Removal of sealant:

After removing mounting nuts and bolts, separate the mating surface using the seal cutter and remove old sealant.

Be careful not to damage the mating surfaces.

Insert the cutter, and then slide it by tapping on the side as shown in the figure.

In areas where the seal cutter is difficult to use, please use a plastic hammer to lightly tap the parts to remove it.

If for some unavoidable reason tool such as a screwdriver is used, please be careful not to damage the mating surfaces.

Sealant application procedure:

Using a scraper, remove old sealant adhering to the application surface and the mating surface.

Remove sealant completely from the groove of the sealant application surface, mounting bolts, and bolt holes.

Wipe the sealant application surface and the mating surface with unleaded gasoline to remove adhering moisture, grease and foreign materials.

Apply sealant without breaks to the specified location with the specified dimensions.

EM001

JAC-T1F017

Slide

Knock

EM002

Scraper

EM003

2.Remove upper cover latch of air cleaner.

3.Remove intake hose, and take off air cleaner upper cover and intake hose.

4.Remove 3 bolts securing air cleaner base, and take off the base.

Tightening torque: 8~12 N·m

EM005

Checking and changing air cleaner element: Removal:

1.Loosen locking clip of air cleaner upper cover, and lift the cover.

EM006

2.Remove air cleaner element.

Inspection after removal:

Be sure to clean or replace air cleaner element regularly at recommended intervals.

Blow compressed air into back side of air cleaner element until clean air is blown out.

Installation:

Install in the reverse order of removal.

EM007

EM008

Exhaust Manifold and Three Way Catalyst Exhaust manifold removal:

Removal procedure:

1.Loosen 4 bolts securing exhaust manifold cover, and take off the cover.

2.Loosen bolt securing exhaust front tube to front catalyst, and disconnect the tube.

3.Disconnect harness connectors of front and rear oxygen sensors.

4. Loosen bolts securing exhaust manifold to cylinder block, and take off exhaust manifold and gasket.

5.Checking exhaust system

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EM010

EM011

Ignition Coil and Spark Plug

Removal:

Caution:

Make sure ignition switch is in ―OFF‖ position.

1.Disconnect negative battery terminal.

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2.Screw off 4 bolts securing middle cover, and take off the cover.

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3.Disconnect wire connector from ignition coil assembly.

4.Screw off 2 bolts securing ignition coil, and take out ignition coil.

5.Disconnect secondary cable from ignition coil.

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Check spark plug gap with a feeler gauge. Standard gap: 1.0~1.1mm

If the gap exceeds the standard value, please replace.

Check spark plug electrode surface for fouling. If necessary, please clean with a spark plug cleaner. Cleaner air pressure <588kpa; cleaning time <20 seconds

EM015

1)Releasing fuel pressure in fuel piping:

①Turn ignition switch to ―OFF‖ position, and remove battery negative (-).

②Open fuel tank cap.

③Put a thick rag or towel on test port of fuel rail, and depress needle valve to release pressure.

2)Disconnect intake manifold side PCV hose connector.

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EM017

3)Disconnect harness connectors of MAP sensor and fuel injector.

4)Disconnect throttle body side accelerator cable and cable holder.

EM018

Check fuel injector nozzle opening for clogging. If any, please use special apparatuses to clean or replace.

Standard value:

Working pressure: 350 kPa

Fuel injector resistance: 11~16Ω

Working temperature: -40~130℃

2)Fuel rail

EM019

Caution:

Upper and lower O-rings are different. Please do not confuse them.

Fuel tube side: thick

Nozzle side: thin

Please install O-ring with bare hands.

Lubricate O-ring with gasoline.

Please do not clean O-ring with solvent.

EM020

Removal:

Timing belt and sheave removal:

1.Loosen sheave bolt.

2.Remove sheave.

3.If timing belt is to be reused, draw an arrow on it with a marker pen to indicate its direction of rotation before

removal. This can ensure proper installation of timing belt during reuse.

EM021

Camshaft timing gear bolt removal:

1.Use the special tool shown in the figure to lock camshaft timing gear to corresponding position.

2.Unscrew camshaft timing gear bolt.

Timing belt inspection after removal:

EM022

2.Cracks occur on back-side rubber surface.

3.Canvas is torn (or separated from rubber).

4.Cracks occur at tooth root.

5.Cracks occur at side face of belt.

6.Abnormal wear occurs on side face of belt.

Caution:

Side face of belt is normal if it is knife-cut sharp.

Separation

Crack side

Cracked tooth root

7.Tooth is worn abnormally. Initial stage:

Canvas fibers are slack; rubber structure disappears; white fade occurs; canvas structure is difficult to identify.

Final stage:

Canvas is worn to expose rubber (tooth width decreases).

8. Tooth has disappeared.

EM025

Canvas wear causing rubber exposed

Toothless

Sheave:

Check if pulley rotates smoothly without play and abnormal noise. If necessary, replace.

1.Align marks (blue dot marks).

2.Align timing mark on crankshaft timing gear with that on front housing.

3.Install timing belt into crankshaft timing gear, water pump pulley, idler pulley, camshaft timing gear and sheave pulley in turn.

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EM027

Inspection after removal:

Checking camshaft:

1.Measure cam height. If the height exceeds the specified limit value, replace camshaft.

2.Service limit value of camshaft height: Intake: 34.87 mm

Exhaust: 34.41 mm

Installation:

Hydraulic tappet installation:

EM028

Tips for air bleeding:

Put a single hydraulic tappet in light oil. Depress the steel ball in the tappet lightly with a hard wire while pressing ball head of the tappet 4~5 times to set the tappet to its maximum stroke.

Caution:

Hard wire

Light oil

Troubleshooting:

1.Warm up for 1~3 minutes with engine idling.

2.Operate in the mode (30s per cycle) as shown in the figure at right.

Throttle opens slowly

Throttle closed

Idle edge

15 15

seconds seconds

1 cycle

Hydraulic tappet exhaust operation mode

Use the special tool shown in the figure to drive oil seal into cylinder head.

EM031

Rocker arm chamber cover installation:

Order of tightening: Tighten in the order shown in the figure.

Tightening torque: 3~4N·m

Tightening method: After tightening them for 2 times in the order shown in the figure above, retighten the bolts with SNs 1, 2, 3, and 4.

EM032

Oil seal

Crankshaft front oil seal removal:

1.Run engine until timing mark on camshaft timing gear and that on cylinder head are aligned.

2.Turn crankshaft clockwise until timing mark on crankshaft timing gear and that on front housing are aligned.

3.Unscrew sheave bolt, and remove timing belt.

4.Using special tool, remove crankshaft timing gear.

5.Take out front oil seal with a suitable tool as shown.

EM033

EM034

EM035

Crankshaft rear oil seal removal:

1.Using the special tool shown in the figure, lock flywheel to corresponding position, and then screw off bolt securing flywheel and remove flywheel.

2.Pry off crankshaft rear oil seal from cylinder block with a flat head screwdriver gently. In addition, be careful not to leave any scratches on crankshaft sealing surface.

Installation:

1.Clean oil seal groove on cylinder block and working surface on crankshaft. Ensure that these surfaces are thoroughly clean without residual sealant and are dry.

2.Apply a little engine oil to oil seal lip and dust seal lip of oil seal retainer.

EM038

EM039

3.Apply 1.5mm sealant to new oil seal. Use the oil seal installer to press the oil seal into cylinder block quickly and stay there for 1 minute. Before turning crankshaft or topping up engine oil, allow at least 30 minutes for sealant to flow into and fill the device.

4.Remove oil seal installer, and install flywheel.

Camshaft oil seal removal and installation:

Removal:

1.Run engine until timing mark on camshaft timing gear and that on cylinder head are aligned.

2Turn crankshaft clockwise until timing mark on crankshaft timing gear and that on front housing are aligned.

Oil seal installation

EM041

3.Unscrew sheave bolt, and remove timing belt.

4.Use the special tool shown in the figure to lock camshaft timing gear to corresponding position.

5.Screw off nut securing camshaft timing gear, and remove the gear.

6.Wrap head of flat head screwdriver with a piece of rag, insert the screwdriver into notch groove on oil seal, and pry oil seal to take it off slowly.

EM-29

EM042

EM043

Removal:

Cylinder head bolts removal:

Unscrew cylinder head bolts using the tool shown in the figure.

Collet removal:

Tie labels to remove valves, springs and other parts to indicate their cylinder numbers and locations for easier reassembly. Store these parts securely.

Valve oil seal removal:

Valve oil seal is non-reusable part which can not be reused after removal.

Inspection after removal:

Cylinder head:

1.Before cleaning cylinder head, check it for water leak, air leak, cracks, and other damages.

2.Clear all engine oil, scale, sealant and carbon deposit. After cleaning oil passage, blow compressed air into it to make sure it is not clogged.

EM045

EM047

EM048

2.If margin thickness is less than the specified value, replace valve.

Exhaust valve: 1.7mm Exhaust valve: 1.2mm

1.Measure free height of valve spring. If the measurement is less than the specified value, replace valve spring.

Standard value: 45.0 mm

Limit value: 44.5 mm

2.Measure valve spring squareness. If the measurement exceeds the specified limit value, replace valve spring.

Standard value: 2°

Limit value: 4°

Valve guide:

1 Measure valve guide to stem clearance.

2.If the specified limit value is exceeded, replace either part or both parts.

Standard value:

Intake valve guide: 0.020-0.047mm

Exhaust valve guide: 0.035-0.062mm

Perpendicular

alignment

Free height

EM051

Valve guide

Outside diameter of valve stem

Inside diameter of valve guide

Limit value:

Intake valve guide: 0.10mm

Exhaust valve guide: 0.15mm

Valve seat:

Install valve, and then measure valve protrusion height between valve stem end face and valve spring seat surface. If the measurement exceeds the specified limit value, replace valve seat.

Protrusion height of valve

Valve spring retainer face

Operation tips for valve seat replacement:

1.To reduce wall thickness, cut off the valve seat to be replaced from its inside and then remove valve seat.

2.Rebore valve seat hole on cylinder head until it matches the selected valve seat of increased diameter.

EM054

Cut off

3.Before press-fitting, prevent valve seat cooled by liquid nitrogen from chafing cylinder head hole.

4.Reface valve seat until the specified width and angle. (Refer to operation tips for valve seat refacing).

Valve height

Increased hole bore

Operation tips for valve guide replacement:

1.Drive out valve guide with a press towards cylinder block side.

2.Rebore valve guide hole on cylinder head until it matches the oversized valve guide to be installed.

EM056

Protrusion

height

Installation:

Valve oil seal installation:

1.Install valve spring seat first.

2.Then install new valve oil seal using the special tool shown in the figure.

Caution:

Valve oil seal can not be reused.

Valve oil seal must be installed using proper special tool. Improper installation may result in oil leak from valve guide.

Valve spring installation:

When installing valve spring, position its painted end to rocker arm side.

Collet installation:

1.Install valve spring collet using the special tool shown in the figure.

2.If valve spring is over compressed, bottom end of collet will contact it, causing damage to valve stem seal.

Cylinder head bolts installation:

1.Before reusing a cylinder head bolt, check if its length exceeds the specified limit value. If the measurement exceeds the limit value, replace this bolt.

Limit value: 96.4 mm

2.Install washer as shown in the figure.

3.Apply engine oil to washer on threaded portion of bolt.

EM057

Valve stem oil

seal

Valve spring

retainer

4.Tighten bolts in the order shown in the figure until torque of each bolt is 20±2N·m.

5.Tighten each bolt for another 180° sequentially.

6.Unscrew bolts completely.

Timing belt side

Inspection after removal:

Crankshaft clearance:

Crankshaft clearance can be measured easily with a plastigage. Follow the procedure below to measure crankshaft clearance using plastigage.

1.Wipe off all engine oil from crankshaft journal and bearing inner surface.

2.Install bearing.

3.Cut plastigage so that its length matches bearing width. Then put it on journal along axial direction of journal.

4.Install crankshaft bearing shell cover gently, and tighten bolts to the specified torque.

5.Remove bolts, and remove crankshaft bearing shell cover gently.

6.Measure squeezed part on plastigage at the widest point using the scale printed on plastigage bag.

Standard value: 0.015-0.048mm

Limit value: 0.1mm

Caution:

Both connecting rod journal and main journal of crankshaft are rolled and need not to be machined to reduced sizes.

Cylinder block

1.Inspect for cracks, rust and corrosion visually and check cylinder block using defect inspection agent. Repair defects as far as possible or replace cylinder block.

2.Keep top surface free of gasket debris and other foreign materials. Check for cylinder block top surface distortion using straightedge and feeler gauge.

Standard value: <0.03mm

Limit value: <0.1mm

EM-38

Plastigage

Plastigage

Fillet rolling area

Feeler gauge

No. 5 main journal No. 4 main journal No. 3 main journal No. 2 main journal No. 1 main journal

Grade mark of crank journal

GradeMark

2.Identification mark of bearing shell bore is stamped at the position as shown.

Be sure to select and install bearings according to these identification marks.

3.Select bearing shell from above table based on identification mark check in steps 1 and 2.

See the following example:

a.If the measured journal is 50.000mm, it corresponds to the first grade in above table.

b.If the identification mark on bearing shell bore on cylinder block is 1, select a bearing shell with identification mark 2.

4.All bearing shell upper halves are grooved; all bearing shell lower halves are grooveless.

Bearing cap installation:

EM068

GroovelessGrooved

Main bearing shell lower half (No. 1, No. 2, No. 3, No. 4, No. 5)

Main bearing shell upper half (No. 1, No. 2, No. 3, No. 4, No. 5)

2.After installing main bearing shell, measure axial clearance of crankshaft. If the measurement exceeds the specified limit value, replace crankshaft bearing shell.

Standard value: 0.05-0.25mm

Dial indicator

Measure axial clearance of crankshaft.

Caution:

Also install thrust plate while installing intermediate main bearing shell. When installing, please pay attention to installation direction of thrust plate.

Crankshaft gasket installation:

Install crankshaft gasket with its chamfered side facing flywheel side (as shown in the figure).

Piston and connecting rod:

EM071

Leave this fillet forward

Crankshaft gasket

Crankshaft

Connecting rod cap removal:

Cylinder number is stamped on side face of connecting rod big end for easier reinstallation.

Cylinder number

Piston pin removal:

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

2.Install piston and connecting rod assembly onto piston pin mount set (special tool) with front mark on piston upward.

3.Drive out piston pin with a press.

Caution:

After piston pin is removed, put piston, piston pin and connecting rod together. Do not put pistons, piston pins and connecting rods of cylinders together with them mixing up.

EM073

Push rod

Piston pin

Mark of front

Mark of

front

Guide sleeve A

Base

Guide sleeve B

Inspection after removal:

Piston rings:

1.Check piston ring side clearance. If the clearance exceeds the specified limit value, replace piston ring or piston or both.

Standard value:

Top ring: 0.03-0.07mm

Second ring: 0.02-0.06mm

Limit value:

Top ring: 0.1mm

Second ring: 0.1mm

2.Put piston rings in cylinder bore, and push them down using piston. Ensure that piston top comes into contact with piston rings and that rings are perpendicular to cylinder wall. Then measure the piston ring end gap with a feeler gauge. If the end gap is too large, replace piston ring.

Standard value:

Top ring: 0.25-0.40mm

Second ring: 0.40-0.55mm

Oil ring: 0.10-0.35mm

Limit value:

Top ring: 0.8mm

Second ring: 0.8mm

Oil ring: 1.0mm

Connecting rod bearing shell clearance (plastigage method):

1.Wipe off all engine oil from connecting rod journal and connecting rod bearing shell.

2.Put a plastigage cut to a length equal to bearing shell width on connecting rod journal. Plastigage must be placed at center of connecting rod journal and is parallel to axis of the journal.

Feeler gauge

Push in together with piston

Piston ring Gap clearance

Contrast scale

Plastic ruler

3.Place connecting rod cap in position gently and tighten bolts to the specified torque.

4.Remove bolts, and remove connecting rod cap slowly.

5.Measure squeezed part on plastigage at the widest point using the scale printed on plastigage bag.

Standard value: 0.015-0.048mm

Limit value: 0.1mm

Installation:

Piston pin installation:

1.Measure the following lengths (as shown in the figure).

①Piston boss to piston boss outside dimension

②Piston boss to piston boss inside dimension

③Piston pin length

④Connecting rod small end thickness

2Incorporate measured value into the following formula:

L= ( A − C) − (B − D) 2

3.Insert a push rod (special tool) into piston pin, and then install guide A (special tool).

4.When installing piston and connecting rod, ensure that their front marks are at the same side.

5.Apply engine oil to external circle of piston pin.

6.Start with guide A. Press guide A, piston pin and push rod into front mark side of piston in turn.

EM-45

Connecting rod

Piston pin

Piston

7.Screw guide B into guide A. The clearance between the 2 guides is 3mm plus the L value calculated in step 2.

8.Install piston and connecting rod onto piston pin mount set with front mark on piston downward.

9.Install piston pin with a press. If press-fit load exceeds the specified value, replace piston pin and piston assembly and connecting rod or both.

Standard value: 1000±500 kg/cm2

Mark of front

Push rod

Piston pin

Mark of front

Guide sleeve A

Base

Guide sleeve B

Oil ring installation:

1.Install oil ring spacer into piston ring groove.

2.Then install top and bottom steel rings.

Steel ring

Space ring

Caution:

Installation positions of spacer and steel rings are shown in the figure. Top and bottom steel rings are same.

3.When installing a steel ring, as shown in the figure, install its one end into the groove by hand and then press the rest of it in place.

EM-46

4.After steel rings are installed, check if they can move smoothly in both directions.

Second piston ring/top piston ring installation:

Using piston ring expander, install second and top piston rings with their identification marks upward (on piston top side).

Identification mark:

Top piston ring: Manufacturer ID 1

Second piston ring: Manufacturer ID 2

Piston ring expander

Identification mark ―manufacturer ID 1‖

Top ring

2nd ring

Piston and connecting rod assembly installation:

1.Apply engine oil to piston, piston rings and piston pin. As shown in the figure, align gaps of gas rings and oil rings (steel rings and spacers).

2.Press piston and connecting rod assembly into cylinder with front arrow on piston top facing timing belt side.

EM086

Connecting rod cap installation:

1.Install connecting rod bearing cap onto connecting rod, aligning the marks mad at disassembly. In the case of a new connecting rod (without mark), ensure that bearing shell lock gaps are at the same side.

EM088

Install with mark ―93‖ forward

2.Check if connecting rod big end side clearance is within specification.

Standard value: 0.10-0.25mm

EM-49

Feeler gauge

Connecting rod nut installation: Caution:

If cylinder head has been installed before connecting rod nut installation, spark plugs must be removed first. Connecting rod bolts and nuts are tightened by means of plastic deformation tension. When a bolt is to be reused, be sure to check it for scratches.

Paint mark

Paint mark

Nut Bolt

Oil Pan and Oil Strainer

Removal:

1.Remove mounting bolts of oil pan.

2.As shown in the figure, drive the special tool in between oil pan and cylinder block.

3.Tap side face of special tool to move the tool along sealing surface of oil pan and cylinder block, and then remove oil pan.

EM093

Caution:

If the gasket is installed in wrong direction, oil leak may result.

2.The required torque for drain plug is 33~35N·m. Under torque will result in loose plug; over torque may cause damage to oil pan threads.

Oil pan side

Installation positions of components: They are mounted on PCV valve body.

Positive crankcase ventilation (PCV) inspection:

1.Remove breather hose from PCV valve.

2.Remove PCV valve from cylinder head cover.

3.Then install PCV valve onto breather hose.

4.Start engine and run it under idle speed.

EM-52

EM095

Positive crankcase ventilation valve

PCV valve inspection:

1.Insert a thin rod into PCV valve from the side shown in the figure (installation side of rocker arm cover), and move this rod back and forth to make sure the plunger is moving.

2.If plunger is stationary, it indicates internal clogging of PCV valve. In such a case, clean or replace this valve.

EM096

Positive crankcase ventilation valve

①Install hangers onto engine lifting hooks.

②Lift engine and secure it in position.

③Use a manual lift table caddy or equivalent tool to securely support bottom of engine and transmission assembly, and simultaneously adjust hoist tension.

Caution:

EM097