J5 AT Service Manual
Engine-Contents
1
Engine
General Information and Maintenance .......................
GI-1
GI General Information ........................................
GI-1
Precautions .........................................................................................
GI-1
How to Use This Manual ...................................................................
GI-6
Model Identification Information ......................................................
GI-7
Lifting Points .....................................................................................
GI-12
Tow Truck Towing .............................................................................
GI-13
Tightening Torques of Standard Bolts ...............................................
GI-14
Terminology .......................................................................................
GI-15
MA Maintenance .................................................................
MA-1
Preparation .........................................................................................
MA-1
General Maintenance .........................................................................
MA-2
Periodic Maintenance.........................................................................
MA-3
Recommended Oils and Lubricants ...................................................
MA-4
Engine Maintenance...........................................................................
MA-6
Chassis and Body Maintenance .........................................................
MA-11
Engine ..............................................................................
EM-1
EM Engine Mechanical ......................................................
EM-1
Precautions .........................................................................................
EM-1
Preparation .........................................................................................
EM-3
Engine Structure Overview ................................................................
EM-6
Drive Belts .........................................................................................
EM-8
Air Cleaner and Air Duct ...................................................................
EM-10
Intake Manifold ..................................................................................
EM-12
Exhaust Manifold and Three Way Catalyst .......................................
EM-14
Ignition Coil and Spark Plug..............................................................
EM-15
J5 AT Service Manual
Engine-Contents
2
Fuel Injector and Fuel Rail ................................................................
EM-17
Timing Belt ........................................................................................
EM-21
Camshaft and Rocker Arm .................................................................
EM-24
Oil Seal...............................................................................................
EM-27
Cylinder Head and Valves ..................................................................
EM-30
Cylinder Block and Crankshaft ..........................................................
EM-37
Oil Pan and Oil Strainer .....................................................................
EM-50
Positive Crankcase Ventilation ..........................................................
EM-52
Engine Assembly Removal and Installation ......................................
EM-53
Trouble Diagnosis ..............................................................................
EM-56
Service Data and Specifications .........................................................
EM-59
LU Lubrication System ........................................................
LU-1
Precautions .........................................................................................
LU-1
Preparation .........................................................................................
LU-1
Engine Oil ..........................................................................................
LU-2
Oil Filter .............................................................................................
LU-4
Oil Pump ............................................................................................
LU-6
Service Data and Specifications .........................................................
LU-8
CO Cooling System ...............................................................
CO-1
Precautions .........................................................................................
CO-1
Preparation .........................................................................................
CO-2
Cooling System Circuit ......................................................................
CO-3
Engine Coolant...................................................................................
CO-4
Radiator ..............................................................................................
CO-6
Cooling Fan ........................................................................................
CO-8
Water Pump ........................................................................................
CO-9
Water Inlet and Thermostat Assembly ...............................................
CO-10
Water Outlet and Water Piping ..........................................................
CO-12
Trouble Diagnosis ..............................................................................
CO-13
J5 AT Service Manual
Engine-Contents
3
Service Data and Specifications .........................................................
CO-15
FL Fuel System ......................................................................
FL-1
Precautions .........................................................................................
FL-1
Preparation .........................................................................................
FL-2
Fuel System Composition ..................................................................
FL-2
Fuel Injector and Fuel Rail ................................................................
FL-3
Fuel Filter ...........................................................................................
FL-4
Feed Pipe Assembly and Vapor Pipe Assembly .................................
FL-6
Fuel Level and Sensor Unit................................................................
FL-6
Fuel Tank ............................................................................................
FL-9
Fuel Pump ..........................................................................................
FL-9
Fuel Evaporative Emission System ...................................................
FL-12
Trouble Diagnosis ..............................................................................
FL-14
Service Data and Specifications .........................................................
FL-15
ACC Accelerator Control System ........................................
ACC-1
Accelerator Control Unit....................................................................
ACC-1
Service Data and Specifications .........................................................
ACC-2
EC Engine Control System ..................................................
EC-1
Precautions .........................................................................................
EC-1
Preparation .........................................................................................
EC-2
Engine Control System Overview .....................................................
EC-3
Engine Control System Components .................................................
EC-9
On-Board Diagnostic (OBD) System ................................................
EC-25
Trouble Diagnosis ..............................................................................
EC-29
Service Data and Specifications .........................................................
EC-85
CL005
J5 AT Service Manual
GI-1
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.
General precautions:
Do not operate the engine for an
extended period of time without proper
exhaust ventilation. Keep the work
environment well ventilated and away
from any inflammable materials. Special
care should be taken when handling any
inflammable or poisonous materials,
such as gasoline, refrigerant, natural gas,
etc. When working in a pit or other
enclosed room, ensure the working place
is ventilated well before handling any
hazardous materials. Do not smoke while
working on the vehicle.
GI001
J5 AT Service Manual
GI-2
Before jacking up the vehicle, put wheel
chocks or other tire blocks under the
wheels to prevent the vehicle from
moving. After jacking up the vehicle,
support the vehicle weight with safety
stands at the points designated for proper
lifting before working on the vehicle.
This operation should be done on a level
ground.
When removing a heavy component such
as the engine or transmission, please do
not waggle it using excessive force in
order to disconnect it. Also, do not allow
them to strike adjacent parts, especially
the brake pipes and master cylinder.
Before starting repairs which do not
require battery power: Turn off ignition
switch and disconnect the negative
battery terminal.
If the terminal is disconnected, memory
in the control module will be cleared.
To prevent scalds: Avoid contact with hot
metal parts. Do not remove the radiator
cap when the engine is hot.
Dispose of drained oil or the solvent
used for cleaning parts in an appropriate
manner.
Clean all removed parts in the designated
liquid or solvent prior to inspection and
assembly.
Replace oil seals, gaskets, packings,
O-rings, locking washers, cotter pins,
self-locking nuts, etc. with new ones.
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
components.
GI005
GI004
GI003
GI002
Battery
J5 AT Service Manual
GI-3
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.
Before repairing the vehicle:
① Protect fenders, upholstery and
carpeting with appropriate covers.
② Be careful not to allow things like keys
and buttons to scratch paintwork.
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 4G93D DL 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
emission control equipment and system, and could also affect the warranty
coverage validity.
Seat cover
Fender pad
J5 AT Service Manual
GI-4
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:
① Turn ignition switch to “OFF” position.
② Disconnect 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.
Precautions for hoses:
1. Hose removal and installation
To prevent damage to a rubber hose, do
not pry off it with pointed tool or
screwdriver.
To fix the rubber hose securely, make
sure that hose insertion length is
adequate and clamp position is correct.
(If metal tube is equipped with hose
stopper, insert hose into tube until it
butts up against hose stopper.)
2. Hose clamp
If old rubber hose is reused, install hose
clamp in its original position (at the
indentation where the old clamp was). If
there is a trace of metal tube bulging left
on the old rubber hose, align rubber
hose at that position.
Discard old clamps; be sure to replace
with new ones.
GI009
GI008
GI007
Do not scratch tube
Insert hose to here
Hose stopper
Trace of clamping
Bulge
Tube
Hose
J5 AT Service Manual
GI-5
After installing plate clamps, apply
force to them in the direction of the
arrow in the figure, clamping rubber
hose equally.
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
water sources; the laws and regulations concerning pollution vary between regions.
GI010
Depress for better fitting
Plate clamp
J5 AT Service Manual
GI-6
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
mark.
J5 AT Service Manual
GI-7
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
B-Class MPV
4G93D DL
F5M41-G6
Vehicle identification number (VIN):
1) Vehicle identification number (VIN) location: On name plate or at lower left
corner of windshield.
J5 AT Service Manual
GI-8
2) Vehicle identification number description
① The 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
② The 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:
A number
Digit capacity
Geographic region
Country
Maker
Vehicle feature code
Serial number
Assembly plant
Check digit
Year
A letter or number
Vehicle type
Digit capacity
Check digit
Engine type/rated power
Wheel base of truck/length of passenger
vehicle, bus and chassis
Maximum total mass
Body type
J5 AT Service Manual
GI-9
① Vehicle type: 2 represents passenger vehicle.
F: 3-box 4-door
② Body type
G: 2-box 5-door
③ Maximum total mass: K: >1000~2000
④ Wheel 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.
4: Passenger vehicle manufacturer/car plant/general assembly
shop/assembly plant
Assembly plant
7: Commercial vehicle manufacturer/general assembly shop of
commercial vehicles
8: 2008
Year 9: 2009
A: 2010
Year
Digit capacity
Production SN
Name of assembly
plant
J5 AT Service Manual
GI-10
Engine model:
Location of 4G93D DL engine model is shown in the figure:
Manual transmission model:
Location of F5M41-G6 transmission model
is shown in the figure.
GI012
GI011
Engine model
Engine serial number
Rear view of cylinder block
J5 AT Service Manual
GI-11
Vehicle parameters:
List of Vehicle Parameters
Overall body size
Overall length (mm)
4550
Overall width (mm)
1775
Overall height (mm)
1660
Front tread (mm)
1505
Rear tread (mm)
1495
Wheel base (mm)
2710
Front overhang (mm)
940
Rear overhang (mm)
900
Mass parameters
No. of seats (occupants)
5/7
Kerb mass (kg)
Vehicle
1450
Fore axle
850
Back axle
600
Gross mass (kg)
Vehicle
1920
Fore axle
920
Back axle
1000
Wheels
Size
16×6 1/2J
Tires
Regular
205/55R16 91V
Spare tire
J5 AT Service Manual
GI-12
Lifting Points
Service tools:
Tool name
Description
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.
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.
J5 AT Service Manual
GI-13
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.
Tow Truck Towing
Caution:
All applicable local laws regarding the
towing operation must be obeyed.
Be sure to use proper towing equipment
to avoid possible damage to the vehicle
during towing operation. For more
details regarding towing, refer to related
instructions on the “Owner’s Manual”.
Be sure to attach safety chains before
towing.
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.
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.
GI013
×
J5 AT Service Manual
GI-14
Tightening Torques of Standard Bolts
Tightening Torque Table
Grade
Bolt size
Bolt diameter
mm
Pitch
mm
Tightening torque (without lubricant)
Hexagon head bolt
Hexagon flange bolt
N·m
N·m
4T
M6
6.0
1.0
5.5
7
M8
8.0
1.25
13.5
17
1.0
13.8
17
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
7T
M6
6.0
1.0 9
11
M8
8.0
1.25 22
28
1.0
22
28
M10
10.0
1.5
45
55
1.25
45
55
M12
12.0
1.75
90
100
1.25
90
100
M14
14.0
1.5
190
170
9T
M6
6.0
1.0
11
13.5
M8
8.0
1.25
28
35
1.0
28
35
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.
J5 AT Service Manual
GI-15
Grade Mark
4T ………………… 4 M 6
7T ………………… 7 Nominal diameter of bolt threads (unit: mm)
9T ………………… 9 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)
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
J5 AT Service Manual
General Information and Maintenance
MA-1
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
J5 AT Service Manual
General Information and Maintenance
MA-2
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
Tires
Check tire pressure (including spare tire) with a pressure gauge at a service station
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
wiper blades
Check for fracture or wear if they do not wipe properly.
Doors and
engine hood
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
necessary. Make sure that the secondary latch keeps the hood from opening when
the primary latch of the engine hood is released.
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.
Lamps
Make sure that the headlights, fog lights, stop lights, taillights, turn signal lights,
and other lighting are all operating properly and fixed securely. Also check
headlight aim.
Inside the vehicle:
Item
Warning lights
and buzzers
Make sure that all warning lights and buzzers are operating properly.
Windshield,
wipers and washer
Check that the wipers and washer operate properly and that the wipers do not
streak.
Windshield
defroster
Check that the air comes out of the defroster outlets properly and that air is
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
abnormal noise.
J5 AT Service Manual
General Information and Maintenance
MA-3
Seat belts
Check that buckles, anchor bolts, adjusters and retractors of seat belts operate
properly and smartly and are installed securely; check seat belts for cracking,
fraying, wear or damage.
Accelerator pedal
Check the pedal for smooth operation and make sure it does not catch or
require uneven effort.
Keep the undercover mat away from the pedal.
Brake pedal and
booster
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.
Keep the undercover mat away from the pedal.
Parking brake
Check that the pedal has the proper travel.
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
washer fluid
Check that there is adequate fluid in the reservoir tank.
Engine coolant
level
Check the coolant level when the engine is cold.
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.
Fluid leaks
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
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.
J5 AT Service Manual
General Information and Maintenance
MA-4
Recommended Oils and Lubricants
Table of Oils and Lubricants
Name
Recommended oils/lubricants
L
Engine oil
drain and refill
With oil filter
change
3.5
SAE 5W-30 (winter in northern areas)
SAE 15W-40 (year round in southern areas
and summer in northern areas), SJ quality
grade above
Without oil
filter change
3
Cooling
system
With reservoir
tank
6~6.5
ELQ-L3 long life antifreeze
Reservoir tank
0.8
ELQ-L3 long life antifreeze
Manual transmission fluid
2.1 (Top off to
lower edge of
filler)
Hypoid gear oil SAE 75W~85W
API GL-4 grade above compliant
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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MA-5
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
Engine coolant mixture ratio
Coolant temperature ℃ (℉)
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.
If necessary, please replace.
② Check 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 98 N at the marked point.
Adjust if the belt deflection exceeds the limit.
Specified value of belt deflection: 7~10mm.
Tension adjustment:
Table of Locations for Drive Belts Tension Adjustment
Location
Belt tightening method for adjustment
Alternator
Adjusting bolt on pulley
Power steering oil pump and A/C compressor belt
Adjusting bolt on power steering oil pump
Caution:
When deflection of a belt being used exceeds “limit value”, please adjust it to the
specified value.
When checking belt deflection immediately after installation, first adjust it to the
specified value. Then, after turning crankshaft two turns or more, readjust to the
specified value to avoid variation in deflection between pulleys.
When installing belt, please make sure that it is correctly engaged with pulley
groove.
Please keep fluids such as engine oil and engine coolant away from belts.
Please do not wind or bend belt excessively.
1. Alternator
① Loosen idler pulley lock nut, and then adjust tension by turning adjusting bolt.
Follow the specified belt tension.
② Tighten adjusting nut.
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MA-7
③ Tighten lock nut.
2. Power steering oil pump and A/C compressor belt
① Loosen lock bolt.
② Loosen mounting bolt of power steering oil pump.
③ Adjust tension by turning adjusting nut.
Follow the specified belt tension.
Caution:
Loosen adjusting bolt by turning it counterclockwise.
④ Tighten lock bolt.
⑤ Tighten mounting bolt of power steering oil pump.
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.
Coolant consumption is very small under
normal conditions. When coolant level drops,
it indicates possible leaks. If this occurs,
immediately drive to a JAC approved service
station for inspection.
If the coolant level drops to below the level of
the “MIN” line on the coolant expansion tank,
please add coolant promptly.
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.
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
MA002
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General Information and Maintenance
MA-8
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:
① Remove radiator cap.
② Remove radiator drain valve (from lower left part of radiator), and drain coolant in
radiator and engine water jacket.
③ Remove expansion kettle and drain coolant in it.
④ Loosen 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.
⑤ Tighten radiator drain valve firmly.
⑥ Pour 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.
⑦ Fill expansion tank with coolant until liquid level reaches line “MAX” (full).
⑧ Install expansion tank cap.
⑨ Start engine and warm it up until thermostat opening.
⑩ After 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
Minimum ambient temperature (℃)
-10
-20
-35
-45
Ethylene glycol content (%)
25
30
35
40
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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:
① Install 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.
② Remove air duct component.
③ Disconnect heater hose.
Raise heater hose as high as possible.
④ Fill 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.
⑤ Install air duct component.
⑥ Run engine and warm it up to normal operating temperature.
⑦ Rev engine 2 or 3 times under no-load.
⑧ Stop engine and wait until it cools down.
⑨ Drain water from the system.
⑩ Repeat steps 1~9 until clear water begins to drain from radiator.
Checking cooling system:
1. Checking cooling system hose
Check hose for improper attachment, leaks,
cracks, damage, loose connections, wear or
aging. If necessary, please repair or replace
damaged parts.
2. Checking radiator cap
① Pull out negative-pressure valve to open
it, and make sure that it closes
completely after pressure release.
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Make sure that there is no dirt or damage
on the valve seat of radiator cap
negative-pressure valve.
Make sure that there are no unusualness
in the opening and closing conditions of
negative-pressure valve.
② Check radiator cap relief pressure.
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.
① Apply water by hose to flush the back side of the radiator core vertically
downward.
② Apply water to flush all radiator core surfaces once per minute.
③ Stop washing if any dirt no longer flows out from radiator.
④ Blow compressed air into the back side of radiator core vertically downward.
Use compressed air lower than 490 kPa and keep distance more than 30cm.
⑤ Blow compressed air into all the radiator core surfaces once per minute until no
water sprays out.
4. Checking cooling system for leaks
To check for leaks, apply pressure to the
cooling system with the radiator cap tester
(commercial service tool) and radiator cap
tester adapter.
Warning!
Do not remove radiator cap when engine is hot.
Otherwise serious burns could be caused by
high-pressure engine coolant escaping from
radiator.
MA004
MA005
Hose connector
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Caution:
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.
① Warm up the engine, and check for oil leakage from engine room.
② Stop the engine and wait for 10 minutes.
③ Loosen filler cap, and then remove drain plug.
④ Drain engine oil.
⑤ Install drain plug with new washer.
Caution:
Be sure to clean drain plug and install with new washer.
⑥ Refill with fresh engine oil.
Caution:
When filling engine oil, do not pull out oil level gauge.
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.
⑦ Warm up the engine and check area around drain plug and oil filter for engine oil
leakage.
⑧ Stop the engine and wait for 10 minutes.
⑨ Check if the oil level is within the normal range.
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
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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:
① Check oil volume after vehicle driving with transmission still hot.
② When 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.
③ Set shift lever to neutral position.
④ Screw 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.
⑤ If 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
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
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MA-13
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.
3. Checking disc brake
1) Brake disc
Check condition, wear, and damage.
2) Brake caliper
Check for oil leaks.
3) Brake shoe
Check for wear and damage.
(Refer to service data of Chassis section.)
Checking steering gear and linkage:
Steering gear:
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.
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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.
Please use the “recommended oil: PSF-3”.
Caution:
Please do not overfill.
It is recommended that the oil designated
by JAC or equivalent be used.
Check lines for improper attachment,
leaks, cracks, damage, loose connections,
wear or aging.
Check rack boots for accumulation of
power steering fluid.
Axle and suspension parts:
Check front and rear axle and suspension parts
for excessive play, cracks, wear or other
damage.
Shake each wheel to check for excessive
play.
Check wheel bearings for smooth
operation.
Check axle and suspension nuts and bolts
for looseness.
Check strut (shock absorber) for oil
leakage or other damage.
Check suspension ball joint for grease
leakage.
Check ball joint dust cover for cracks or
other damage.
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.
MA009
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MA007
Strut
Ball joint
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MA-15
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/cm
2
) per month. Also check spare
tire each time all tires are checked.
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/cm
2
) 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.
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MA-16
Caution:
Inappropriate wheel balance weights will damage aluminum alloy wheels.
Therefore, use original wheel balance weights of JAC to keep wheels balanced
only.
Tire rotation:
To prolong service lives of tires and ensure
even tire wear, rotate tires every 8,000km. At
each rotation, move tires to the positions
shown by the figure at right. The figure at right
indicates how to rotate tires of a vehicle
provided with a standard spare tire.
If directional tires are used, swap tires on front
and rear wheels only at tire rotation. If a
standard spare tire is used at tire rotation,
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.
MA010
Vehicle front
(Non-directional
tire and wheel)
(Directional tire
and wheel)
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MA-17
Use of tires of different sizes or structures will
result in anti-lock brake system (ABS) failure
to work normally. ABS works by comparing
speeds of wheels. When replacing a tire, be
sure to use one of same size as original tires of
the vehicle. Size and structure of tires will
affect wheel speed and may result in
uncoordinated movements of the system.
It is preferable that the 4 tires be replaced at
the same time. If impossible or unnecessary,
replace 2 front or rear tires in pairs. Replacing
only one tire will affect steerability of your
vehicle badly.
If a wheel replacement is required, ensure the
new wheel and the original one match in size.
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.
MA011
Vehicle front
Vehicle front
Non-directional tire and wheel
Directional tire and wheel