JAC HFC7151M1V-U221B Workshop Manual Download

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WORKSHOP MANUAL

HFC7151M1V-U221B

Engine

Version No

：

JAC-201511030415001

Summary of Contents for HFC7151M1V-U221B

Page 1: ...WORKSHOP MANUAL HFC7151M1V U221B Engine Version No JAC 201511030415001...

Page 2: ...etin or supplementary volume Therefore please obtain the latest information about this Manual JAC reserves the right to make change in design addition or improvement for the product This manual is a g...

Page 3: ...ne All rights reserved without the written consent of JAC it may not be translated all or a part of this manual Tel 0086 551 62296644 Fax 0086 551 62296633 JAC International Customer Service Depart 20...

Page 4: ...mmon Troubles XIII Parameters for Maintenance Section II Engine Lubrication System I Precautions II Preparation III Lubrication system schematic diagram IV Engine Oil V Oil Pan and Engine Oil Pump Sec...

Page 5: ...rol System II Forced Ventilating System of Crankcase Chapter II Electrical Part of Engine Section I Ignition System I Ignition coil II Diagnosis of Common Troubles III Parameters for Maintenance Secti...

Page 6: ...d 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 replacement Check the sub...

Page 7: ...aces 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 a plastic hammer...

Page 8: ...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 in order to avoid...

Page 9: ...ft timing sprocket 2 Pin Used together with the end forked clamp 3 Locating tool for piston pin JAC T1F005 Used to install and dismantle the piston pin 4 Guide sleeve Used together with the locating t...

Page 10: ...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 crankshaft 12 Installer...

Page 11: ...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 unleaded petrol or...

Page 12: ...eparation 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 Discharge...

Page 13: ...xing support of oil pipes See Power Steering Pump Low and high pressure pipes of air compressor See Air Compressor Dismount the steering fluid reservoir Dismantling of shifting cable Disconnect the wi...

Page 14: ...operation Make sure that the work will not affect the vehicle Make sure that all connecting parts have been disconnected In order to avoid falling due to changes of vehicle gravity use the jack to su...

Page 15: ...er there is fuel leakage at the connecting positions during engine increasing During running of engine check for any abnormal noise and or vibration With engine warmed up verify that there are no leak...

Page 16: ...f tension is out of range Attention When checking belt tension after installation firstly to adjust tension to specified value Then revolve the crankshaft for more than two laps to re adjust in order...

Page 17: ...the adjusting bolt 3 Lock adjusting bolt and power steering pump fixing bolt 5 Dismantlement of Drive Belt 1 Completely loosen all belts in accordance with the instructions in Tension Adjustment 2 Di...

Page 18: ...r Tightening torque 5 7 N m Disconnect the locking clamp of intake hose and then take off upper cover and intake hose Tightening torque 6 9 N m Dismount the fixing bolt of air filter base and then tak...

Page 19: ...nd lift the upper cover Dismount air filter element 2 Check after Dismantlement Periodically clean or replace the filter element with recommended period See Periodical Maintenance Blow the filter elem...

Page 20: ...oolant See Engine Coolant Dismount the engine trimming cover Tightening torque 8 12 N m Dismount the air filter assembly See Air filter Assembly Disconnect the wire harness connectors of the following...

Page 21: ...ng bolts and valve body take off valve body assembly Dismount the fuel injector assembly See Fuel Injector Tightening torque 18 4 1 4 N m Dismount the supporting bracket of intake manifold and engine...

Page 22: ...ON position check whether there is fuel leakage at the connecting positions With engine started recheck whether there is fuel leakage at the connecting positions during engine increasing With engine w...

Page 23: ...1 0 N m Unscrew fixing bolt to remove the exhaust manifold Tightening torque M8 35 2 N m 2 Check after Dismantlement Check whether the matching face of exhaust manifold is distorted 3 Installation Ins...

Page 24: ...on after the exhaust system has completely cooled down for the temperature of exhaust system remains hot when the engine has just stopped 1 Dismantlement Disconnect every joint and fixed part 2 Instal...

Page 25: ...rd rightward twist or stretch 3 Check after Installation Verify clearance between rear muffler and rear bumper WIth engine running check the connecting position of exhaust pipe for air leakage and abn...

Page 26: ...ng bolt of water pump belt pulley Tightening torque 7 8 2 N m Note It is permissible to perform the dismantlement by means of the friction force of drive belt before drive belt is removed b Dismantle...

Page 27: ...ing pump bracket f Dismantle oil pan and cylinder head cover Attention Only when oil pan and cylinder head cover are disassembled can the oil pump assembly be dismantled g Dismantle oil pump assembly...

Page 28: ...bnormalities Tightening torque Automatic tensioner 9 11 N m Set track 10 12 N m Dynamic track 19 28 N m j Dismantle exhaust camshaft sprocket bolt Tightening torque 78 98 N m Fig 1 1 033 Fig 1 1 032 F...

Page 29: ...ke cam timing controller Tightening torque 64 5 5 5 N m 2 Installation Reverse the above steps for installation Be aware of timing and tightening torque during installation X Camshaft assembly 1 Parts...

Page 30: ...cylinder head Tightening torque 9 11 N m Attention Handle with care to avoid collision or damage Remove the camshaft from cylinder head 2 Inspection after removal Camshaft Measuring camshaft base cir...

Page 31: ...07 L1 3 09 2 86 286 0 19 0 25 3 09 L1 3 11 2 88 288 0 19 0 25 3 11 L1 3 13 2 90 290 0 19 0 25 3 13 L1 3 15 2 92 292 0 19 0 25 3 15 L1 3 17 2 94 294 0 19 0 25 3 17 L1 3 19 2 96 296 0 19 0 25 3 19 L1 3...

Page 32: ...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 00 300 0 27 0 33 3 31...

Page 33: ...Check after Dismantlement Check for proper position of all parts installed Check the level of engine oil before starting the engine If the engine oil is less than the required volume replenish to spec...

Page 34: ...f the pressures in some cylinders are low add some engine oil to the spark plug holes of such cylinders and then inspect again The piston ring may be worn or damaged if the cylinder pressure rises aft...

Page 35: ...ng Sprocket Mechanism Loosen the cylinder head bolts with special tool Remove the cylinder gasket 2 Check after Dismantlement Cylinder head Bolt Measure the length of cylinder head bolt Limit 143 5 0...

Page 36: ...the cylinder head bolt and follow the given steps to install cylinder head A Intake side B Exhaust side Front end of engine a Install washer b Apply a film of engine oil onto washer which is at the th...

Page 37: ...check the engine oil coolant level If the level is lower replenish the engine oil coolant till the specified level is reached Perform the following steps to check whether the oil leakage occurs Turn t...

Page 38: ...ng 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 intake valve guide 18 exhaust valve guide 19 intake valve sea...

Page 39: ...it has been dismounted See Valve Guide Install valve seat if it has been dismounted See Valve Seat Install valve oil seal a Install the valve spring seat b Install the new valve oil seal with the spe...

Page 40: ...lace the valve if the measurement is less than the specified value For intake valve 1 35 1 65mm For exhaust valve 1 85 0 15mm Inspect the total length of valve Replace the valve if the measurement is...

Page 41: ...10 615mm extend the size of valve guide by 0 05mm For the hole with diameter of 10 805 10 815mm extend the size of valve guide by 0 25mm For the hole with diameter of 11 055 11 065mm extend the size...

Page 42: ...at 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 head til...

Page 43: ...bearing shell 9 crankshaft 10 lower main bearing shell 11 crankshaft thrust 12 crankshaft signal wheel 13 cylinder block 2 Disassembly and Assembly 1 Disassembly Dismount the engine assembly from the...

Page 44: ...move crankshaft rear oil seal bracket Tightening torque 7 0 8 2N m Insert the screwdriver between the crankshaft and the rear oil seal housing to dismantle Attention Once dismounted the rear oil seal...

Page 45: ...e piston ring expander Dismount the piston ring from the connecting 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...

Page 46: ...ggle the crankshaft bearing cap forwards and backwards by the bolts of crankshaft bearing cap See Fig 1 1 055 Dismount the crankshaft 2 Check after Disassembly Axial clearance of Crankshaft Detection...

Page 47: ...ton ring 0 1mm If the measurement exceeds the limit replace the piston ring and then remeasure the gap Replace the piston if the measurement is still out of the limit End Gap of Piston Ring Ensure tha...

Page 48: ...t Measure planeness of cylinder body in different directions at six positions using ruler and feeler gauge Standard values below 0 05mm Limits below 0 1mm If the limit is exceeded replace cylinder bod...

Page 49: ...linder till it obtains the calculated boring size Attention To avoid the distortion due to heat during the boring course bore the cylinders in following sequence Cylinder 2 Cylinder 4 Cylinder 1 Cylin...

Page 50: ...crankshaft journal and main connecting rod journal at four different positions as shown in the figure The difference between X and Y of A and B represents the roundness The difference between A and B...

Page 51: ...orted or cracked Attention Do not disassemble the flywheel Crankshaft signal wheel Check whether the crank signal wheel has distortions cracks and other anomalies Check whether the bolts are loose 3 A...

Page 52: ...ngine oil to the bearing surface Do not use oil on the back but to thoroughly clean it During installation align the extrusion on bearing shell with the cut of cylinder body and main bearing cap Add o...

Page 53: ...rod into the piston front mark side g Screw in the guide sleeves clearance between the two sleeves should be 3mm plus the calculated L in Step 2 h With the front mark facing downwards install piston...

Page 54: ...th the identification marks facing upwards on the piston top side by using expander Notes Piston ring opening direction Install bearing shell onto the connecting rod and the connecting rod cover Apply...

Page 55: ...er wall or crankshaft journal by the big end of connecting rod Do not to damage big bonnet and connecting rod fitting surface Install connecting rod cover During installation first use high pressure g...

Page 56: ...knock sensor Hall sensors oil pressure switch Attention Do not screw the nut when grasping the joint If the knock sensor is shocked replace with a new one Note Be sure that there is no foreign body a...

Page 57: ...sion mounting support loosened Tighten The engine support loosened Tighten The heat shield for engine is damaged Replace The engine support heat shield is damaged Replace The heat shield for transmiss...

Page 58: ...or replace Ineffective fan The sensor or the starter is at fault Repair or replace The fan relay or the wire harness is damaged Repair or replace Exhaust system leaks The joint loosened Tighten it The...

Page 59: ...angle of valve 45 45 5 Protrusion of valve stem mm Intake valve 53 21 53 71 Exhaust valve 54 10 54 60 Total length of valve mm Intake valve 89 61 89 11 Exhaust valve 90 94 90 44 Free height of valve...

Page 60: ...iameter 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 0 014 0 059 0 1 Side clearance of big end...

Page 61: ...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 5 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 bolt...

Page 62: ...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 manif...

Page 63: ...lication 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 completely on appointed p...

Page 64: ...tion 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 pressure switch socket D...

Page 65: ...ting valve Oil pump valve Oil pickup Main bearing Main shaft journal of crankshaft Connecting rod journal of crankshaft Connecting rod bearing Timing chain lubrication nozzle Automatic tensioner Main...

Page 66: ...he vehicle disconnect harness connector at oil pressure switch and remove the oil pressure switch Install oil pressure gauge and hose Start engine and warm up to normal working temperature Inspect oil...

Page 67: ...ne oil Stop the engine and wait for 10min Loosen engine oil filler cap and remove the oil drain bolt Discharge the engine oil Install the oil drain bolt with new washer Attention Be sure to clean oil...

Page 68: ...llation Remove any foreign substances attached on mounting surface of oil filter Apply a film of engine oil on oil seal surface of new oil filter Tighten the oil filter until the O ring seating on the...

Page 69: ...age bolt 10 oil drainage bolt washer 11 water pump seal 12 oil pump assembly 13 automatic tensioners observation manhole cover 14 crankshaft front oil seal 15 Pump 2 Dismantlement Caution Do not disch...

Page 70: ...long the sealing surface of oil pan 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 Tighte...

Page 71: ...installation surface re tighten the 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...

Page 72: ...rainage 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 oil level and fill a...

Page 73: ...inder cover Thermostat off Thermostat on Warm air heat exchanger Air throttle body Fixing bolts of coolant pump pulley Coolant pump puller Bolts for water pump Water pump assembly Seal ring of water p...

Page 74: ...y 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 detected that the...

Page 75: ...ose Please 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...

Page 76: ...oolant Install the air filter upper cover and air intake hose Please refer to Air Filter Assembly Run engine to warm it up to normal working temperature Increase engine speed for several times with no...

Page 77: ...ck Start and warm up the engine Visually inspect whether there is any coolant leakage 2 Inspect Radiator Cap 1 Pull out the negative pressure valve and open it Check if it can be fully closed after pr...

Page 78: ...keep the distance above 30cm 5 Blow each surface of radiator core with compressed air every 1min until no water is blown out III Radiator Cooling Fan 1 Dismantlement and Installation 1 Dismantlement...

Page 79: ...ease 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 Tightening...

Page 80: ...b assembly 1 Dismantlement and Installation 1 Dismantlement Discharge the engine coolant through water drain plug of radiator Please refer to Replace Engine Coolant Attention Operate after the engine...

Page 81: ...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 Replace the therm...

Page 82: ...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 Please dismount th...

Page 83: ...end ratio of coolant Poor quality of engine coolant Viscous engine coolant Insufficient engine coolant Engine coolant leaks Coolant hose Loose clamp Broken hose Water pump Improper sealing Radiator ca...

Page 84: ...anical Part of Engine VIII Parameters for Maintenance Technical specification for cooling system Temperature of thermostat opening 82 Initially open 95 Fully open Maximum lift of thermostat valve stem...

Page 85: ...y 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 fixed Make sure the j...

Page 86: ...ctrical 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 Dismount the nut fo...

Page 87: ...aution Do read the General Precautions before dealing with fuel system Please refer to General Precautions 1 Disconnect the PCV hose joint at intake manifold side 2 Disconnect the injector wiring harn...

Page 88: ...ence with fuel injector during removal Absorb the fuel leaked from fuel pipe with cleaning cloth 6 Dismount the fuel injector from fuel guide rail with following steps a Pry and dismount the snap in b...

Page 89: ...will not be scraped by tool or fingernail and it is not distorted or stretched during installation Insert new O ring into fuel injector straightly Do not deflect or distort it 2 Mount fuel injector on...

Page 90: ...n the engine stops and then check the connection of fuel pipe for leakage 2 Start the engine increase its speed and recheck the connection of fuel pipe for leakage V Fuel Filter 1 Dismantlement Cautio...

Page 91: ...oint 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 being heated Spec...

Page 92: ...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 resin pipe and its...

Page 93: ...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 fuel may overflow...

Page 94: ...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 Special attention...

Page 95: ...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 time so...

Page 96: ...ance 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 after con...

Page 97: ...ns 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...

Page 98: ...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 preca...

Page 99: ...rom 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 introduced into in...

Page 100: ...ine 6 Fuel 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 follow...

Page 101: ...Mechanical Part of Engine slip joint pliers pull out the vacuum hose...

Page 102: ...ze 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 with the variation o...

Page 103: ...p 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 evaporation to ambient...

Page 104: ...tilation 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 inhales fresh air from...

Page 105: ...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 chamber cover sid...

Page 106: ...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 Vent hose of PC...

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