2018WXSC-4GB-002-1

 

HFC4GB2.4D 1.5T engine

Maintenance Manual  

 

 

 

 

 

 

 

November 15, 2018

Engine After-Sales Service Department

 

Countersign
Approve	Checking	Approval	Prepared by:

Preface

 

To help JAC engine authorized professional maintenance technicians for an effective and proper maintenance and repair of the JAC 1.5T engines, this special engine maintenance manual is prepared.

In order to ensure the customer satisfaction of JAC engine products, it is absolutely necessary for the service technician of JAC engine to have a friendly and correct operation. Therefore, the maintenance technicians must fully understand the contents of this manual. This manual shall be accessible for reference at any time.

All contents in this manual, including pictures, technical parameters are the latest. Due to the product updates, JAC engine company will provide technical briefs or supplemental volumes, so please pay close attention to the latest developments in obtaining relevant information. JAC engine company reserves the right to make changes in product design, additions or improvements.

This manual may not be reproduced or modified in any form, including but not limited to electronic, paper, audio-visual and mechanical, without the written authorization of JAC Engine Company.

The final interpretation of this manual belongs to the Customer Service Department of JAC Engine Company.

In the process of maintenance and repair of JAC engine product, the use of non-JAC engine parts or unqualified fuel, may cause damage to the engine.

 

JAC Engine Company, Anhui Janghuai Automobile Co., Ltd.

November 2018

Contents

序言............................................................... I

目录.............................................................. II

缩写定义........................................................... 1

第一章 发动机机械.................................................. 2

1.1 发动机的主要技术规格和参数.................................. 2

1.1.1 主要技术规格.......................................... 2

1.1.2 主要部件规格.......................................... 3

1.1.3 环保关键零部件标识.................................... 3

1.1.3 主要检查与调整参数.................................... 3

1.1.4 螺栓打紧力矩一览表.................................... 4

1.1.5 维修极限.............................................. 6

1.2 发动机本体.................................................. 8

1.2.1 一般注意事项.......................................... 8

1.2.2 密封胶注意事项........................................ 9

1.2.3 准备工作............................................. 10

1.2.4 发动机弹性皮带....................................... 14

1.2.5 进气歧管和排气歧管................................... 15

1.2.6 正时链轮机构......................................... 18

1.2.7 凸轮轴总成........................................... 22

1.2.8 缸盖................................................. 27

1.2.9 气门................................................. 31

1.2.10 缸体总成............................................ 34

1.3 发动机润滑系统............................................ 49

1.3.1 注意事项............................................. 49

1.3.3 润滑系统原理图....................................... 51

1.3.4 发动机机油........................................... 51

1.3.5 机油滤清器........................................... 53

1.3.6 油底壳和机油泵....................................... 54

1.4 发动机冷却系统............................................. 58

1.4.1 冷却回路............................................. 58

1.4.2 发动机冷却液......................................... 58

1.4.3 水泵................................................. 61

1.4.4 节温器组件........................................... 62

1.4.5 水管组件............................................. 63

1.4.6 故障分析............................................. 65

1.5.1 燃油蒸发系统......................................... 67

1.5.2 曲轴箱强制通风系统................................... 70

第二章 发动机电器................................................. 73

2.1 点火系统................................................... 73

2.1.1 点火线圈............................................. 73

2.1.2 常见故障诊断......................................... 74

2.1.3 维修参数............................................. 74

2.2 起动充电系统............................................... 75

2.2.1 蓄电池............................................... 75

2.2.2 起动系统............................................. 76

2.2.3 充电系统............................................. 81

第三章 发动机电子控制系统......................................... 85

3.1 注意事项................................................... 85

3.1.1 维修过程注意事项..................................... 85

3.1.2 诊断工具............................................. 86

3.1.3 发动机的车载诊断（OBD）系统注意事项................. 86

3.2 发动机控制系统结构原理与检修............................... 89

3.2.1 系统说明............................................. 89

3.2.2 电控系统组成功能..................................... 89

3.2.3 车载诊断系统......................................... 91

3.2.4 发动机故障诊断....................................... 95

3.3 发动机电子元件结构原理与检修.............................. 103

3.3.1 进气温度压力传感器.................................. 104

3.3.2 冷却液温度传感器.................................... 106

3.3.3 电子节气门.......................................... 108

3.3.4 霍尔传感器.......................................... 110

3.3.5 氧传感器............................................ 112

3.3.6 喷油器.............................................. 113

3.3.7 爆震传感器.......................................... 114

3.3.8 连续可变凸轮相位调节器及其控制阀.................... 116

3.3.9 碳罐电磁阀.......................................... 117

3.3.10 点火线圈........................................... 119

3.3.11 火花塞............................................. 121

3.3.12 增压压力控制阀..................................... 123

3.3.13 RCV阀............................................. 125

3.3.14 ECM............................................... 126

3.4 发动机控制系统常见故障诊断................................ 130

3.4.1 电控系统常见故障及主要原因.......................... 130

3.4.2 电控系统常见故障的诊断.............................. 131

3.5 发动机控制系统故障诊断流程................................ 137

3.5.1 根据故障码诊断...................................... 137

Abbreviation Definition

Mil: malfunction indicator light

SVS: system fault light

DTC: fault code

ECM: engine control module

ECU: electronic control unit

PWM: duty cycle signal

ETC: electronic throttle valve control

TPS1: throttle valve position sensor signal 1

TPS2: throttle valve position sensor signal 2

APP1: electronic throttle foot pedal position sensor signal 1

APP2: electronic throttle foot pedal position sensor signal 2

OFF: Off

OBD: vehicle diagnostic system

ROM: read only memory

RAM: read and write memory

VVT: variable valve timing

VCP: variable cam phaser

OCV: oil control valve

Delphi: Delphi system

CTS: coolant temperature sensor

MAT: intake air temperature

MAP: intake air pressure

RPM: revolutions per minute

OCV: oil control valve

Unit:

1MPa=10bar=1000KPa

1V=1000mV

1Kg=1000g

1min=1 minute

Chapter 1  Engine Machinery

1.1 Engine main technical specifications and parameters

1.1.1 Main technical specifications

Engine technical specification table

 

1.1.2 Main parts specifications

Main parts parameter table

 

1.1.3 Environmental protection key component identification

 

1.1.3 Main inspection and adjustment parameters

Main inspection and adjustment parameters table

1.1.4 Bolt torque table

1.1.5 Maintenance limitation

 

1.2 Engine body

1.2.1 Common precautions

1. Precautions for discharging engine coolant

Discharge engine coolant after engine is cooling.

2. Precautions for disconnect fuel tube

1) Make sure there is no object in the working area that will cause combustion or spark before starting work.

2) Release the fuel pressure before disconnection and disassembly.

3) Disconnect the pipe and plug the opening to prevent fuel leakage.

3. Precautions for disassembly

1) When a dedicated service tool is required, please use a dedicated service tool. Please always pay attention to safety work and do not operate without following the instructions.

2) Take special care not to damage mating or sliding surfaces.

3) If necessary, block the opening of the engine system with tape or the like to prevent foreign objects from entering.

4) Organize the disassembled parts systematically for troubleshooting and reassembly.

5) The basic principle for loosening the bolts and nuts is to loosen the outermost part and then release its diagonal position. If you have specified a release order, please follow the order specified.

4. Precautions for inspection, maintenance and disassembly

Before repair or replacement, thoroughly inspect the parts and replace if necessary.

5. Precautions for assembly

1) Tighten the nuts and bolts with a torque wrench.

2) The basic principle of tightening the bolts and nuts is to tighten the middle with multi-step with the same degree of tightness, then tighten the internal and external diagonal position. If you have specified a release order, please follow the order specified.

3) Replace with new liner, oil seal or "O" ring.

4) Rinse thoroughly, clean and dry each part. Carefully check engine oil or engine coolant lines for any blockage.

5. Do not damage the sliding surface and matching surface. Thoroughly remove foreign materials such as fabric debris or dust. Before assembly, lubricate the sliding surface with oil.

6) After draining the engine coolant and refilling, release air from the line first.

7) After repair, start the engine and increase the engine speed,check the engine coolant, fuel, engine oil and intake and exhaust leaks.

6. Parts with the setting tightening angle

1) Use an angle wrench to finally tighten the following engine parts:

①　Cylinder head bolt

②　Main bearing cover bolt

③　Connecting rod cover nut

2) Do not make the final torque according to the torque value.

3) The torque values for these parts apply to the pretensioning step.

4) Make sure thread and base surface are clean and oil is applied.

1.2.2 Precautions for sealant

1. Remove the sealant

After removing the retaining nut and bolt, separate the mating surfaces using a scraper and remove the old sealant.

Attention：

Slide

■Be careful not to damage mating surfaces.

Squeegee

Tap

■ Insert the squeegee and tap it to slide it sideways as shown.

■Where the scraper is difficult to use, please use a rubber hammer to tap the parts for removal.

■ If you have to use tools such as a screwdriver, be careful not to damage the mating surfaces.

2. Sealant application steps

1) Use a squeegee to remove the old sealant attached to the pad application surface and mating surface.

Attention：

■ Thoroughly remove the old sealant from the grooves, fixing bolts and bolt holes in the sealant application surface.

2) Wipe clean sealant application surface and mating surface with  unleaded gasoline, remove the attached water, grease and foreign matter.

3) Place the specified size of the sealant completely in the designated location.

■ If there is a groove for the sealant, please put the sealant into the groove.

■ For bolt holes, please place the sealant inside the hole.Occasionally use outside the hole.

■ Install the binding element within 5 minutes of applying the sealant

■If there is a stain on the sealant, remove it immediately.

groove

Bolt Hole

■Do not re-tighten the bolts or nuts after installation.

■ Thirty minutes after installation, refill with engine oil and engine coolant.

Inner Side

Inner Side

Caution：

■ If there are any special instructions in this manual, please follow the instructions.

1.2.3 Preparation work

1. Maintenance tool

Special tools list

Serial Number	Tool	Outside View	Instructions
1	Flywheel stop		Fixed flywheel
2	Air valve spring compressor		Compression air valve spring
3	Oxygen sensor sleeve		Remove and install oxygen sensor
4	Oil pan remover		Remove the oil pan
5	Air valve oil seal installing device		Install the air valve oil seal
6	Camshaft oil seal installing device		Installing camshaft oil seal
7	Crankshaft front oil seal director		Guide when installing crankshaft front oil seal
8	Crankshaft front oil seal installer		Install crankshaft front oil seal
9	Crankshaft rear oil seal installer		Install the crankshaft rear oil seal
10	Piston pin locating tool		Install and remove piston pin
11	Guide sleeve		Coordinate with piston pin locating tool
12	Elastic belt tools		Install the elastic belt

2. Sealing and fastening adhesive for engine assembly

3. Lubricant oil

1.2.4 Engine elastic belt

1. Check elastic belt

Attention：

■ Be sure to operate after the engine has stalled.

■ It should be carried out when the engine is cold, or it has been shut down for 30min.

1) Check whether the belt has aging, cracks, wear and oil stain. If necessary, please replace it.

Attention：

■ Elastic belt after the engine is running around 15 min, the tension will decay 30%-40% to reach stability at 330 ~ 330 N, if it continues to decay more than 10% after reaching stability , the skid appears, the belt has reached the limit, the belt should be replaced.

Attention：

■ The belt groove should not be wrong with teeth during elastic belt installation, otherwise it will damage the belt;

Special auxiliary equipment should be used when elastic belt is installed, otherwise it is easy to cause belt damage.

■When installing the belt, make sure it meshes properly with the belt wheel groove。

■ Do not let engine oil and engine coolant splash on the belt.

■Do not twine or bend the belt too much.

   

Attention：

■ Make sure the belt meshes properly with the belt wheel groove。

■ Make sure engine oil and engine coolant do not splash on the belt and each pulley groove.

1.2.5 Air inlet manifold and exhaust manifold

Vacuum booster connecting tube

1. Elements

Canister connection hose

Fixed bolt

Air inlet manifold

Throttle seal ring

Air inlet manifold bracket

 

Catalytic converter

Compressor outlet pipe

Compressor air inlet pipe

Three-way catalytic converter

Exhaust manifold

Thermal insulation cover

Turbocharger

Exhaust manifold

2. Air inlet manifold

1)Removal

①　Disconnect the wire harness connector of the absolute pressure sensor.

②　Disconnect hose connectors below:

■ PCV valve connection hose

■ Brake vacuum booster hose at the side of air inlet manifold

■ Vacuum hose at the side of charcoal canister solenoid valve

③　Disassemble throttle valve self-tapping bolt,take down electronic throttle valve.

④　Remove the fixing bolts of air inlet manifold and intake manifold bracket.

■Tightening torque: (22.5±2.5) N·m

⑤　Disassemble air inlet manifold bolt

■ Tightening torque: (18±1.0) N·m.

⑥　Take down Air inlet manifold assy.

2)Inspection After Removal

Check whether or not the air inlet manifold has crack or other damage, the mating surface is deformed, and the air inlet manifold seal ring and throttle seal ring are damaged. If it has any abnormal, repair or replace.

3) Installation

■ Install in the reverse order of removal.

Attention：

■ Do not reuse the unusable parts

3. Exhaust manifold

1)Removal

Attention：

■ This operation is performed when the exhaust system is completely cooled.

Warning:

■ Emissions from the engine are harmful to the environment.

①　Disconnect the wire plug of the front oxygen sensor. Remove the front oxygen sensor with a special tool if necessary.

■ Tightening torque: (50±10) N·m.

Attention：

■ Don't damage the oxygen sensor.

■ Any oxygen sensor that falls from a place more than 0.5m to the hard ground cannot be used again. Please replace it.

②　Disassemble the fixing bolts of thermal insulation cover I on the exhaust manifold,take down the cover.

■ Tightening torque: (10±1) N·m

③　Disconnect the boost pressure control valve connection hose and RCV valve plug.

④　Disconnect the turbocharger compressor intake and outlet connecting pipe

⑤　Loosen the three-way catalytic converter and bracket connection bolts.

■ Tightening torque: (22.5±2.5) N·m

⑥　Loosen the three-way catalytic converter and the booster connecting bolt and take off the three-way catalytic converter. Loosen the booster and exhaust pipe connection bolts and remove the supercharger.

■ Tightening torque: (40±5) N·m.

⑦　Disassemble  exhaust manifold nuts,and then take down exhaust manifold.

■Tightening torque: (35±2) N·m.

2)Inspection After Removal

①　Check whether the exhaust manifold mating surface is deformed or not.

②　Check whether the gaskets are intact and not damaged.

③　There is no stuck problem with the booster actuator push rod.

④　The turbocharger compressor blade has no foreign matter damage; the shaft rotation is smooth and there is no stuck; the blade and the volute have no scratching phenomenon.

3) Installation

Follow the opposite sequence of the demounting sequence.

Attention：

■ Do not reuse the unusable parts

■ Do not over-tighten the oxygen sensor to avoid damaging the oxygen sensor.

4、Turbocharger fault diagnosis

When the whole vehicle failure encountered during use is suspected to be a turbocharger problem, the fault should be diagnosed first. Do not remove the supercharger immediately. Sometimes the malfunction is not the cause of the supercharger itself, so replacing the supercharger if the cause is not ascertained sometimes does not solve the problem fundamentally.

 

1.2.6 Timing sprocket mechanism

1、Element

Timing sprocket mechanism breakdown drawing

1- Timing chain 2-Exhaust camshaft sprocket 3-Sprocket bolt 4-Track bolt assembly 5-Track assembly 6-tensioner bolt 7-Automatic tensioner 8-Track assembly 9-Orbital bolt assembly  10-Valve timing regulator

2. Timing chain disassembly and installation

1)Removal

①　Remove the fixing bolt of water pump belt pulley.

■ Tightening torque: (8.4±0.6) N·m.

Note: the elastic belt can be disassembled by the friction of the driving belt when elastic belt is not disassembled.

②　Remove the drive belt and check the drive belt for wear, aging, cracks, etc. Replace the drive belt if necessary.

③　Disassemble oil level gauge assembly.

■ Tightening torque: (8.4±0.6) N·m.

④　Remove crankshaft pulley.

■ Tightening torque: （100±5）N·m+（90±2）°.

⑤　Remove the generator.

⑥　Remove oil pan and cylinder head shield.

Note: The oil pump housing can only be removed after removing oil pan and cylinder head shield.

Remove oil pump housing.

⑦　Check the timing condition.

Note: check whether or not the timing points shown in the diagram meet the requirements.

	Tag plates (align with circular notch on exhaust camshaft sprocket)
			Tag plates (align with the circular notch on the VVT and side grooves)

 

Horizontal alignment mark

Tag plates (the gap between the two pieces is aligned with the groove of the timing sprocket of the crankshaft)

⑧　Remove the fixing and moving rails of automatic tensioner and timing chain. And check for exceptions.

■ Tightening torque: automatic tensioner (10±1) N·m.

Fixing rail: (10±2) N·m.

Moving rail: (23.5±4.5) N·m.

⑨　Remove the exhaust camshaft sprocket bolts.

■ Tightening torque: (88±10) N·m.

⑩　Remove air valve timing regulator.

■ Tightening torque: (70±5) N·m.

2) Installation

Follow the reverse procedure above for disassembly. Pay attention to the timing points and installation torques during installation.

Oil pump housing installation meets the following requirements:

a.         When the oil pump housing is assembled, the glue coating surface should be clean, no oil, dirt, etc

and then adopt Corning 3-0115 surface sealant or equivalent products according to the following picture. The diameter of the rubber strip at point A is 22mm±0.5mm. The diameter of the rubber strip at point B is 1.5mm±0.5mm.

A

B

Oil pump housing gluing introductions

b.        Before assembling the sprocket cover, ensure that the sealing surface of the cylinder and cylinder head is clean, free from oil and dirt, etc., and remove the residual sealant at the joint between the sprocket cover and the cylinder and cylinder head. Then apply a new sealant evenly, the strip diameter is 4mm.

Sprocket chamber cover and cylinder block, cylinder head joint surface coated with 4mm diameter sealing tape

Glue description of cylinder and cylinder head joint surface

c.         The tightening sequence of oil pump housing bolts should follow the principle: pre-tightening first,

then fastening from the middle to both sides crosswise. It is required to tighten the bolts with larger diameters first and then tighten the bolts with smaller diameters

■ Bolts’ tightening torque of point 1-4: (39.5±3.0) N·m.

■ Bolts’ tightening torque of point 5-15: (8.4±0.6) N·m.

Oil pump housing bolts tightening sequence

1.2.7 Camshaft Assembly

1、Element

 

 

 

 

 

 

 

 

 

Camshaft assembly breakdown drawing

1-Camshaft front end bearing cap bolt 2-camshaft front end bearing cap 3-camshaft bearing cap bolt

4-Camshaft bearing cap 5-Exhaust camshaft 6-Mechanical tappet 7-Intake camshaft

2.Removal and Installation

1)Removal

①　Disassemble the ignition coil.

②　Disassemble cylinder head guard assy.

③　Rotate crankshaft , let cylinder-1 piston stay at the stop point of compression.

④　Measure valve clearance.

a.         The valve clearance is measured at position A in the figure

b.        If valve clearance does not meet the standards, it needs to be adjusted.

■ It is important to note the measurement value as an important parameter to calculate the proper tappet label.

Standard valve clearance (Cooling engine state)

⑥　Turn the crankshaft 360º clockwise to let cylinder-4 piston stay at the stop point of compression.

⑦　Measure the valve clearance at position B in the figure.

■ It is important to note the measurement value as an important parameter to calculate the proper tappet label.

⑧　Remove engine front end belt, idler wheel and shock absorbing belt pulley.

⑨　Remove oil pan and engine oil suction filter.

⑩　Remove oil pump housing and timing chain.

11　Remove air valve timing regulator.

a.         Fix the camshaft with a wrench.

b.        Loosen the valve timing adjuster bolts.

■ Tightening torque: (70±5) N·m.

c.         Remove the valve timing adjuster.

12　Remove air inlet and exhaust camshaft.

a.         Remove camshaft front bearing cover in reverse numerical order as shown in the figure below.

b.        Remove camshaft bearing cover in reverse numerical order as shown in the figure below.

Camshaft bearing cover

Camshaft bearing cover

Camshaft front bearing cover bolt

13　Measure the height of the camshaft

Inlet: (44.7054±0.1) mm

Exhaust: (44.2836±0.1) mm

If the measured value is not within the standard value, replace the camshaft.

 

 

14　Remove the mechanical tappet in the unqualified valve clearance and adjust the valve clearance.

■ Mark the removed tappet and the corresponding installation position to prevent forgetting the position of the column.

a.         Measure the thickness of the removed mechanical tappet with a screw micrometer.

b.        According to the measured valve clearance and the thickness of the old tappet,Calculate the thickness of the new tappet to make the valve clearance reach the specified range.

 

 

 

 

New tappet thickness table

※Example

ü  Measured intake valve clearance＝0.26mm, marked as A.

ü  Measured old tappet thickness＝2.79mm, marked as B.

ü  Measured intake valve clearance+Measured old tappet thickness＝The clearance between the base circle of the camshaft and the top of the valve tappet, marked as C. C＝3.05mm.

ü  C＝Intake valve clearance standard value+Ideal new tappet thickness. So Ideal new tappet thickness＝3.05mm－0.22mm＝2.83mm.

■ When calculating the thickness of the exhaust side tappet, the above equation should be replaced with exhaust valve clearance standard value.

c.         The closest new tappet thickness ＝2.82mm or 2.84mm. Select tappet 282 or tappet 284.

d.        Select a new tappet with the closest thickness to the calculated value.

■The available tappets have 31 sizes, ranging from 2.70 to 3.30mm, increasing by 0.02mm.

■ The identification number in the mechanical tappet indicates the thickness (e.g., 272 indicates the thickness value of 2.72mm).

Tappet thickness group table

2)Installation

①　Install the new tappet selected after the calculation.

■ Confirm the specific position of each new tappet selected after calculation (corresponding to the mounting hole), preferably mark the new tappet.

②　Install the camshaft and bearing cover and pre-tighten the bolts in the opposite order of disassembly.then tighten in this order.

■Engine oil should be applied to the camshaft journal and cam.

■Camshaft front bearing cover bolts(number 3) tightening torque: (20±1) N·m

■Camshaft bearing cover Bolts(number 16)  tightening torque: (11±1) N·m

③　Measure again whether or not the valve clearance after adjustment meets the standard. If it is beyond the standard range, first check whether the tightening torque of bearing cover bolts meets the requirements or not.

■The bolt torque meets the requirement,Remove the mechanical tappet in the unqualified valve clearance and adjust the valve clearance.

■If the tightening torque of bolts does not meet the requirements, loosen all the bolts on this camshaft and tighten them to the specified torque in order. Measure valve clearance again. If there is any unqualified clearance, remove the mechanical tappet in the unqualified valve clearance and adjust the valve clearance.

④　Install air valve timing regulator.

⑤　Install timing chain and oil pump housing.

⑥　Install engine oil suction filter and oil pan.

⑦　Install front-end power accessory and elastic belt.

⑧　Install cylinder head guard and ignition coil.

■ Check the sealing ring of cylinder head guard before installation to ensure no loss, no damage, no scratch, no crease and other defects, so as to ensure its sealing performance.

■ The cylinder head guard bolts must be pre-tightened and fastened in the order shown in the figure with tightening torque:（9±1)N·m.

 

 

 

 

 

 

1.2.8 Cylinder head

1. Vehicle maintenance

Check cylinder pressure:

①　Turn off the engine after thoroughly warming it up.

②　Release the fuel pressure.

■ Remove the fuel pump fuse from the fuse box.

■ Start the engine.

■ After the engine is out, start the engine to idle  two or three times to release the fuel pressure completely .

③　Remove ignition coils and spark plugs.

④　Install a spliced cylinder pressure gauge on the spark plug hole.

⑤　Step the accelerator pedal to the bottom and turn the ignition switch to "START" to start. When the meter pointer is stable, read the compression pressure and engine speed. Do the above steps to check the remaining cylinders

■ Standard pressure: 12 ± 1bar (200rpm).

■ Cylinder pressure difference limit: 9.1 bar.

■ Allowable difference between cylinders: no more than 98kPa.

Attention：

■ Prevent foreign matter from entering the cylinder through the inlet.

■Always use a fully charged battery to get the required engine speed（200r/min）。

■ If the compression pressure is below the minimum, check the valve clearance and other related parts (valve, valve seat, piston, piston ring, cylinder diameter, cylinder head and cylinder head gasket). After checking, measure the compression pressure again.

■ If the compression pressure of some cylinders is low, add 10ml engine oil into the spark plug hole of the cylinder and re-check the cylinder pressure.

■ If the cylinder pressure increases after the engine oil is added, the piston ring may be worn or damaged. Check the piston ring and replace it if necessary.

■ If the compression pressure is still low after the engine oil is added, the valve may fail. Check if  the valve is damage. Replace damaged valve or valve seat.

■ If the compression pressure of two adjacent cylinders is low and the pressure is still low after adding oil, the cylinder gasket may leak. Please replace cylinder head gasket.

⑥　After the inspection, please install the removed parts.

⑦　Start the engine and make sure it runs smoothly.

2.Removal and Installation

1)Removal

①　Release the fuel pressure.

②　Discharge engine coolant and oil. Refer to  "Replace engine coolant" and "Replace engine oil".

Attention：

■ Be sure to operate after the engine is cooling.

■ Do not let engine oil and engine coolant splash on the belt.

③　Remove the following components and related parts:

■ Cylinder head guard.

■ Elastic belt. Refer to “Elastic belt”.

■ Oil pan.

■ Oil pump housing and timing mechanism. Refer to “Timing sprocket mechanism”.

■ Air inlet manifold. Refer to “Air inlet manifold”.

 

■ Exhaust manifold. Refer to “Exhaust manifold”.

■ Thermostat housing. Refer to “Thermostat assy.”.

■ Engine oil dipstick guide pipe.

④　Unscrew cylinder head bolt.

■Disassemble in numerical order as shown below。

⑤　Remove cylinder head gasket.

2) Inspection after disassembly

①　Check whether the cylinder head has cracks or other damage.

②　Check whether the waterways and oil channels between cylinder body and cylinder head are blocked. Please clean it if necessary.

③　Check cylinder head flatness.

Note: when this inspection is carried out, the flatness of cylinder block should also be checked. Refer to“Cylinder block  flatness”.

a.Wipe the oil off the cylinder head and clear away sealant and carbon deposition.

Attention：

■ Be careful not to let impurities fall into the cylinder head channel and oil channel.

b.Measure the flatness in six directions at multiple positions on the bottom surface of the cylinder head.

Standard value: 0.03mm below

Limit value: 0.10mm

Cylinder head height (new): (113±0.1)mm

If the value is exceeded standard value, please grinding according to the specification. If the value is exceeded the limit value, please replace according to the specification.

Attention：

■ The total grind able allowance of cylinder head and cylinder block mating surface is no more than 0.2mm.

3) Installation

①　Install new cylinder head gasket.

②　Install the cylinder head as follows:

a.Install the washer as shown in the picture on the right.

b.Apply appropriate amount of engine oil to the screw position and washer of cylinder head bolt.

c.Tighten bolts in numerical order as shown in the figure below until each bolt reaches torque (24.5 + 2) N·m.

       d.Loosen the bolts completely.

e.Tighten bolts in the order again until each bolt reaches torque (24.5±2) N·m.

f.Paint the head of the cylinder head bolt and cylinder head (as shown in the right picture).

g.According to tighten the sequence, tighten each bolt by extra 90 ° twist.

H.Tighten each bolt 90 ° again, check whether the paint marks on bolt head aligns with the cylinder head.

Paint marker

 

Attention：

■ If the bolt tightening Angle is less than 90 °, that means the fastening torque is not enough.

■ If the bolt tightening Angle is more than 90 °, the bolt  should be completely removed, and reinstall again.

i.If the cylinder head bolts are replaced during maintenance, maintain it  according to the above steps a ~ h.

j.If the cylinder head bolts are not replaced during maintenance,maintain according to the order of a, b, e, f, g, h.

③　Follow the opposite sequence of the disassembly procedures to install.

4) Inspection after assembly

The following are the steps to check oil leakage, lubricant leakage and tail gas leakage:

①　Before starting the engine, please check the level of the engine cooling fluid and engine oil.

②　Turn the ignition switch to the "ON" position (when the engine is off) to check the connection for fuel leakage.

③　Start the engine. When accelerating the engine ,check the connection again for fuel leakage.

④　Run the engine to check for abnormal noise and vibration.

⑤　Thoroughly warm up the engine and check for leakage of fuel oil, exhaust gas or any oil/liquid (including engine oil and engine coolant).

⑥　After the engine has cooled, recheck the oil/liquid level(including engine oil and engine coolant). If necessary, refill to the specified level.

1.2.9 Valve

1. Elements

 

 

 

 

 

 

 

 

 

Valve element diagram

1-Exhaust valve seat ring 2-Exhaust valve 3-Intake valve 4-Intake valve seat 5-valve oil seal 6-Valve spring lower seat 7-Valve spring 8-Valve spring seat 9-Valve lock clamp 10- Valve guide

2. Disassembly and installation

1）Disassembly

①　Use spark plug sleeve to remove spark plug.

②　Remove the valve lock, valve spring and valve spring seat.

■ Use the valve spring compressor to compress the valve spring.

 

 

Attention:

■ All the valve, valve spring and other components that being removed should be attached with the label, indicating the cylinder number and location.

■ The parts should be stored securely.

 

 

③　Remove the valve oil seal.

④　Remove the valve seat ring.

⑤　Remove the valve guide pipe.

 

 

 

2) Installation

①　Install the valve guide pipe.

②　Install the valve seat ring.

③　Install the valve oil seal.

a.Install the valve spring lower seat

b.Install new valve oil seal with special tools..

Attention：

■ Valve oil seal cannot be reused.

■ The valve oil seal must be installed with the correct special tool.

④　Install the valve.

⑤　Install the valve spring.

Note:  the items with paint mark should be installed facing up.

⑥　Install the air valve spring upper seat.

⑦　Install  the valve lock clamp.

■ Install with valve spring compressor.

■ After installation, tap the valve stem edge with a rubber hammer to check the installation.

⑧　Use spark plug sleeve to install spark plug.

3) Inspection after disassembly

①　

Poor

Poor

Properly

Air valve

■ Check that the gas facade is in proper contact. If the contact is uneven or incomplete, repair the valve seat surface.

 

 

■ Air valve edge thickness inspection. If it is less than the limit, please replace the valve.

Intake valve  Standard value: 1.35mm

Contact surface (must be in the center of the face)

       Limit value: 0.85mm

Intake valve  Standard value: 1.85mm

The thickness of the edge

       Limit value: 1.35mm

 

 

 

■ Check the total length of the air valve. If it is less than the limit, please replace the valve.

Intake valve  Standard value: 89.61mm

        Limit value: 89.11mm

Intake valve  Standard value: 90.94mm

        Limit value: 90.44mm

②　Air valve spring

■Check free height of valve spring. If the limit is exceeded, replace the valve spring.

Standard value: 43.1mm

Limit value: 42.7mm

Verticality

Free Height

■Check the verticality of the valve spring. If the limit is exceeded, replace the valve spring.

Standard value: ＜2°

Limit value: 4°

1.2.10 Cylinder block assembly

1、Component

Cylinder block assembly exploded view

1-Main bearing cap bolts 2-Main bearing caps 3-Spindle lowers 4-Spindle uppers 5-cylinders 6-Crankshaft rear oil seal assembly 7-Crankshaft rear oil seal bolts 8-Thrust blades 9-Flywheel bolts 10 Flywheels 11-Crankshaft 12-Crankshaft signal wheel locating jacket 13-Crankshaft signal wheel 14-Crankshaft signal wheel bolt 15-Crankshaft pulley 16-Crankshaft pulley retaining ring 17-Crankshaft pulley bolt

2. Disassembly and installation

1）Disassembly

①　Remove the following engine accessories. Refer to the relevant chapters for details of the disassembly process.

■ Engine air inlet manifold and engine exhaust manifold.

■ Generator elastic belt.

■ Generator.

■ Engine timing mechanism.

■ Water pump.

■ Water pipe components.

■ Generator fixing bracket, air condition compressor fixing bracket.

■ Ignition coil.

②　Fix the engine overall.

③　Discharge engine oil Refer to “Replace the engine oil”.

④　Remove flywheel assembly. Please use the special tool to fix the flywheel and then remove the fixing bolt.

Attention：

■ Fixing bolts should be loosened in diagonal order.

⑤　Remove crankshaft rear bearing.

Attention：

■ Once the rear bearing of crankshaft is disassembled, it cannot be used again. Please replace it with a new one.

⑥　Remove the following system. Refer to the relevant chapters for details of the disassembly process.

■ Cylinder head

■ Oil pump housing

■ Oil pan

⑦　Remove knock sensor.

Attention：

■ Do not drop or tap the sensor.

⑧　Remove rear oil seal bracket.

■ The screwdriver is inserted between the crankshaft and the rear oil seal housing for disassembly.

Attention：

■ Once the rear oil seal is disassembled, it cannot be used again. Please replace it with a new one.

⑨　Remove piston and connecting rod assembly:

Before removing piston and connecting rod assembly, please check the clearance of the connecting rod head. Refer to “Inspection after disassembly" below.

a. Rotate the crankshaft.  Place the corresponding crankshaft of the connecting rod to be removed in the center of the bottom.

Note: For the re installation convenience, a cylinder number can be printed on the side of the removed connecting rod head.

 

The cylinder number

 

 

 

b.Remove connecting rod cover.

       ■ Connecting rod bolts could only be used once and shall not be reused.

c.Use a rubber hammer or similar tool to push the piston and connecting rod assembly out of the cylinder block.

Attention：

■ Be careful not to let the connecting rod head damage the cylinder wall and crankshaft journal.

⑩　Remove the connecting rod bearing bush from the connecting rod and the connecting rod cover.

Attention：

■ Identify the installation locations and keep them in place without confusion.

11　Remove piston ring from piston.

Check the side clearance of the piston ring before removing it. Refer to “Inspection after disassembly" below.

Attention:

piston ring expander

■Using piston ring expander.

 

 

 

 

 

12　Remove the piston from connecting rod as follows:

a.Insert the push rod (special tool) from the arrow mark side in the front

Push rod

Forward sign

and install guide sleeve D.

Forward sign

b.place the piston front mark up

and install the piston and connecting rod assembly on the piston pin mounting base

guide pipe D

base

(special tool).

c.Press the piston pin out with the press machine.

d.Separate the connecting rod and piston from from

the piston and connecting rod assembly.

Attention：

■ After removing piston pin, put the piston, piston pin and connecting rod together in the same cylinder. Do not mix with the piston, piston pin and connecting rod of other cylinders.

13　Remove crankshaft main bearing cover.

Before releasing the crankshaft bearing cover, measure the crankshaft axial clearance. Refer to “Inspection after disassembly" below. Please loosen the main bearing cover bolts of crankshaft in numerical order as shown in the figure below.

As shown in the picture on the right,When disassembling, the crankshaft bearing cover bolts can be used to shake the crankshaft bearing cover backwards and forwards to disassemble it.

14　Remove crankshaft.

15　Remove crankshaft signal wheel.

■Crankshaft signal wheel bolts are removed clockwise。

 

 

2）Post-disintegration inspection

①　Crankshaft axial clearance

Use the driver to  lever the crankshaft, record the reading of the dial indicator at the same time.

Standard : 0.09～0.27mm

 

If the measured value is not within the standard value, please replace the thrust plate and remeasure it. If it is still not within the standard range, please replace the crankshaft.

②　Connecting rod big head clearance

Measure the clearance between the connecting rod and the crankshaft arm with a feeler gauge.

Standard clearance: 0.10～0.25mm

Limit value: 0.4mm

If the measured value exceeds the limit, replace the connecting rod and measure again. If the limit is still exceeded, replace the crankshaft.

③　Piston ring side clearance

Measure the clearances between piston ring and piston ring grooves with a feeler gauge.

Poor

Standard:

First groove: 0.03～0.07mm

Properly

Environment

filler gauge

filler gauge

Second groove: 0.02～0.06mm

Limit value:

First groove: 0.10mm

Second groove: 0.10mm

If the measured value exceeds the limit, replace piston ring and measure again. If the limit is still exceeded, replace the  piston ring.

④　Piston ring end clearance

Make sure the cylinder inner diameter is within the specified range. Refer to “Cylinder cylindricity”.

Lubricate the piston and piston ring with engine oil and insert the piston ring until the piston reaches the middle of the cylinder,and use feeler gauge to measure piston ring end clearance.

Standard:

Fix it

Piston

First groove: 0.15～0.30mm

Measurement point

Piston ring

filler gauge

Piston ring

Second groove: 0.30～0.45mm

 

Limit value:

First groove: 0.8mm

Second groove: 0.8mm

 

If the measured value exceeds the limit, replace piston ring and measure again. If the limit is still exceeded, replace the cylinder block.

⑤　Cylinder block flatness

Clean the liner on the cylinder block surface, as well as engine oil, scale  carbon or other contaminants.

Attention：

■ Be careful not to let gasket chips fall into engine oil or engine coolant.

The flatness of cylinder block is measured with a ruler and a feeler gauge in six different directions.

Standard value: 0.05mm below

Limit value: 0.1mm

If the limit is exceeded, replace the cylinder block.

 

 

 

⑥　Cylinder block cylindricity

Use the dial gauge to measure the thrust direction and the axial bore diameter at positions A and B of each cylinder.

Standard value: cylinder inner diameter: 75.000 ~ 75.015mm

Cylindricity: less than 0.007mm

Position B

Position A

Thrust washer

Axial Direction

Engine front end

    If the average cylinder diameter of the four positions is greater than the maximum value, the cylinder is replaced.

⑦　Piston skirt diameter

Check the piston skirt for deformation with an outer diameter micrometer.

Standard value: （74.970±0.005）mm

Please replace the piston if it surpasses the standard value.

 

⑧　

micrometer

Piston and bore clearance

Calculated by the piston skirt and cylinder bore.

(Clearance) = (Cylinder inner diameter) - (Piston skirt diameter)

Standard value: 0.025 ~ 0.05mm

If the calculated value exceeds the limit, replace the piston and piston ring assembly.

⑨　

micrometer

Crankshaft main journal diameter

Measure the crankshaft journal with the outside micrometer.

Standard clearance: 46.004～46.029mm

Please replace the main bearing if it surpasses the standard value.

⑩　Connecting rod shaft journal diameter

Use the outer diameter micrometer to measure the diameter of the connecting rod main journal.

Standard Value:39.982～40.000mm.

If the standard is exceeded, replace the connecting rod.

Connecting rod bearing bushing

Crankshaft connecting rod journal		Connecting rod bearing selection (up/down)
Mark	Dimension	Mark	Dimension
1	φ40	1 (yellow)	1.5
2	φ40	2 (black)	1.5
3	φ40	3 (red)	1.5

 

11　Connecting rod journal clearance

Note: use a plastic wire gauge for measurement.

a.Remove all engine oil from the connecting rod journal and the connecting rod bearing bush.

b.Place the plastic wire gauge on the connecting rod journal and cut it into the same length as the width of the bearing bush. plastic wire gaugemust be at the center of connecting rod journal and parallel to its axis.

c.Gently place the connecting rod cover in its position and tighten the bolts to the specified torque.

d.Remove the bolts and slowly remove the connecting rod cover.

e.Measure the extruded part of the plastic wire gauge at the widest point using a ruler printed on the plastic wire gauge bag.

Standard Value:0.03～0.055mm.

Limit value: 0.07mm

f.Remove the plastic clearance gauge completely after measurement.

If the clearance is greater than the limit, replace the connecting rod  bearing bush. Replace the crankshaft if necessary.

12　

Plastic wire gauge

Crankshaft main journal diameter clearance

a.       Clean the engine oil of crankshaft journal and inner surface of bearing bush.

b.      Install bearing bush.

c.       Cut the length of the plastic wire gauge to

match the width of the bearing bush Then place it on the journal along the axis of the journal.

d.      Lightly install the crankshaft bearing cover and tighten the bolts to the specified torque.

e.       Remove the bolts and gently remove the crankshaft bearing cover.

f.        Measure the extruded part of the plastic wire gauge at the widest point using a ruler printed on the plastic wire gauge bag.

Standard value: 0.02 ~ 0.05mm

Limit value: 0.10mm

If the clearance is greater than the limit, replace the main bearing bush. Replace the crankshaft if necessary.

3) Installation

①　Pre-install the crankshaft signal wheel.

■Ensure no engine oil in the threaded hole of crankshaft signal wheel when assembling.

■Crankshaft signal wheel screw must be coated with Loctite 262 thread fastener or equivalent product before installation

■Crankshaft signal wheel bolts are tightened counterclockwise as shown in the figure below

Locating pin

②　Blow engine coolant and engine oil out of cylinder block, cylinder diameter and crankshaft box ,remove foreign matter.

Attention：

■ Use goggles to protect your eyes.

③　Install main bearing bush upper bearing bush

Attention：

■ Select the bearing bush according to the identification mark or color code of the crankshaft (refer to the assembly table of the main bearing bush). If it cannot be identified, the crankshaft diameter should be measured and the corresponding bearing bush should be selected to match it.

There are grouping marks on the crankshaft, marking a total of 10 digits. The first 5 digits correspond to the 1st to 5th main journals respectively. The 6th bit is printed "B", indicating the end of main journal grouping and the beginning of connecting rod journal grouping; the 7th to 10th bits correspond to the 1st to 4th connecting rod journals respectively.

The exhaust rear end of the lower end face of cylinder block is marked with the dimension mark of the main shaft hole, corresponding to the dimension of the 1st to 5th main shaft hole respectively.

Main bearing bush shall be selected according to the following table

Main bearing bush installation table

■ When installing, aim the protrusion of the bearing bush at the cutting of the cylinder block and the main bearing cover.

■ Make sure the engine oil hole on the cylinder block is aligned with the oil hole on the corresponding bearing bush

④　Install crankshaft to cylinder block. When rotating the crankshaft by hand, please check whether the rotation is flexible or not.

■ Before installing crankshaft, appropriate amount of engine oil should be applied to the inner part of upper bearing bush.

⑤　Install thrust plate

Install oiled thrust plate in installation groove side of the main bearing seat(fourth), 100% measure and ensure that the crankshaft axial clearance is 0.09 ~ 0.27 mm, when installing two thrust surfaces ensure that the flat side joint fourth position, with groove side facing the cylinder holes.

⑥　Install main bearing cover.

■ The main bearing cover can be identified by identification marks.

■ Starting from the front end (timing belt side), install the main bearing cover in order of number.

■ The arrow must point to the front.

⑦　Tighten the main bearing cover bolts as shown in the figure below.

a.Apply engine oil to the thread and fixed surfaces of the main bearing cover bolts.

b.Tighten the main bearing cover bolts in several steps.

■ Tightening torque: （35±2）N·m+（62±2）°.

■ After installing the main bearing cover bolts, make sure the crankshaft can be rotated flexibly by hand.

■ Check crankshaft axial clearance. Refer to “Crankshaft axial clearance”.

⑧　Pre-assemble the piston connecting rod assembly.

■ When installing the piston pin, make sure the top of the piston marked forward and the connecting rod marked forward are the same.

a.Measure the following lengths（As shown in diagram below）

A：Dimensions from piston boss to piston boss outside

B：Dimensions from piston boss to piston boss inside

C：Piston pin length

D：Connecting rod small end thickness

b.The measured value is putted into the following formula：

L=[（A-C）-(B-D)]/2

c.Insert the push rod (special tool) into the piston pin and install guide sleeve A (special tool).

d.When piston and connecting rod are installed, the front marks should be on the same side.

e.Apply engine oil to the outer ring of the piston pin.

f.Starting with guide sleeve A, press guide sleeve A ,piston pin and push rod into the front marking side of the piston successively.

g.Screw guide sleeve B into guide sleeve A, and the gap between the two sleeves is 3mm plus the L value calculated in step 2.

h.Install the piston and the connecting rod on the piston pin mounting base in a downward marked state in front of the piston.

i.Install the piston pin with the press machine.

Guide sleeve B

Guide sleeve A

Caution：

■If the pressure distribution load exceeds the specified limit, the piston pin and the piston assembly and the connecting rod shall be replaced, or both shall be replaced.

Standard value: 108±54N·m

⑨　Install piston ring.

■ Be careful not to damage the piston when installing piston rings.

■ Be careful not to damage the piston ring because of overextending.

piston ring expander

a.         Install the oil ring.

ü  Install the oil liner ring into the piston ring groove. Then install the oil ring body.

When installing the ring body, put one end of the ring body into the groove by hand, and then press the rest into the position.

Attention：

■ Do not use piston ring expander to install ring body, otherwise it may lead to wiper blade fracture.

ü  After installing the combined oil ring body, check whether it can move smoothly in both directions.

b.        Install1st and 2nd air ring.

ü  Install the air ring with the piston ring expander. The identification mark on the air ring should be toward the top of the piston.

c.         Piston ring opening direction.

Engine front end

Combination oil ring on the blade opening direction

Combination oil ring lining ring opening direction

Combination oil ring lower blade opening direction

The second air ring open direction

The first air ring open direction

⑩　Install the connecting rod bearing bush on the connecting rod and the connecting rod cover.

■ Apply engine oil to the surface of the connecting rod bearing bush before installing it.

■ Connecting rod bearing bush shall be installed with special tool to ensure the installation position: as shown in the figure below, the difference between A and B length is less than 0.5mm.

11　Install piston connecting rod assembly on crankshaft.

■ Rotate crankshaft journal corresponding to the connecting rod to be removed in the center of the bottom.

■ Apply engine oil to cylinder diameter, piston and crankshaft journal.

■ Install the connecting rod to the corresponding cylinder hole according to the mark on the connecting rod

■ Make sure the mark on the top of the piston is pointing forward.

■ Using the piston guide tool, put the piston connecting rod assembly into the guide tool from the cylinder fire surface and press the piston into the cylinder block with the rubber rod.

Attention:

■ Be careful not to let the connecting rod head damage the cylinder wall and crankshaft journal.

12　Install connecting rod cover.

13　Tighten connecting rod bolts according to the “5N·m→10N·m→13N·m+45+45°”  approach to tighten alternately.

Attention：

■ When assembling, use high-pressure air purging or vacuum suction connecting rod to increase the cross-section to ensure foreign matter such as inorganic oil and metal scraps, and report good adhesion without gaps. Forbid mixed and reverse  installation of connecting rod big end cover.

■ Before installing the bolts, apply engine oil to the threaded parts and seating surfaces.

■After installing the piston connecting rod assembly, rotate the crankshaft to check whether the crankshaft can rotate flexibly or not.

■ Connecting rod big head backlash: 0.10-0.30mm.

14　

Oil sealing

Install the rear oil seal bracket with the crankshaft rear oil seal on the cylinder block. Use special tools to press the rear oil seal on the rear oil seal bracket

Shell oil seal

■When installing crankshaft rear oil seal bracket, ensure that the coating surface is clean, no oil, dirt, etc., apply Dow corning sealant 3-0115 or equivalent product on the surface of the cylinder block back-end as shown below, the sealant can also be applied on the corresponding position of crankshaft rear oil seal bracket. Rubber strip diameter (2±0.5) mm. Apply lubricating oil to the rear oil seal lip and crankshaft joint, Be careful not to scratch the oil seal when installing.

■Bolts’ tightening torque: (7.6±0.6) N·m

Section B-B’

Section A - A’

Crankshaft rear oil seal glue line.

15　Install the knock sensor.

■Bolts’ tightening torque: (20±4) N·m

Note: make sure there is no foreign matter between cylinder block and knock sensor.

16　Install the flywheel

■Bolts’ tightening torque: (100±5) N·m

Attention：

■ Follow the principle of pre-tightening first and then symmetrical cross - tightening.

 

1.3 Engine lubricating system

1.3. Installation precautions

Sealant application steps:

1. Use a squeegee to remove the old sealant attached to the pad application surface and mating surface.

 

 

 

 

 

Attention：

■ Thoroughly remove the old sealant from the grooves, fixing bolts and bolt holes in the sealant application surface.

2. Wipe clean sealant application surface and mating surface, remove the attached water, grease and foreign matter.

3. Place the sealant in the designated location.

1) Install the binding element within 5 minutes of applying the sealant

2) If there is a stain on the sealant, remove it immediately.

3) Do not re tighten the bolts or nuts after installation.

4) Thirty minutes after installation, refill with engine oil and engine coolant.
1.3.2 Preparation work

1、Maintenance tool

Maintenance tool list

1.3.3 Lubrication system schematic

Open pressure: 196±25kpa

Piston cooling nozzle oil passage

Piston bottom

Cylinder oil return hole

Supercharger returning oil

Supercharger oil

Chain tensioner

Oil pan

Cylinder head oil return hole

Chain lubrication road

Camshaft lubrication

OCV control oil passage

Cylinder head main oil passage

Cylinder main oil passage

PRV valve

Crankshaft lubrication hole

Filter

Engine oil pump

Oil filter bracket

Oil filter

1.3.4 Engine oil

1. Inspection

1) Engine oil  level

Note: before starting the engine, stop the car horizontally and check the engine oil level. If the engine has started, turn off the engine and wait for 10min to check again.

①　Pull out the engine oil dipstick and wipe it clean.

②　Insert the engine oil dipstick and make sure the oil level of the engine is within the range  as shown in the figure.

③　

Make sure the oil level is between "L" and "H”

Please adjust it if it is out of the range.

2) Engine oil appearance

①　Check engine oil for white turbidity or serious contamination.

②　If engine oil is turbid or contaminated, it is likely to be contaminated by engine coolant. Repair or replace damaged parts.

3) Engine oil leakage

Check for oil leakage around the following areas:

■ Oil pan

■ Oil pan oil drain bolt

■ Engine oil pressure switch

■ Engine oil filter

■ The mating surface of cylinder block and cylinder head

■ Front and rear crankshaft oil seal

■ The mating surface of cylinder block and oil pump

■ The mating surface of cylinder head guard and cylinder head

■Front and rear camshaft oil seal

4) Oil pressure inspection

Attention：

■ The engine oil is very hot, be careful not to get scalded.

■ Check the oil pressure after parking.

①　Check the oil level

②　Lift the vehicle, disconnect the wire connector of engine oil pressure switch and remove the switch.

③　Install oil pressure gauges and hoses.

④　Start the engine and warm it to normal working temperature.

⑤　Check oil pressure during engine running with no-load.

Note: when the engine oil temperature is low, the oil pressure increases.

■ If there is any obvious difference, please check the oil pipeline and oil pump for leakage.

⑥　After inspection, install the pressure switch as follows:

a.Remove old sealant that is attached to pressure switches and engines.

b.Use sealant as required and tighten pressure switch.

■ Please use the specified sealant: Tonsan 1243 thread sealing adhesive.

■Tightening torque: (10±2) N·m.

c.After warming up the engine, make sure there is no oil leakage when the engine is running normally.

2、Engine oil replacement

①　Start engine and preheat until the engine coolant temperature reaches (80 ~ 90 ℃).

②　Remove engine oil filler cover from the cylinder head guard.

③　Remove the drain screw plug from the oil pan to drain the oil. The oil discharge time shall not be less than 15min.

Attention：

■The engine oil is very hot, be careful not to get scalded.

④　Use special spanner to disassemble the oil filter;

⑤　Clean filter installing surface on oil filter bracket.

⑥　Replace the new oil filter: Apply a small amount of oil to the O-ring of the oil filter. When the O-ring of the oil filter contacts the flange of the oil filter bracket, use a special wrench to rotate one turn or equivalent to (22-28) N·m.

⑦　Install oil duct screw plug on the oil pan.

■Bolts’ tightening torque: (39±5) N·m

⑧　Inject the oil from the oil inlet on the cylinder cover guard, about 4L.

⑨　After starting the engine without load and running for (2-3) min, check the interface between filter and bracket to ensure no oil leakage.

⑩　Turn off the engine and wait for 10min to check whether the oil level is between the upper and lower scale. If oil is insufficient, please add.

■ Measurement method of the engine oil: when measuring, the car should be parked horizontally, after the oil level of oil is stable, pull out oil dipstick, wipe engine oil with a clean cloth, then insert it in oil pan to measure the oil level The engine oil level shall be kept in the middle and upper part of two scale lines of the oil dipstick. The height of oil level should also be checked before leaving the vehicle and every driving (300 ~ 500)km. If the oil quantity is insufficient, it should be added timely.

1.3.5 Engine Oil Filter

1  disassembly and installment

1)Removal

Use special tools to disassemble the oil filter.

Attention：

■ Use original JAC oil filter.

■The engine oil is very hot, be careful not to get scalded.

■When disassembling, prepare a cloth to dry the leaking or splattering engine oil.

■ Do not let the engine oil stick to the elastic belt.

■ Thoroughly dry the engine oil spilled on the engine and the car.

2）MOUNTING

①　Clean filter installing surface on oil filter bracket.

②　Replace the new oil filter: Apply a small amount of oil to the O-ring of the oil filter. When the O-ring of the oil filter contacts the flange of the oil filter bracket, use a special wrench to rotate one turn or equivalent to (22-28) N·m.

Attention：

■ The oil filter must be tightened with the filter wrench.

■ If the filter is tightened by hand, oil may leak due to insufficient tightening torque.

2. Inspection after installation

1) After starting the engine without load and running for (2-3) min, then check the interface between filter and bracket ,engine oil should not leak.

Turn off the engine and wait for 10min,then check whether or not the oil level is between the upper and lower scale. If the oil is insufficient, please add.

1.3.6 Oil pan and Oil pump

1. Disassembly

1) Discharge the engine oil.

2) Remove the oil pan.

a.Loosen the retaining bolt in the order of both sides first and middle.

b.As shown in the figure, tap in a special tool between the oil pan and the cylinder block.

c.Tap the side of the special tool and move the tool along the oil pan/cylinder block sealing face, then remove the oil pan.

 

Note:

■ Be careful not to damage mating surfaces.

3) Remove engine oil suction filter

■Bolts’ tightening torque: (8.4±0.6) N·m

4) Remove oil pump housing.

2. Inspection after disassembly

1) Engine oil suction filter

■ Clean the attachment clearly.

2) Oil pump housing

■ Check whether all the oil holes on the oil pump are clogged, and clean the holes if it is necessary .

■ Check the oil pump housing for cracks or other damage If any,please replace it.

3. Engine oil pump

■ Check that the oil pump rotor is flexible and has no stuck.

3. Installation

1) Install oil pump housing.

■ Ensure the glue coating surface be clean, no oil, dirt, etc.

■ Apply Dow corning 3-0115 surface sealant or equivalent products. Refer to "Timing sprocket mechanism - oil pump housing installation".

2) Install crankshaft front oil seal.

■ Place the special tool at the front of the crankshaft and apply engine oil to its periphery.

 

 

 

 

■ Apply the engine oil to the sealing lip, then push the oil seal along the guide sleeve by hand until it touches the front oil seal housing. Tap the oil seal with a special tool to put it in place.

4) Install the engine oil suction filter.

5) Install the oil pan.

■ Before installing the oil pan, make sure the cylinder block, sprocket chamber cover, the bottom end face of the oil seal bracket are clean, no machine oil, no dirt, etc.

■ Remove the remaining sealing glue of the previous process at the three-point joint surface of the sprocket chamber cover, oil seal bracket and cylinder block, and uniformly apply the new sealing glue on the joint surface. The diameter of the rubber strip is 4mm.

The front sprocket chamber cover, the rear oil seal of the crankshaft and the body are coated with 4 mm diameter sealing strip

■Ensure the glue coating surface be clean, no oil, no dirt, etc.

■ Apply Dow corning 3-0115 surface sealant or equivalent products along the center of glue tank on flange face of oil pan.

■The control method for the amount of glue applied is: the diameter of the glue strip is combined with its weight, and the diameter is: the diameter of glue strip in zone A is 3mm±0.5mm. The diameter of glue strip in zone B is 4mm±0.5mm, as shown in the figure below.

■glue strip weight：The glue weight of each oil pan is controlled between 13g to15g.

■Tightening method of oil pan bolts: follow the tightening from the middle to both sides, as shown in the following sequence.

■ First pre-tighten, then tighten to the specified torque: (11±1) N·m.

Gluing position and direction

6) Install oil drain bolts on oil pan.

■Bolts’ tightening torque: (39±5) N·m

7) Add engine oil with an amount of about 4L.

Attention：

■ Wait at least 30 minutes after installing the oil pan before adding the engine oil

4. Inspection after installation

1) Start the engine and make sure there is no oil leakage.

2) Turn off the engine and wait for 10min,then check whether or not the oil level is between the upper and lower scale. If the oil is insufficient, please add.

1.4 Engine cooling system

1.4.1 Cooling circuit

1. Cooling principle schematic

Water inlet

Thermostat (82°C)

Water Pump

Radiator

Turbocharger

Heating wind

Water outlet

blower water inlet steel tube

Expansion kettle

Cylinder block, cylinder sleeve water jacket

Cooling principle map

1.4.2 Engine Coolant

1. Inspection

1) Liquid level inspection

■ When the engine is cooled down, check if the engine coolant level in  a range from MIN to MAX.

■If necessary, adjust the engine coolant level.

■If the coolant level is too low, check for leakage.

 

 

 

2) Leakage inspection

Apply pressure on the cooling system to 120kPa by the radiator cap leak detector to check and confirm that the pressure has not decreased If the pressure drops, check hoses、radiators and water pump for leaks. If no external leakage is found,check the heating core、cylinder block and cylinder cover.

 

 

 

 

 

Attention：

■ Do not remove the radiator cap when the engine is hot; otherwise, the high-pressure engine coolant escaping from the radiator can cause serious burns.

■ Exceeding test pressure may damage the heat sink.

■ When engine coolant decreases, add engine coolant to the radiator. If parts are found damaged, please repair or replace them.

3) Coolant quality inspection

Check the quality of the antifreeze. If there is turbidity, deterioration, odor, foaming, etc., you need to replace the coolant and clean the water channel.

2. Engine coolant replacement

Attention：

■ To avoid burns, do not replace the coolant when the engine temperature is high.

■ Cover the radiator cap with a thick cloth and unscrew it carefully. Release the pressure inside the radiator and then completely unscrew the cover.

■ Be careful not to spill engine coolant on the drive belt.

1) Discharge the engine coolant

①　Open the radiator drain plug at the bottom of the radiator and open the radiator cap.

②　Check the engine coolant for iron rust and other impurities or discoloration

2) Refill the engine coolant

①　Install the removed tank and radiator drain plug.

Attention：

■ Be sure to clean the drain plug and install a new O-ring.

②　Confirm that each hose clamp is firmly tightened.

③　Disconnect the warm air outlet hose. Raise the hose as high as possible

④　Fill the radiator and reservoir with coolant to the specified level.Slowly add the engine coolant so that the air in the system is gradually discharged.

Attention：

■ Use the original JAC engine coolant. Refer to “Recommended oil/liquid and lubricants”.

■ Reconnect and continue filling engine coolant when engine coolant overflows blower water outlet hose.

⑤　Install the radiator cover.

⑥　Warm to open the thermostat.

Make sure the thermostat is open by touching the radiator down pipe to feel if there is any warm water coming out.

Attention：

■ Check the engine water temperature indicator to avoid overheating.

⑦　Turn off the engine to reduce the temperature.

⑧　The engine coolant in the tank was added to the MIN to MAX range.

⑨　install the radiator cap and Repeat ③～⑧more than twice with  until the engine coolant level no longer drops.

⑩　Run engine check cooling system for leaks.

3) Flush the cooling system

Attention：

■ Be sure to clean the drain plug and install a new O-ring.

①　Disconnect the blower water outlet hose. Raise the hose as high as possible.

②　Add engine coolant to the radiator and reservoir and install the radiator cap.

③　Reconnect and continue filling engine coolant when engine coolant overflows warm air outlet hose.

④　Run the engine to preheat to normal working temperature.

⑤　Speed up the engine speed several times under no-load condition.

⑥　Turn off the engine and wait for cooling.

⑦　Drain water from the system. Refer to “Drain engine coolant”.

⑧　Repeat steps ①～⑦ until the radiator begins to drain clear water.

1.4.3 Water pump

1、disassembly and installment

Attention：

■ When removing the pump, be careful not to spill engine coolant on the drive belt.

■ The water pump cannot disintegrate and should be replaced as a whole.

■ After installing the pump, connect the hose and fix it with a clamp, then use the radiator cap leak detector to check for leakage.

1)Removal

①　Drain engine coolant from the radiator. Refer to “Engine coolant replacement”.

②　Loosen the fixing bolt of water pump belt pulley.

■ Tightening torque: (8.4±0.6) N·m.

③　Remove the elastic belt.

④　Remove the fixing bolt of water pump.

■ Tightening torque: (8.4±0.6) N·m.

2) Inspection after disassembly

■ Check the water pump assembly for serious corrosion, water seal leakage or corrosion.

■ Check for excessive end clearance resulting in poor work.

■Check whether the pump bearing is stuck or has other damage. Please replace it if necessary.

3) Installation

①　Clean the water pump sealing surface.

②　Install the water pump.

■ Tighten each fixing bolt evenly and alternately.

③　Install the water pump belt pulley.

④　Install the drive belt and adjust it to the specified tension.

⑤　Fill the engine coolant.

2. Inspection after installation

■ Use the radiator cap leak detector to check for leakage.

■ Start and warm up the engine. Visually check engine coolant for leakage.

1.4.4 Thermostat assy.

1、disassembly and installment

1)Removal

①　Drain engine coolant from the radiator water drain plug.. Refer to “Engine coolant replacement”.

Attention：

■ Be sure to operate after the engine is cooling.

■ Do not let engine coolant splash on the drive belt.

②　Disconnect the radiator inlet and outlet pipes and short circle pipes on the side of the thermostat housing

③　Disconnect the wire harness connector of the coolant temperature sensor and the water temperature attention switch, and the fixing bolt of the fixing bracket of the front and rear oxygen sensor wire harness connector and remove them.

④　Remove the fixing bolt of the warm air water return pipe and remove the pipe.

⑤　Remove the fixing bolts of thermostat upper cover and remove the thermostat.

2）Inspection After Removal

①　Thermostat

■ Check the throttle valve opening at normal room temperature

The opening temperature of the thermostat: 82°C（open start）,95°C（full open）.

Maximum lift of valve rod：≥8mm

The closing temperature of the thermostat：>77°C

If the measured value exceeds the specified range, please replace the thermostat.

②　thermostat upper cover and thermostat housing

Check for cracks or other damage.

3) Installation

Please note the following items and install in the reverse order of disassembly.

①　Be careful not to spill engine coolant on the engine. Use a cloth to dry the engine coolant.

②　Replace the "O" ring of water inlet pipe with the new "O" ring, and then apply the coolant to the "O" ring so that they can be easily embedded in the water pump and thermostat housing.

Attention：

■Do not apply engine oil or other oil substances to the “O” ring.

■The water pipe behind the thermostat housing must be securely installed.

③　When installing a thermostat, keep its jump valve in the highest position.

puppet valve

 

 

 

 

④　If the water temperature sensor is to be reused, the specified sealant should be applied to its threads.

■Specified sealant: Tonsan 1243 thread sealant.

 

2. Inspection after installation

■ Use the radiator cap leak detector to check for leakage. Refer to "Leakage Inspection"

■ Start and warm up the engine. Visually check engine coolant for leakage.

1.4.5 Water pipe assy.

1. Disassembly

①　Drain engine coolant from water drain plug at the bottom of  the radiator Refer to “Engine coolant replacement”.

Attention：

■ Be sure to operate after the engine is cooling.

②　Remove the radiator upper and lower  water hose

③　Remove warm water hose and short circle hose.

④　Remove the inlet pipe fixing bolt and remove the water inlet pipe from the back end of the water pump.

Attention：

■ Before disassembling, remove the battery negative terminal first

2. Installation

Please note the following items and install in the reverse order of disassembly.

1) Firmly insert each hose Install the clamp ring, and the clamp ring will not clamp the boss of the pipe

2) Replace the "O" ring of water inlet pipe with the new "O" ring, and then apply the coolant to the "O" ring so that they can be easily embedded in the water pump and thermostat housing.

Attention：

■ Do not apply engine oil or other oil substances to the “O” ring.

■ The water pipe behind the thermostat housing and water pump must be securely installed.

3. Inspection after installation

1) Use the radiator cap leak detector to check for leakage.

2) Start and warm up the engine. Visually check engine coolant for leakage.

1.4.6 Common fault analysis

Analysis of overheating

 

. Parts other than cooling system malfunction	—	Engine overload	Abnormal driving	Engine speed is too high under no-load conditions
				Long time driving
				Over-speed driving
	—	—	Transmission system failure	—
			Incorrect size wheels and tires installed	—
			Braking retardation
			Ignition timing is incorrect
	Poor air circulation	Bumper vents blocked	—	—
		Radiator grille blocked	Car cover installed
			Dust or paper jammed
		Radiator jammed	—
		Condenser clogged	Poor air circulation

 

1.5 Engine emission control system

1.5.1 Fuel  evaporation system

1. System description

 

 

 

Fuel  evaporation system map

 

 

 

 

 

 

 

 

 

Fuel  evaporation system theory map

 

The fuel evaporation system is used to reduce hydrocarbon emissions from the fuel system into the atmosphere. Use activated carbon in EVAP tanks to reduce hydrocarbon emissions. When the engine is not running or refueling to the tank, the vapors from the sealed tank are guided into the EVAP tank with activated carbon and stored there. When the engine is running, the fuel vapor in the EVAP carbon tank is carried into the intake manifold through the clean line. EVAP Carbon canister solenoid valve is controlled by ECM. When the engine is working, the steam flow controlled by the EVAP carbon tank solenoid valve is adjusted proportionally to the increase of air flow.

2. Fuel evaporation exhaust pipeline map

Fuel evaporation system map

1-Carbon can assembly 2-Engine oil inlet hose 3-Carbon canister solenoid valve tube 4-Carbon canister solenoid valve hose

5-Engine oil inlet pipe 6-Fuel filter

Attention：

Do not use soapy water or any cleaner when installing vacuum tubes or cleaning tubing.

3. Component inspection

1) EVAP Carbon canister solenoid valve

Steam by-pass line opening of EVAP Carbon canister solenoid valve controls airflow rate. According to the signal sent by ECM, the EVAP carbon canister solenoid valve repeatedly opens/closes (ON/OFF), and the valve opening changes to achieve the best engine control. The optimal value stored in the ECM is determined by the different states of the engine. When the engine is running, the airflow rate of fuel steam from EVAP carbon canister is adjusted with the change of air flow.

①　Component description

The EVAP carbon canister solenoid valve uses the ON/OFF duty ratio to control the flow rate of fuel steam out of the EVAP carbon canister. The EVAP carbon canister solenoid valve is driven by an open /OFF (ON/OFF) duty ratio signal sent from the ECM. The longer width of the (ON) pulse, the more fuel vapor will flow through the valve.

②　Removal

a.
Disconnect the vacuum hose of the EVAP carbon canister solenoid valve.

 

b. Disconnect the wire harness connector of the EVAP carbon canister solenoid valve.

c.Take down the EVAP carbon canister solenoid valve from air inlet manifold bracket.

3) Oil filler cover

A vacuum relief valve is installed on oil filler cover When the pressure in the fuel tank is high (more fuel vapor), the vacuum relief valve is closed to prevent the fuel vapor from escaping into the atmosphere. When the pressure in the fuel tank is low (negative pressure), the vacuum relief valve opens to allow the outside air to enter the fuel tank.

 

1.5.2 Crankshaft box force ventilation system

1、System instruction

Crankshaft box force ventilation system map

1-Air filter    2-air inlet hose    3-throttle valve body 4-purification can       5-PCV valve

6-PCV valve connecting hose 7-Air inlet manifold   8-Injector

 

The crankcase forced ventilation system is designed to send the cylinder air back to air inlet manifold

The crankcase forced ventilation valve(PCV) is designed to send the cylinder air back to air inlet manifold. When the throttle of the engine is partially opened, the air inlet manifold is sucked into crankshaft box air through the PCV valve. Normally, the PCV valve has enough air volume to fully inhale the crankshaft box air and a small amount of ventilation air. ventilation air is drawn into the crankshaft box from the air inlet pipe In this process, the air passes through a hose that connects air inlet pipe to the rocker chamber cover. When the throttle of the engine is fully opened, The vacuum of the air inlet manifold is not sufficient to open the PCV valve and inhale the crankshaft box air. The air will flow in the opposite direction through the connecting hose. The PCV valve cannot meet the requirements in a vehicle with a particularly severe gas leakage. because in any case a portion of the gas will pass through the hose to the air inlet pipe.

2、Component inspection

PCV（Crankshaft box force ventilation ）valve inspection as follow：

1) Working principle:

 

 

PCV valve working principle table

Engine working conditions	Out of action	Engine working conditions	Idle or decelerate
PCV valve	Not working	PCV valve	Fully open
Vacuum degree change	Limit	Vacuum degree change	Slightly
		No vacuum    Cylinder head guard
Engine working conditions	Working normally	Engine working conditions	Acceleration and high speed abnormal
PCV valve	Working normally	PCV valve	Working slowly
Vacuum degree change	Large amplitude	Vacuum degree change	Very large

2)Removal

①　Disconnect the respirator vent tube from the head cover.

②　Remove the PCV valve from the cylinder cover guard side.

3) Inspection after disassembly

①　PCV valve

A normal working valve makes a hissing noise when airflow passes. When your finger is at the entrance of the valve, you immediately feel a strong vacuum pressure.

②　Respirator ventilation tube

a.Check hoses and hose connections for leaks

b.Disconnect all hoses and clean with compressed air. If the plug in the hose cannot be removed, replace it.

4)        Installation

①　Install PCV valve

■ Tightening torque is about 4N; it cannot be too big.

②　Install the respirator air duct.

■Pay attention to the direction of installation.

Connect the PCV valve