MIN” and “MAX” lines on the tank. Brake fluid level will slightly drop when brake pad is worn.

If brake fluid level drops significantly in a short period of time, it indicates oil leaks in

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brake system. If this occurs, immediately drive to a JAC approved service station to have your vehicle serviced.

Use DOT 4 brake fluid. Brake fluids are water absorbing liquids. Braking performance will be reduced if the brake fluid contains excessive moisture. In addition, the brake fluid cup is provided with a special sealing gland in order to prevent air entry. This gland can not be removed at will.

Brake fluid level is monitored by a float. When brake fluid level drops to below the “MIN” line, the brake fluid warning light will come on.

1.Changing brake fluid

The brake fluid can absorb moisture, so it will absorb the moisture in the surrounding air as time elapses. However, excessive water content in the brake fluid could cause corrosion damage to the brake system. In addition, boiling point of the brake fluid will drop significantly. Therefore, be sure to change the brake fluid every 2 years.

Caution:

If the brake fluid has been used for an extended period of time, bubbles will be produced in the brake system under extremely high braking load, thus impairing braking efficiency and driving safety seriously.

Use DOT 4 brake fluid approved by JAC only at brake fluid change. In addition, it is required that brake lines be cleaned thoroughly. Ensure hybrid use of 2 types of brake fluid will not occur.

Caution:

Brake fluids are harmful to human health! Therefore, the coolant should be kept properly in its original sealed container and particularly out of reach of children. In addition, take care to prevent brake fluid from corroding automobile finish.

Pay attention to disposal of brake fluid. It will impair both eyes and skin and spray-painted surfaces. Flush clean with clear water immediately if the fluid spills on your body inadvertently.

Be sure to keep brake fluid cup clean. Its gland must be tightened to prevent dirt entry.

When filling brake fluid, wipe clean brake fluid cup gland and filler with a clean rag first and then refill with designated clean brake fluid.

If the brake fluid is found deteriorated, drain the fluid in brake system and then refill with clean designated brake fluid.

2.Checking brake lines and cables

Check brake lines and parking brake cables for improper positions, leaks, wear, chafing and aging, etc.

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1)Check gear housing and boots for looseness, damage and grease leakage.

2)Check connection with steering column for looseness.

Steering linkage:

Check ball joint, dust boots and other parts for looseness, wear, damage and grease leakage.

Checking power steering fluid and lines:

Power steering fluid:

Check power steering fluid level in reservoir tank with engine idling.

Check power steering fluid level in reservoir tank. The level must be between the “MIN” and “MAX” lines on the tank.

Tires:

For safe driving of your vehicle, type and size of tires must be suitable for the vehicle model; in addition, tire treads must be in good condition and appropriate tire pressures must be provided.

The way to service tires and the method for tire replacement are described below.

Warning!

Use of excessively worn or under inflated tires will cause accidents resulting in personal injury or death.

All instruction regarding tire inflation and maintenance in the Operation Manual must be observed.

Overview of inflation:

Keeping tires properly inflated provides the best combination of steerability, tread life and driving comfort.

Underinflation may cause uneven wear of tires and affect steerability and fuel consumption, and much more likely result in air leaks due to overheating.

Overinflated tires will make your ride in the vehicle uncomfortable, are more likely to be damaged by rugged roads, and are subjected to uneven wear.

Measure tire pressure with a tire gauge at least monthly. Even pressure of a tire in good condition may decrease by 10~20KPa (0.1~0.2kgf/cm2) per month. Also check spare tire each time all tires are checked.

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Measure tire pressure when tires are cold. This means that the measurement should be made after your vehicle has been parked for at least 3 hours or when travel distance does not exceed 1.6km. If necessary, inflate or deflate tires until their tire pressures reach the value recommended for cold tires in the name plate on driver side door frame.

When pressure of a tire is checked when hot (after a travel of several kilometers), the reading will be 30~40KPa (0.3~0.4kgf/cm2) higher than that when cold, which is normal. Do not deflate the tire in order to reach the specified cold tire pressure reading, otherwise tire underpressure will result.

When a tubeless tire is punctured, its self-seal function will be activated. If pressure of a tire starts to drop, locate air leak carefully.

Checking tires:

Also check tires for wounds, punctures by foreign materials and other abrasions at each tire inflation check.

Damage and bulge on tread or sidewall. If any is found, replace the tire.

Scratch, crack or fracture on sidewall. If tire fabric or cord can be seen, replace the tire.

Excessive tread wear.

Servicing tires:

In addition to proper inflation, correct wheel alignment also helps reduce tread wear. If uneven tire wear is found, check wheel alignment.

If some kind of continuous vibration is felt during driving, check tires. Perform tire balance as long as a tire has ever been removed from its wheel. When installing a new tire, be sure to perform tire balance. This can increase ride comfort and prolong tire life.

Caution:

Inappropriate wheel balance weights will damage aluminum alloy wheels. Therefore, use original wheel balance weights of JAC to keep wheels balanced only.

please refer to the figure at right.

Replacing tires and wheels:

Select radial ply tires of same size, load range, rated speed and maximum cold pressure (marked on sidewall) for replacement.

Hybrid use of radial ply tires and bias ply tires will reduce braking capacity, driving force (ground adhesion) and steering precision of your vehicle.

Warning!

Installing with unsuitable tires will affect steering mobility and stability of your vehicle and may result in accidents, causing casualty.

Always use the tires of the recommended size and type indicated in the tire name plate affixed to the vehicle.

For size of the tires applicable to this vehicle, please refer to the tire name plate affixed to driver side door frame or consult a JAC authorized after service shop.

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