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Maintenance Manual for J2 Sedan

Mechanical Part of Engine

39

IV.  Engine Assembly

1.  Precautions on Installation and Dismantlement

 

Caution:

Operation in violation of the following instructions may incur personal injury!

■

 

Park the vehicle on flat and firm ground.

Attention:

■

 

Always  pay  attention  to  safe  operation,  and  do  not  conduct  any  forcible  operations  or
operations other than that specified in Instructions.

■

 

Do not start before the exhaust system and engine coolant have completely cooled down.

■

 

If  the necessary  items  or operations  are  not mentioned  in the  sections of  Engine, see  relevant
chapters.

■

 

Use the specified lifting points all the time and select appropriate lifters according conditions.

2.  Preparation for Dismounting Engine and Transmission Assembly

1)  General

Dismount  the  engine  and  transmission  assembly  from  the  vehicle,  and  then  detach  the  engine  from
transmission.

2)  Preparation

①

 

Discharge the engine coolant from the radiator. See “Change Engine Coolant”.

②

 

Discharge the engine oil, transmission oil and clutch oil. See "Engine Oil", “Transmission Oil” and
“Clutch Pipeline”.

③

 

Collect the refrigerant  in AC pipeline.

Attention:

■

 

Perform this step after the engine has cooled down.

■

 

Do not spill engine cooling fluid or brake fluid to the drive belt.

④

 

Dismount the following parts:

■

 

Engine trimming cover. See “Intake Manifold”.

■

 

Front wheels and tyres. See “Wheels and Tyres”.

■

 

Engine deflectors (left and right).

■

 

Air duct and air filter assembly. See “Air Duct”.

■

 

Battery, battery base and base support. See “Battery”.

■

 

Radiator assembly and radiator fan. See “Radiator”.

Summary of Contents for J2

Page 1: ...affected due to product improvement JAC Passenger Car Sales Company will provide technical bulletins or supplementary volumes Therefore you should use this manual and pay close attention to obtaining...

Page 2: ...n 2 II Nameplate 2 III Vehicle Identification Number VIN 3 IV Engine Number 4 Section III Lifting Protection and Towing of Vehicle 6 I Lifting of Vehicle 6 II Protection of Vehicle 6 III Towing of Veh...

Page 3: ...this Manual No description is given for the necessary basic skills of maintenance technicians in this Manual II How to use This Manual comprises four parts i e engine volume chassis volume electrical...

Page 4: ...ehicle 2 ID number of vehicle II Nameplate 1 Position of nameplate at the firewall of engine compartment 2 Instructions of nameplate Example of Nameplate Made by China Anhui Jianghuai Automobile Co Lt...

Page 5: ...e below Table Worldwide Manufacturer Identification ID Manufacturer Applicable Models LJ1 JAC Co Ltd ANHUI Freight truck incomplete vehicle bus passenger car tractor special vehicle Part 2 vehicle des...

Page 6: ...ype and rated power 2 gasoline 70 90Kw 3 gasoline 90 110Kw Part 3 indication of vehicle 8 digitals 4 General Assembling Workshop of Passenger Car Manufacture Company Factory assembled 7 General Assemb...

Page 7: ...ance Manual for J2 Sedan Overview 5 2 Meaning of Engine Number 3GB4 C Engine model 1 0 3 cylinder gasoline engine A3408769 A the year of 2010 3 engine type petrol local parts 408769 Production SN Fig...

Page 8: ...l injury or even death II Protection of Vehicle 1 Appearance Protection Be sure to use the four protection appliances including seat cover steering wheel cover gearshift lever cover and foot mat befor...

Page 9: ...ing If no towing vehicle is available under emergency a rope may be fixed to the emergency towing hole under the vehicle for temporary traction 1 Front towing hole It is under the front bumper A drive...

Page 10: ...tems to be Frequently Inspected for the Exterior of Vehicle Item Inspection Tyre Use an air gauge to inspect the pressure of tyres including spare tyre in the service station regularly adjust pressure...

Page 11: ...al would not be seized or loaded unevenly Keep floor pad away from the pedal Brake pedal and booster Check if the pedal can be operated smoothly make sure the pedal still keeps an appropriate distance...

Page 12: ...I I I I I I I 10 Exhaust fittings leakage I I I I I I I I I I 11 Throttle body C C C C C 12 Injector C C C C C C C C C C 13 Valve clearance I I I I I I Notes C For cleaning operation of fuel injector...

Page 13: ...eat Wall AC refrigerant 600 25g R134a Wiper cleaning liquid 3 Water AC compressor lubricating oil 0 12 PAG56 V Service of Engine 1 Inspection of Driving Belt Warnings Be sure to operate only with engi...

Page 14: ...pen the water drain plug at the bottom of radiator and then open the cap of radiator If necessary please dismount coolant reservoir drain the engine coolant and reinstall it after cleaned Check if the...

Page 15: ...emoved above Attention The drain screw plug must be cleaned a new O ring must be installed Dismount air filter upper cover and the intake hose Refer to Air Filter Assembly Disconnect outlet tube of he...

Page 16: ...imit 59 KPa Connect the radiator cap to radiator leak detector paste engine coolant onto the sealing face of cap If any failure is found in above mentioned three inspection items replace radiator cap...

Page 17: ...h engine hot otherwise the high temperature and high pressure liquid overflowing from the radiator may cause severe scald Attention A pressure exceeds the specified test pressure may cause damage to t...

Page 18: ...ssible 1 Warm up the engine and check for any oil leakage in the engine compartment Refer to Leakage of engine oil 2 Stop engine and wait for ten minutes 3 Loosen engine oil filler cap and then remove...

Page 19: ...be prepared to wipe up the leaked or splashed oil Please keep the driving belt free from engine oil Clean any oil splashed on engine and vehicle 2 Installation Clear any foreign substance on mounting...

Page 20: ...case ignition knock frequently occurs with standard ignition plug the cold ignition plug should be used Long time traveling on the expressway Engine is frequently running with high speed Attention Be...

Page 21: ...nition switch to ON with engine stopped and then check for leakage at the joints of fuel pipeline Start engine and run with increased speed check again for fuel leakage at the joints of fuel pipeline...

Page 22: ...information refer to Change Manual Transmission Oil 2 Inspect oil level For detailed information refer to Inspection of Manual Transmission Oil Level 6 Wheel Balance 1 Dismantlement Dismount the wheel...

Page 23: ...uld be replaced every time At most three balance blocks are allowed to be installed The original balance blocks should be used any time c In case the calculated weight of balance block is more than 50...

Page 24: ...se check brake system for leakage 9 Inspection of Brake System Pipeline and Cable Check for correct positions of brake pipeline and parking brake cable and any leakage worn scratching or ageing etc 10...

Page 25: ...d then step on the brake pedal to close the release valve Repeat there procedures for all wheels 5 Bleed air See also Air Bleeding of Brake Pipeline 11 Inspection of Brake 1 Brake disc Check for worn...

Page 26: ...Cylinder bore of brake slave cylinder 17 46 mm Clearance adjustment Automatically Brake drum Circular runout 0 05 mm 3 Brake caliper Check for any oil leakage 4 Rear brake slave cylinder Check for any...

Page 27: ...ion with the steering column is loose 2 Steering pull rod Check ball joint dust boot and other components for loosening worn damage and grease leakage 13 Check the pipeline Stop engine check fluid lev...

Page 28: ...orber for oil leak or other damages Check the suspension ball joint for grease leakage check ball joint dust boot for crack or other damages 15 Inspection of Drive Shaft Check dust boot and drive shaf...

Page 29: ...nt of seat belt assembly has problems please do not repair it but replace the seat belt assembly In case the seat belt is broken worn or damaged don t repair but replace the seat belt assembly Be sure...

Page 30: ...torques listed above are not applicable for following conditions a When the component is to be tightened with spring or tooth washer b Tightening of the plastic parts c Self tapping screw or self loc...

Page 31: ...balance shaft assembly 58 XI Cylinder head 64 XII Valves 68 XIII Cylinder Body Assembly 72 XIV Diagnosis of Common Troubles 86 XV Parameters for Maintenance 88 Section II Engine Lubrication System 92...

Page 32: ...ubles 137 III Parameters for Maintenance 137 Section II Starting and Charging System 138 I Principle Diagram of Starting and Charging System 138 II Battery 138 III Starting System 141 IV Charging Syst...

Page 33: ...n Sensor 183 IV Crankshaft Position Sensor 185 V Camshaft phase sensor 188 VI Oxygen sensor 191 VII Fuel Injector INJ 194 VIII Knock sensor 195 IX Air conditioning switch and relay 197 X Canister sole...

Page 34: ...al ones second and so on Conduct the operation in compliance with the loosening sequence if specified 4 Precautions on Check Repair and Replacement Thoroughly check the parts before repair or replacem...

Page 35: ...ge the matching faces Insert the scraper and then knock its side to slide it as shown in the figure For the positions where it is difficult to use scraper lightly knock the parts to dismount them with...

Page 36: ...ally put outside the bolt hole Install the matching part in a certain period of time after applying sealant Eliminate any dirt from the sealant Do not re tighten the bolts or nuts after installation i...

Page 37: ...camshaft timing sprocket 2 Pin JAC T1D001 Used together with the end forked clamp 3 Locating tool for piston pin Used to install and dismantle the piston pin 4 Guide sleeve JAC T1F005 Used together w...

Page 38: ...staller for valve oil seal JAC T3F001 Used to install the valve oil seal 11 Guide for front oil seal of crankshaft JAC T3F003 Functioning as a guide during the installation of front oil seal of cranks...

Page 39: ...valent 3 Sealant Oil pressure switch draining screw plug and flywheel bolt LT243 or equivalent 4 Sealant Coolant temperature sensor and water temperature alarm switch LT648 or equivalent 5 Petrol 93 u...

Page 40: ...ifters according conditions 2 Preparation for Dismounting Engine and Transmission Assembly 1 General Dismount the engine and transmission assembly from the vehicle and then detach the engine from tran...

Page 41: ...ee Air Compressor Remove the brake fluid reservoir Remove the accelerator cable Disconnect the wire harness connectors and buckles of the following parts and then take them away Oxygen sensor Engine c...

Page 42: ...due to changes of vehicle gravity use the jack to support the rear lifting point 6 Detachment Remove A C compressor assembly from the engine and transmission assembly Dismount starter See Starter Lif...

Page 43: ...e check for any abnormal noise and or vibration With engine warmed up verify that there are no leakage of fuel exhaust gas or other oil and liquid including engine coolant and oil Bleed air and replen...

Page 44: ...oning force for new belt 1 2 1 5 Adjust if tension is out of range Attention When checking belt tension after installation firstly to adjust tension to specified value Then revolve the crankshaft for...

Page 45: ...4 Dismantlement of Drive Belt 1 Completely loosen the alternator belt as per the instructions in Tension Adjustment 2 Remove the alternator belt 5 Installation of Drive Belt 1 Mount the belt onto the...

Page 46: ...d Air Duct 1 Parts Diagram of Positions 2 Intake Pipe 1 Dismantlement Remove the fastening bolts and clamps of front intake pipe and remove the front intake pipe assembly Tightening torque 17 19 N m L...

Page 47: ...the base Tightening torque 8 12 N m 2 Check after Dismantlement Check whether there is any crack or wearing on the air duct assembly If any replace 3 Installation Install with steps contrary to disman...

Page 48: ...al Maintenance Blow the filter element from its back side with compressed air till nothing is blown off 3 Installation Install with steps contrary to dismantlement VII Intake Manifold and Exhaust Mani...

Page 49: ...ottle position sensor Carbon canister control solenoid Accelerator cable Disconnect the following hose joints Water hose joint insert a plug to prevent the engine coolant leakage PCV hose Vacuum hose...

Page 50: ...nstall with steps contrary to the dismantlement Attention Do not reuse the non reusable parts Before starting the engine check the level of engine coolant If the level is lower refill engine coolant a...

Page 51: ...ge the oxygen sensor It is forbidden to use any oxygen sensor which has dropped to the hard ground from a height above 0 5m Such an oxygen sensor should be replaced Unscrew the fixing bolt for heat sh...

Page 52: ...nverter 6 Bellow 7 Rear oxygen sensor 2 Inspection of Exhaust System Check whether the exhaust pipe the three way catalytic converter the muffler and the fixing devices are properly installed and whet...

Page 53: ...t Such joints should be firmly connected to avoid gas leakage Pre tighten the fixing nuts and bolts on exhaust manifold side and those on vehicle side Check whether there is any intervention between p...

Page 54: ...cover plate 8 Balance shaft chain wheel fastening bolt 9 Balance shaft chain wheel 10 Secondary chain 11 Balance shaft idler gear 12 Secondary tensioner 13 Secondary tensioner torsion spring 14 Fixed...

Page 55: ...place drive belt c Dismantle oil gauge assembly Tightening torque 7 8 2 N m d Dismantle damping wheel Tightening torque 160 170 N m e Remove the alternator bracket f Dismantle oil pan and cylinder hea...

Page 56: ...heck the timing point shown in the diagram for compliance Fig 1 1 028 Timing mark of primary chain Timing mark of secondary chain Timing mark of secondary chain Timing mark for crankshaft chain wheel...

Page 57: ...track 10 12 N m Dynamic track 19 28 N m j Dismantle exhaust camshaft sprocket bolt Tightening torque 88 10 N m k Remove t he bolts of intake cam chain wheel Tightening torque 88 10 N m l Remove the r...

Page 58: ...ve the secondary chain tensioner Tightening torque 10 2 N m n Remove the bolts of balance shaft chain wheel and remove the balance shaft chain wheel Tightening torque 45 5 N m 2 Installation Reverse t...

Page 59: ...t 8 Balance shaft gear 9 Balance shaft 10 Balance shaft rear end cap gasket 11 Balance shaft rear end cap 12 Balance shaft rear end cap bolts 2 Disassembly and installation 1 Disassembly of camshaft R...

Page 60: ...remove the balance shaft front end cap Tightening torque for balance shaft front end cap 7 6 0 5N m Remove the balance shaft idler gear remove the bolts of balance shaft front gear and remove the bal...

Page 61: ...shaft assembly should be assembled according to grouped drawings The mechanical tappet at the intake side will be grouped and assembled as per the following table to ensure the intake valve clearance...

Page 62: ...0 25 3 25 L1 3 27 3 04 304 0 19 0 25 3 27 L1 3 29 3 06 306 0 19 0 25 3 29 L1 3 31 3 08 308 0 19 0 25 3 31 L1 3 33 3 10 310 0 19 0 25 3 33 L1 3 35 3 12 312 0 19 0 25 3 35 L1 3 37 3 14 314 0 19 0 25 3...

Page 63: ...9 2 88 288 0 27 0 33 3 19 L2 3 21 2 90 290 0 27 0 33 3 21 L2 3 23 2 92 292 0 27 0 33 3 23 L2 3 25 2 94 294 0 27 0 33 3 25 L2 3 27 2 96 296 0 27 0 33 3 27 L2 3 29 2 98 298 0 27 0 33 3 29 L2 3 31 3 00 3...

Page 64: ...timing chain wheel of balance shaft During installation notice to align the timing mark of balance shaft Backlash of balance shaft gear 0 06 0 12mm Backlash of balance shaft idler gear 0 08 0 14mm Be...

Page 65: ...tention It is required to obtain the specified engine speed always by the battery which is fully charged Inspect valve clearance and other relevant parts such as valve valve seat piston piston ring cy...

Page 66: ...ed down Do not splash engine coolant or oil onto the drive belt Dismount the following elements and the relevant parts Engine trimming cover See Intake Manifold Drive belt See Drive Belt Cylinder head...

Page 67: ...ant and the carbon deposit Attention Be careful to prevent impurities from falling into coolant gallery and oil passage of cylinder head b Measure the planeness in six directions at several positions...

Page 68: ...on should be performed in sequence a b e f g and h Then perform the installation steps which are just contrary to dismantlement 4 Check after Dismantlement The steps for checking oil leakage lubricant...

Page 69: ...r 10 exhaust valve spring upper seat 11 exhaust valve spring 12 exhaust valve 13 intake valve oil seal 14 intake valve spring lower seat 15 exhaust valve seal 16 exhaust valve spring lower seat 17 int...

Page 70: ...e the valve seat if required See Valve Guide to replace the valve guide if required 2 Assembly Install valve guide if it has been dismounted See Valve Guide Install valve seat if it has been dismounte...

Page 71: ...at if the contact is uneven or incomplete Inspect thickness of valve edge Replace the valve if the measurement is less than the specified value For intake valve 1 35 1 65mm For exhaust valve 1 85 0 15...

Page 72: ...iameter of 10 655 10 665mm extend the size of valve guide by 0 05mm For the hole with diameter of 10 855 10 865mm extend the size of valve guide by 0 25mm For the hole with diameter of 11 105 11 115mm...

Page 73: ...ve seat Replacement of Valve Seat a Cut away the replaced valve seat from its inner side in order to decrease the wall thickness Then remove the valve seat b Rebore the valve seat hole on cylinder hea...

Page 74: ...engine assembly from the vehicle and then detach the transmission from engine See Engine Assembly for detailed dismantlement steps Fix whole engine Discharge engine oil See Change Engine Oil Dismount...

Page 75: ...r oil seal housing to dismantle Attention Once dismounted the rear oil seal must not be reused It should be replaced by a new one Dismount the piston and connecting rod assembly Before dismounting the...

Page 76: ...rod with method below a Insert the push rod special tool from the front side with a arrow mark and then install the guide sleeve D b With the front mark of piston face upwards install piston and conn...

Page 77: ...after Disassembly Axial clearance of Crankshaft Detection methods are as shown in the figure Standard value 0 09 0 27mm If measurement is not within the standard range replace the thrust washer and re...

Page 78: ...iston and the piston ring with new engine oil then insert the piston ring till the piston reaches the middle part of cylinder measure end gap of piston ring by the feeler gauge Standard values For 1st...

Page 79: ...r to check whether the piston skirt is distorted Standard values 74 973mm Clearance between Piston and Cylinder Bore Calculate per the actual measurement of piston skirt and cylinder bore Gap inner di...

Page 80: ...rules of selection to replace Diameter of Main Journal of Connecting Rod Measure the diameter of main journal of connecting rod by using outside micrometer Standard values 43 0mm Replace the connecti...

Page 81: ...f Crankshaft a Wipe off oil from the crankshaft journal and the inner surface of bearing shell b Mount the bearing shell c Set the plastic divicer till its width equals to the width of bearing shell T...

Page 82: ...bearing shell to match the crankshaft Crankshaft group marking Main bearing Hole group marking 1 2 3 4 5 0 up down Black Black Black Yellow Black Red Black White Black Purple 1 up down Yellow Black Ye...

Page 83: ...bolts of main bearing cap verify that the crankshaft can be rotated smoothly by hand Check the axial clearance of crankshaft See Axial clearance of Crankshaft Install piston onto the connecting rod wi...

Page 84: ...expansion a Install oil ring a Install oil ring lining ring into the piston ring groove Then install the upper and lower blades Attention Lining ring and blade can be installed in two directions There...

Page 85: ...kshaft journal Align air ring opening with oil ring opening See Fig 1 1 097 Install piston rod assembly in corresponding cylinder according to marks on connecting rod Make sure that the front mark on...

Page 86: ...ould be followed After piston connecting rod assembly is installed verify that clearance for the connecting rod big end is 0 10 0 30mm Attention Connecting rod bolts can only be used once Before insta...

Page 87: ...ng bolt loosened Tighten The transmission mounting support loosened Tighten The engine support loosened Tighten The heat shield for engine is damaged Replace The engine support heat shield is damaged...

Page 88: ...The sensor or the wire harness is at fault Repair or replace The sensor or the starter is at fault Repair or replace Ineffective fan The fan relay or the wire harness is damaged Repair or replace The...

Page 89: ...ve stem and valve guide mm Exhaust valve 0 030 0 045 0 15 Conical angle of valve 45 45 5 Intake valve 89 61 89 51 Total length of valve mm Exhaust valve 90 91 90 41 Free height of valve spring mm 43 1...

Page 90: ...20 0 50 1 0 Outer diameter of piston pin mm 18 0 Pressing load on piston pin under room temperature N 4900 14700 Oil gap of crankshaft pin clearance of connecting rod journal mm 0 02 0 04 0 1 Side cle...

Page 91: ...oil seal bolt M6 10 E8 6 7 6 0 6 Rear lug blot M8 20 E10 2 18 4 1 4 Intake manifold bolt M8 40 E10 4 18 1 0 Oil pan bolt M6 12 E8 14 7 6 0 6 Sprocket cover bolt I M10 90 E14 2 39 5 3 0 Sprocket cover...

Page 92: ...ud nut M6 1 3 10 1 Q2580614 crank signal wheel bolt M6 3 12 5 2 5 Water temperature sensor 1 20 4 Hall sensor bolt Inner hex M6 1 16 2 8 4 0 6 Knock sensor bolt Inner hex M8 1 25 30 1 20 4 Exhaust man...

Page 93: ...es on sealant application surface 2 Wipe sealant surface and matching surface clean with special cleaner remove water drops grease and foreign substances 3 Set the sealant with specified type complete...

Page 94: ...ine 93 II Preparation 1 Repair Tools List of repair tools No Tool Outline Drawing Explanation 1 Oil pressure gauge Measure oil pressure 2 Hose Connect oil pressure gauge to cylinder body 3 Oil pressur...

Page 95: ...of engine oil Check the engine oil for any white turbidity and or severe pollution If the oil is turbid or polluted it may be caused by engine coolant Please repair or replace the damaged parts 3 Leak...

Page 96: ...e with the following steps after inspection a Remove any used sealant attached on pressure switch and engine b Apply sealant as specified and tighten the pressure switch Please use the specified seala...

Page 97: ...the above data are only for reference Always use oil gauge to check oil filling volume Warm up engine and check the oil drain bolt and oil filter for oil leakage Stop engine and wait for 10min Check t...

Page 98: ...surface tighten the oil filter by more 0 75 lap or get the tightening torque to 11 1N m Attention The oil filter must be tightened with filter spanner If the filter is tightened by hand oil leakage m...

Page 99: ...4 O ring 5 Engine oil collector filter gasket 6 Engine oil collector filter 7 Oil drainage bolt washer 8 Oil drainage bolt 9 Engine oil filter 10 Oil sump assembly 2 Dismantlement Caution Do not disch...

Page 100: ...cylinder body and then dismount the oil pan Attention Do not damage the matching surface 4 Dismount oil pump housing assembly 5 Dismount oil pickup Attention Tightening torque 8 4 0 65 N m 3 Check af...

Page 101: ...he oil filter by 0 75 lap or get the tightening torque to 11 1N m Attention The oil filter must be tightened with filter spanner If the filter is tightened by hand oil leakage may occur due to inadequ...

Page 102: ...Install the oil drainage bolt washer of oil pan shown in the figure Attention After the installation of oil pan wait at least 30min before filling engine oil 5 Check after Installation 1 Check the oi...

Page 103: ...a n g e r A i r t h r o t t l e b o d y F i x i n g b o l t s o f c o o l a n t p u m p p u l l e y C o o l a n t p u m p p u l l e r B o l t s f o r w a t e r p u m p W a t e r p u m p a s s e m b l...

Page 104: ...when engine is very hot otherwise the high pressure engine coolant overflowing from radiator will cause severe burns Attention Test pressure over specified value may cause radiator damaged When it is...

Page 105: ...refer to Air Filter Assembly Disconect the outlet pipe of warm water pipe Please lift the hose as high as possible Fill coolant into radiator and reservior until specified level is achieved The coolan...

Page 106: ...refer to Air Filter Assembly Run engine to warm it up to normal working temperature Increase engine speed for several times with no load applied to the engine Stop engine and wait for it to cool Disc...

Page 107: ...coolant leakage 2 Inspect Radiator Cap 1 Pull out the negative pressure valve and open it Check if it can be fully closed after pressure release Make sure there is no dirt on or damage to negative pr...

Page 108: ...above 30cm 5 Blow each surface of radiator core with compressed air every 1min until no water is blown out IV Radiator Cooling Fan 1 Dismantlement and Installation 1 Dismantlement Dismount the air in...

Page 109: ...diator Please refer to Replace Engine Coolant Loosen the fixed bolt for belt pulley of water pump Dismount the drive belt Please refer to Drive Belt Dismount the fixed bolt for water pump Attention Ti...

Page 110: ...leakage VI Thermostat Sub assembly 1 Dismantlement and Installation 1 Dismantlement Discharge the engine coolant through water drain plug of radiator See Replace Engine Coolant Attention Operate after...

Page 111: ...lation Be aware of following precautions to install with steps contrary to dismantlement Be careful not to splash engine coolant onto the engine and wipe and dry the engine coolant with cleaning cloth...

Page 112: ...r and lower water hoses of radiator Dismount the warm water hose and minor cycle water piping Unscrew water inlet pipe bolt before disassembling the water inlet pipe from back of water pump Attention...

Page 113: ...f engine coolant Viscous engine coolant Loose clamp Coolant hose Broken hose Water pump Improper sealing Looseness Poor sealing Broken radiator coolant reservoir Radiator cap Broken radiator core F a...

Page 114: ...J2 Sedan Mechanical Part of Engine 113 IX Parameters for Maintenance Technical specification for cooling system Temperature of thermostat opening 82 Initiall y open 95 Fully open Maximum lift of ther...

Page 115: ...ve pole of battery Replace with new clips all the time Do not distort the fuel pipe during installation Please operate on level ground Connect the fuel pipe joint and make sure the joint has been fixe...

Page 116: ...Do not operate electrical system during inspection Prepare a container under the fuel pipe to be disconnect to avoid fuel splash 1 Fully release fuel pressure Please refer to Release Fuel Pressure 2 D...

Page 117: ...s control circuit IV Fuel Injector and Guide Rail 1 Dismantlement Caution Do read the General Precautions before dealing with fuel system Please refer to General Precautions 1 Disconnect the PCV hose...

Page 118: ...e fixing bolt for fuel guide rail 5 Take off the fuel guide rail with injector from intake manifold Attention Avoid interference with fuel injector during removal Absorb the fuel leaked from fuel pipe...

Page 119: ...e the O ring with petrol Do not wash O ring with solvent Verify that there is no foreign substance on O ring and its matching part Make sure the O ring will not be scraped by tool or fingernail and it...

Page 120: ...lation Check for fuel leakage with following steps 1 Set the ignition switch at ON position when the engine stops and then check the connection of fuel pipe for leakage 2 Start the engine increase its...

Page 121: ...t Attention The joint can not be disconnected when the raised position is fully pressed down Do not excessively distort the joint Do not disconnect the joint with any tool Prevent the resin pipe from...

Page 122: ...il click is heard Check whether the connector is connected properly with following methods after connection Visually inspect that 2 raised positions have been connected to the connectors Stretch the r...

Page 123: ...cates full or to be full discharge the fuel from tank until the meter indicates that the fuel level is lower than position E Attention If fuel level exceeds mounting surface of fuel level sensor the f...

Page 124: ...e joint can not be disconnected until the raised position is fully pressed down Do not excessively distort the joint Do not disconnect the joint with any tool Prevent the resin pipe from being heated...

Page 125: ...ace or wash it Inspect Fuel Pump Operation Actuate the fuel pump with 12V regulated power supply directly and check if the operation is normal Attention Do not make the fuel pump operation for a long...

Page 126: ...n substance and damage Make the connector align with the resin pipe and insert the connector straightly until click is heard Check whether the connector is properly connected with following methods af...

Page 127: ...s before dealing with fuel system See General Precautions Discharge fuel tank if necessary Please refer to Fuel Pump Please operate on level ground Carry out the dismantlement steps 1 6 of fuel pump P...

Page 128: ...its backing plate Check the surface of reinforced plate for scratch and deformation Check the backing plate for crack material loss deformation and breakage 3 Installation Be aware of following precau...

Page 129: ...fuel evaporation from sealed fuel tank will be introduced into EVAP carbon canister with active carbon and stored there During operation of engine the fuel evaporation in EVAP carbon canister will be...

Page 130: ...uel filter Note Do not use soap water or any other detergent when installing vacuum pipe or cleaning pipeline 3 Inspection of parts 1 EVAP carbon canister Check EVAP carbon canister with following met...

Page 131: ...ng so as to optimize engine control The optimum value memorized in ECM lies on the state of engine When the engine operates flow rate of fuel evaporation from EVAP carbon canister is adjusted along wi...

Page 132: ...e 3 Filler cap Vacuum relief valve is mounted at the filler cap When the pressure in fuel tank is high more fuel evaporation the vacuum relief will be closed so as to avoid emission of fuel evaporatio...

Page 133: ...conditions the ventilation volume of PCV valve is sufficient to suck all blow by gas of crankcase and a little air The vent air is brought into crankshaft through air intake pipe Ventilation hose inha...

Page 134: ...of engine Out of work Operating state of engine Idling or deceleration PCV valve Out of work PCV valve Fully open Variation of vacuum Limited Variation of vacuum Slight Valve chamber cover side Valve...

Page 135: ...er Dismantlement PCV valve Hissing may be produced during normal working of valve with air flows through When finger touches the valve at the entrance you can immediately feel a strong vacuum pressure...

Page 136: ...I Ignition coil 1 Parts Ignition coil 2 Dismantlement Installation 1 Dismantlement Attention Be sure that the ignition switch is in the OFF position Dismount the trimming cover of engine Refer to Inta...

Page 137: ...istance of secondary coil Secondary coil resistance 7 75 10 23 K Attention The ignition coil harness connector must be disconnected for secondary coil resistance measurement Spark plug Check the spark...

Page 138: ...lement II Diagnosis of Common Troubles Diagnosis Common Troubles Symptom Possible causes Solution Trouble of ignition coil or ignition switch Check or replace the ignition coil or the ignition switch...

Page 139: ...o the terminals of battery and have good contact 2 Methods to prevent excessive discharging of battery The following precautions should be particularly emphasized to prevent excessive discharging of b...

Page 140: ...reference only If U 13 2V inspect the electrical system If 12 5V U 12 9V the system is normal If 11V U 12 4V inspect charging system If U 11V the battery is damaged or the charging system has trouble...

Page 141: ...rosion If there is clean with warm clean water Battery harness Check for erosion and damage Replace if there is any 3 Installation Install with steps contrary to dismantlement Attention During connect...

Page 142: ...starter is connected with engine body for grounding After the power supply and grounding are provided the starter can turn the crankshaft and thus engine is started 2 Dismantlement and installation C...

Page 143: ...art of Engine 142 Disconnect the harness connector of starter Dismount the fixing bolts of starter then take off the starter 2 Installation Install with steps contrary to dismantlement Attention Be su...

Page 144: ...1 Disassembly Exploded View of Starter 1 Screw 2 Front support3 Stop ring 4 Snap ring 5 Pinion 6 Gear ring 7 Solenoid switch 8 Plantery gear 9 Planetary gear 10 Ball 11 Gasket12 Stator 13 Rotor 14 Ele...

Page 145: ...ed Pinion a Visual inspection of the meshing gear teeth If the teeth are worn or damaged replace meshing gear check teeth of fly wheel in this step b Check the teeth of pinion If the teeth are worn or...

Page 146: ...ngs negative with an ohmmeter If broken replace electric brush retainer b Check for electric brush smoothly moving If electric brush bracket is bent replace If the sliding surface is dirty clean Inspe...

Page 147: ...ductivity between each copper plate and shaft of commutator with ohmmeter If open replace c Check surface of commutator If it is rough use 500 sandpaper to lightly sand with method shown in figure d C...

Page 148: ...by adding high temperature grease And then conduct the following operations Gear clearance adjustment Push the pinion out with the magnetic switch energized meanwhile check the clearance between the p...

Page 149: ...s the gear shaft run Check pinion clutch Yes Repair the starter Normal No Check the reduction gear armature and the gear shaft No Check the fuse and the fusible wire Normal Inspect following items of...

Page 150: ...nt voltage the grounding circuit will be opened while the charging alarm light will be turned off If the charging alarm light is still on with engine running it has troubles 2 Charging alarm light If...

Page 151: ...Drive Belt section Take off the generator from the vehicle 2 Installation Install with reversed order of dismantlement Before installing the generator please inspect tension of generator belt Please...

Page 152: ...Disassembly and Assembly Exploded View of Engine 1 Lock nut 2 Belt pulley 3 Spacer 4 Front end cover 5 Front bearing6 Bearing cap 7 Bolt 8 rotor 9 Rear bearing 10 Stator 11 gasket 12 commutator 13 Ele...

Page 153: ...Resistance test Resistance Approximately 2 0 2 5 If it is beyond the standard range replace b Insulator test If electrically continued replace c Inspect wearing condition of slip ring If it is beyond...

Page 154: ...ntion The rear bearing can not be reused after being taken off Please with new one Lubrication of rear bearing out race is not permitted Installation of rear cover a Mount the carbon brushes assembly...

Page 155: ...itch is on The alarm light is off The alarm light is off The alarm light is on The engine starts with a rev of 1500 rpm The alarm light is on The alarm light is off The alarm light is on Perform follo...

Page 156: ...d be used to test any circuit of airbag system The air bag circuit harness can be identified by the yellow or orange harness or harness connectors II General Precautions 1 Only digital electric meter...

Page 157: ...ot be reversed 5 During inspection of ignition system the sparking should be detected only when it is necessary and the time should be as short as possible The air throttle must not be opened during i...

Page 158: ...diagnose Description of tool diagnose tool of electronic controlled injection system Function reading clearing DTC of electronic injection system view data flow test actions of parts etc Description...

Page 159: ...158 Description of tool digital universal meter Function measure characteristic parameters such as voltage current and resistance of electronic injection system Description of tool vacuum gauge Funct...

Page 160: ...ne 159 Description of tool cylinder pressure gauge Function inspect pressure in each cylinder Description of tool fuel pressure gauge Function inspect pressure of fuel system determine working states...

Page 161: ...he MIL lit After the operation be sure to connect the rubber pipe properly The failed connection of the rubber pipe may cause lighting of MIL because of failure of the EVAP system and fuel injection s...

Page 162: ...he parts and harness of the electronic control system dry Inspect ECM with port and reference value to assure the normal function of ECM before replacing Even the very little leakage in the intake sys...

Page 163: ...em of Engine 162 Tighten clamp of fuel hose to specified torque Don t step on accelerator pedal when starting the vehicle Don t increase the speed of engine immediately after starting the vehicle Don...

Page 164: ...system of ECU monitors various components and control functions in the system Once a malfunction is detected and confirmed the system will save the malfunction code and activate the Limp home function...

Page 165: ...xygen concentration in exhaust Throttle opening sensor Throttle opening Knock sensor Knock of engine Air conditioner switch Air conditioner pressure Wheel speed sensor Vehicle speed Coolant temperatur...

Page 166: ...sed to make vehicles slow down In back tow or towing operation condition fuel injection is cut off in order to reduce the fuel consumption and the emission more importantly the three way catalyst can...

Page 167: ...ing to limit of evaporative emission regulation it is not permitted to exhaust the vapor containing large quantity of HC composition directly into the atmosphere The fuel vapor in the system is collec...

Page 168: ...identifying storing and showing the trouble information through the self diagnosis malfunction indicator lamp MIL 2 Trouble Information Record Electronic control module constantly monitors the sensor...

Page 169: ...f 2Hz 2 When a malfunction is present The malfunction indicator lamp will be always on after the ignition switch is turned on ON After the engine is started the malfunction indicator lamp will go out...

Page 170: ...ed information and confirm the clearing of the trouble 2 Connection of Diagnosis apparatus The K line protocol and ISO9141 2 standard diagnosis joint are adopted for the system as shown in the figure...

Page 171: ...ge of engine coolant temperature sensor circuit P0118 High voltage of engine coolant temperature sensor circuit P0122 Out of lower limit of throttle position sensor circuit voltage P0123 Out of upper...

Page 172: ...80 Open circuit of cooling fan relay control circuit low speed P0481 Open circuit of cooling fan relay control circuit high speed P0501 Inappropriate vehicle speed sensor signal P0506 Lower idling con...

Page 173: ...VS lamp drive circuit P2177 Out of upper limit of air fuel ratio closed loop control self learning Medium load zone P2178 Out of lower limit of air fuel ratio closed loop control self learning Medium...

Page 174: ...emblies of the electronic control system with trouble diagnose apparatus Attention Before dismantling or installing any component read the DTC at first and then disconnect battery negative poles Befor...

Page 175: ...e the symptom described by the user User described the symptom and apparatus did not show DTC 6 Implement the basic check 10 Check the troubled component through the diagnosis steps 9 Use the trouble...

Page 176: ...rt normally 7 Unstable idle fluctuant idle speed and hunting 8 High idle speed abnormal idle speed 9 Idle Stability abnormal idle speed Low idle speed abnormal idle speed 10 The engine stops at the id...

Page 177: ...the current vehicle speed or the temporary decline of vehicle speed rotation speed of engine during acceleration Poor acceleration Poor acceleration refers to that the vehicle is unable to acquire ac...

Page 178: ...for 2min at the idle speed 5 Read idling speed 750 50r min 7 Fuel Pressure Test Attention Before disconnecting the fuel pipeline it is necessary to release the fuel pressure inside the fuel pipeline...

Page 179: ...d of fuel return pipe Repair or replace fuel pipe 8 Turn off engine and check the changes of fuel pressure gauge reading for 5min If the reading drops observe the reduction rate Referring to following...

Page 180: ...ring starting under certain conditions it allows the ECM to be adjusted automatically at different altitudes ECM provides 5V voltage to MAP sensor and receives voltage signal by the signal line The se...

Page 181: ...ircuit open circuit grounding problem exists in sensor wiring harness Whether sensor is highly impacted resulting in sensor failure Operating pressure range 12 5kPa 115kPa Operating temperature range...

Page 182: ...res the engine coolant temperature and sends the signal to the ECM for control of ignition timing and fuel injection pulse width during start idling and normal running It adopts one negative temperatu...

Page 183: ...Solution It mainly checks the connections between wires of sensor and ECU and between wires of sensor and instruments for presence of short circuit and open circuit Short circuit open circuit groundi...

Page 184: ...arness connector With engine idling visually inspect coolant leakage III Throttle Position Sensor 1 Instruction of Parts This sensor is one angle sensor with linear output characteristic and is compos...

Page 185: ...4 Diagnosis Poor acceleration etc 5 Solutions Mainly inspect sensor and ECU wiring harness for short circuit open circuit grounding problems Shift the multimeter to Ohm measurement scale and connect t...

Page 186: ...n of throttle position sensor 1 Dismantlement Disconnect the wire harness connector of air throttle position sensor Note Be sure that the ignition switch is at the Off position Remove the screws of th...

Page 187: ...he crankshaft When the tip of tooth passes through the tip of crankshaft position sensor the signal wheel made of ferromagnetic material cuts the magnetic force line of permanent magnet in the speed s...

Page 188: ...it to ground Sensor unit short circuit to system reference voltage signal wire 5 Trouble Solution Check sensor circuit for normal function and incorrect connection of grounding Connect the sensor and...

Page 189: ...ndard 0 5 1 5mm Tightening torque 7 8 9 N m V Camshaft phase sensor 1 Component Description This sensor provides crankshaft phase information to the ECU namely differentiating the compression top dead...

Page 190: ...is in proportion to the magnetic field induction B perpendicular to the current IS and the current IS The Hall voltage is subject to the varying magnetic field induction strength B Performance Operat...

Page 191: ...short circuit to system reference voltage signal wire 5 Trouble Solution Check sensor circuit for normal function and incorrect connection of grounding Connect the sensor and harness to check whether...

Page 192: ...nd purified in the three way catalytic converter The sensing component is a kind of porous ceramic tube the wall is surrounded by the engine exhaust while the inside is put through to the atmosphere T...

Page 193: ...oxygen sensor heating control 1 To main relay power Pin 39 Upstream oxygen sensor grounding Pin 45 Upstream oxygen sensor signal Pin 2 Upstream oxygen sensor heating control 1 To main relay power 4 D...

Page 194: ...ay attention to the fuel quality meanwhile excessive fuel consumption may also lead to sensor failure Changes of the oxygen sensors should be not less than a certain times in certain period of time 6...

Page 195: ...VII Fuel Injector INJ 1 Instruction of Parts Fuel coming from the fuel pump is stored and distributed via the fuel rail components and provides the fuel system with a more stable pressure environment...

Page 196: ...1 4 12 6 2 Inspect operating time of the fuel injector with trouble diagnosis apparatus Standard operation time 2 0 3 0ms at the idle speed and more during the acceleration 3 Check the operating sound...

Page 197: ...y reduce it until the knock disappeared and then gradually restore to the knock threshold the cycle is done repeatedly 2 Installation position Installed aside of cylinder 3 Inspection 1 Wiring diagram...

Page 198: ...sconnect knock sensor harness connector Unscrew knock sensor locking nut remove the knock sensor Attention Do not drop or damage the sensor 2 Installation Install with reversed steps of disassembly Ti...

Page 199: ...anister has certain limits if evaporation of gasoline attached to the canister is not consumed it may emit into ambient air resulting in pollution and increased insecurity Internal of canister valve i...

Page 200: ...Temperature 40 120 Coil resistance 19 22 Working voltage 8 16V 6 Removal and installation 1 Removal Disconnect hose at canister solenoid valve side Disconnect the canister solenoid valve wiring harne...

Page 201: ...utilize the high voltage generated in the secondary stage of the coil to puncture the gap of spark plug generate strong spark and ignite the gas mixture Due to high air ionization degree and low resi...

Page 202: ...ponding cylinder will be turned off Control cable short circuit with ground Control cable short circuit with power line Control circuit open 4 Diagnosis Internal short circuit open circuit of coil Coi...

Page 203: ...Check the fuel pressure Refer to Fuel System 5 Dismantlement and Installation Refer to Fuel Pump Assembly Attention In order to prevent accidental damage of fuel pump please do not run the fuel pump w...

Page 204: ...ive circuits execute different actions by driving corresponding actuators and control the engine to run as per preset control strategy At the same time the malfunction diagnosis system of ECU monitors...

Page 205: ...minal B of engine speed sensor 15 Diagnosis K line 47 Terminal A of engine speed sensor 16 Sustained power supply 48 Power grounding 1 17 Ignition switch 49 Fuel injector 2 3 rd cylinder 18 5V power s...

Page 206: ...signal normal connection of its circuit 4 Check whether the actuator is normal and whether its line is intact 5 Finally replace the ECM to carry out the test 5 Dismantlement and Installation 1 Disman...

Page 207: ...rcuit with ground or open circuit if the DTC points to high voltage of a specific circuit it indicates that the circuit is likely to have short circuit with power circuit if the DTC points to a circui...

Page 208: ...cantly fast depress the accelerator pedal and almost open the throttle completely and at this moment the displayed value can reach above 90kpa instantly No Replace the sensor Fault code P0108 the inta...

Page 209: ...on the diagnosis meter and at this moment the displayed value increases along with the rising of engine intake temperature No Replace the sensor Fault code P0113 the signal voltage of intake temperatu...

Page 210: ...ure value on the diagnosis meter and at this moment the displayed value shall increase with the rising of engine coolant No Replace the sensor Fault code P0118 the circuit voltage of engine coolant te...

Page 211: ...Maintenance Manual for J2 Sedan Electronic Control System of Engine 210...

Page 212: ...Replace the sensor 6 Check if the voltage between Pins 1 and 2 of this connector is about 5V by the multimeter No Diagnosis help Fault code P0123 the circuit voltage of throttle position sensor is at...

Page 213: ...tep 1 Connect the diagnosis device and adapter and turn the ignition switch to ON position Next step Yes Diagnosis help 2 Start the engine and run the engine idly till the coolant temperature reaches...

Page 214: ...n Next step Yes Next step 2 Start the engine and run the engine idly till the coolant temperature reaches to the normal value Under all the work conditions observe the change of the value of Oxygen se...

Page 215: ...s 5 A Check if the fuel injector drips fuel B Check if the exhaust pipe has leakage C Check if the ignition timing is incorrect Etc No Diagnosis help Fault code P0201 the control circuit of fuel injec...

Page 216: ...tween Pin 2 of the fuel injector connector of Cylinder 2 and Pin 63 of ECU is open or short to power source or ground No Diagnosis help Fault code P0203 the control circuit of fuel injector of Cylinde...

Page 217: ...and turn the ignition switch to OFF position Next step Yes Next step 2 Unplug the knocking sensor connector on the harness and check if the resistance between Pins 1 and 2 of knocking sensor is higher...

Page 218: ...rcuit connecting Pin 3 of phase sensor to Pin 87 of main relay is open or short to ground Check if Pin 1 of phase sensor is grounded improperly No Next step Yes To Step 6 4 Check if the voltage betwee...

Page 219: ...o Pin 87 of main relay is open or short to ground Check if Pin 1 of phase sensor is grounded improperly No Next step Yes To Step 6 4 Check if the voltage between Pin 2 of phase sensor and the negative...

Page 220: ...he canister control valve at 20 is between 22 and 30 by the multimeter No Replace the control valve Yes Diagnosis help 5 Check if the voltage between Pin 1 of the canister control valve connector and...

Page 221: ...tive pole of power source is about 3 7V by the multimeter No Next step Yes Repair or replace the harness 5 Check if the circuit connecting to Pin 86 of relay control side to Pin 62 of ECU is open or s...

Page 222: ...ault code P0506 the idle speed is the lower than the target idle speed S N Step Check result Subsequent step 1 Connect the diagnosis device and adapter and turn the ignition switch to OFF position Nex...

Page 223: ...rive pin of stepping motor is short to power source S N Step Check result Subsequent step 1 Connect the diagnosis device and adapter and turn the ignition switch to ON position Next step Yes Next step...

Page 224: ...attery is too low S N Step Check result Subsequent step 1 Connect the diagnosis device and adapter and turn the ignition switch to OFF position Next step Yes Next step 2 Check if the battery voltage i...

Page 225: ...the relay power supply side namely Pins 87 and 85 of relay and the negative pole of power source is about 12V No Next step Yes Repair or replace the harness 3 Check if the circuit of relay power supp...

Page 226: ...the voltage between the relay power supply side namely Pins 87 and 85 of relay and the negative pole of power source is about 12V No Next step Yes Repair or replace the harness 3 Check if the circuit...

Page 227: ...itions about the occurrence of the trouble And then check the appearance 1 Check fuel pipes for leakage 2 Check vacuum pipes for breakage or kink and proper connection 3 Check intake pipes for blockag...

Page 228: ...ine No Replace battery Yes Next step 2 With ignition switch at the starting position check voltage of starter negative terminal to verify that it is above 8V No Repair or replace wire harness Yes Repa...

Page 229: ...tor and observe whether fuel pressure is about 300kPa No Repair the fuel supply system Yes Next step 2 Connect the electric control system diagnosis apparatus to the engine to observe the data of rota...

Page 230: ...e of the cylinders and connect the spark plug to make the spark plug electrodes about 5mm away from the engine body and start the engine to check whether there is the blue and white high voltage spark...

Page 231: ...the blue and white high voltage spark No Repair the ignition system Yes Repair circuit or replace the sensor 3 Pull out the connector of coolant temperature sensor and start the engine to observe whe...

Page 232: ...body then start the engine to check whether there is the blue and white high voltage spark No Repair the ignition system Yes Next step 4 Check the spark plug of each cylinder to observe whether model...

Page 233: ...with the specification No Adjust or replace Yes Wash 4 Check air throttle body and idle bypass air passage for carbon deposit No Next step Yes Failure of Replacement 5 Dismantle the fuel injector and...

Page 234: ...ck whether there is carbon deposit in the air throttle body idle adjustor or idle bypass air passage No Next step Yes Repair circuit or replace sensor 4 Pull out the connector of coolant temperature s...

Page 235: ...whether there is carbon deposit in the air throttle body idle adjustor and idle bypass air passage No Next step Yes Repair circuit or replace sensor s 4 Pull out the connector of coolant temperature s...

Page 236: ...em diagnosis apparatus to observe the changes of ignition advance angle fuel injector pulse width and intake volume No Next step Yes Next step 3 Connect the adapter of electric control system and disc...

Page 237: ...ystem and vacuum pipeline or leakage No Next step Yes Wash related components 3 Dismantle the idle adjustor to check whether there is carbon deposit in the air throttle body idle adjustor and idle byp...

Page 238: ...ck spark plug of each cylinder to observe whether its model and gap are in compliance with the specification No Adjust or replace Yes Wash related components 4 Dismantle the idle adjustor to check whe...

Page 239: ...rk plug of each cylinder to observe whether its model and gap are in compliance with the specification No Adjust or replace Yes Wash related components 4 Dismantle the idle adjustor to check whether t...

Page 240: ...one of the cylinders and connect the spark plug to keep the spark plug electrodes about 5mm away from the engine body and start the engine to check whether the strength of high voltage spark No Repair...

Page 241: ...rottle position sensor circuit voltage P0123 Out of upper limit of throttle position sensor circuit voltage P0130 Inappropriate upstream oxygen sensor signal P0131 Low upstream oxygen sensor signal ci...

Page 242: ...6 Lower idling control speed against target speed P0507 Higher idling control speed against target speed P0508 Short circuit of stepping motor drive pin to ground P0509 Short circuit of stepping motor...

Page 243: ...Codes UAES P2178 Out of lower limit of air fuel ratio closed loop control self learning Medium load zone P2195 Aged upstream oxygen sensor P2196 Aged upstream oxygen sensor P2270 Aged downstream oxyge...

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