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S5 Workshop Manual

Engine

EM-39

2) Install fuel supply pipe and injector
assembly onto the intake manifold.

Notes:

■ Make sure that there is no clash

between fuel injectors on the intake
manifold.

3) Install pressure stabilizing box support.

4) Connect fuel injector connector and
wire harness, and then install the cover.

5) Connect with vacuum hose.

Tightening Torque

Intake manifold fixing seat and cylinder body: 18

～

N•m

6) Connect PCV valve and brake boosting hose.

7) Install respirator hose

4. Intercooler

1. Component

EM059

Fuel supply pipe

Clip

Intercooler cover

Fan motor switch

Intercooler bracket

Fan motor assembly

Torque:

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Содержание S5

Страница 1: ...and re assembly The basic principles for loosening bolts and nuts are to loosen the exterior first and then loosen the diagonal position and so on If the loosening sequence is specified please follow...

Страница 2: ...ealant Pay attention not to damage matching surface Insert the scraper and then as shown in figure knock it and slide it from the side In some places where it is difficult to use scraper please use pl...

Страница 3: ...side of the hole Install binding parts within 5mins after applying sealant If there is dirt on the sealant immediately clean it Do not re tighten locking bolts or nuts after installation After 30 mins...

Страница 4: ...l seal 3 Crankshaft front oil seal guider JAC T1F003 It can guide to install crankshaft front oil seal 4 Crankshaft front oil seal installer JAC T1F004 Install crankshaft front oil seal 5 Dismantle to...

Страница 5: ...r plug cock of the engine 10 Valve oil seal installer JAC T1F010 Install valve oil seal 11 Flywheel stop dog JAC T1F011 Fixed flywheel easily dismantle 12 Valve spring compressor JAC T1F012 Dismantlin...

Страница 6: ...nch JAC T1F015 It is used for dismantling and installing oxygen sensor 16 Mounting tools for pulley oil seal JAC T1F016 It is used for installing oil seal on engine timing belt pulley 17 Oil pan unloa...

Страница 7: ...sensor water temperature warning switch LT648 or equivalent 5 Gasoline RON93 and above grade of lead free gasoline 6 Sealant Double end bolt LT271 or equivalent Auxiliary Material Table for Cylinder H...

Страница 8: ...view of Engine Engine appearance as show in figure External View of Engine Assembly This engine assembly is mainly used for M2 vehicle model manufactured by JAC as shown in figure SII models www carge...

Страница 9: ...rod 150 Valve Number Air intake valve 8 Air exhaust valve 8 Output Max power 130 kW 5200 rpm Max torque 235 N m 2000 4000 rpm Fuel octane value RON93 and above 93 grade of lead free gasoline It meets...

Страница 10: ...S5 Workshop Manual Engine EM 10 Engine No Position Drive Belt Engine Drive Belt Schematic Diagram www cargeek ir www cargeek ir w w w C a r G e e k i r...

Страница 11: ...screw adjusting locking bolts of electric generator and then loosen engine drive belt 4 Remove electric generator drive belt from electric generator pulley Installation 1 Install belt onto the pulley...

Страница 12: ...antle intake hose and remove upper cover of filter and intake hose 4 Dismantle 3 fixing bolts of air filter seat and remove the seat Tightening torque 8 12 N m Inspection after Dismantling Inspect whe...

Страница 13: ...2 Dismantling air filter element Inspection after Dismantling Regularly clean and replace air filter element according to the recommended time Use compressed air to blow from the back of air filter e...

Страница 14: ...ther cylinder body has scratch rusting and corrosion Meanwhile inspect whether there is crack or other defect If there is any defect replace cylinder body 2 Measure the bore on three shown height in A...

Страница 15: ...he piston and measured along the thrust force Clearance between piston and cylinder 0 02 0 04 mm 6 Inspect whether there is damage or crack 7 Inspect the flatness of upper surface of cylinder body If...

Страница 16: ...der repair four cylinders to make them have the same size Do not only bore one cylinder 5 Installation Install the following parts by referring to relevant sections 1 Crankshaft 2 Flywheel 3 Piston 4...

Страница 17: ...hood rear bracket components Cover plate components of cylinder head protective cover Cylinder head protective cover component Sealing ring of cylinder head protective cover Sealing ring of spark plu...

Страница 18: ...it can t rotate smoothly or there is any loosening replace it Inspect the surface of roller wheel If there is any depression or obvious scratch replace it Inspect whether valve contact surface has dam...

Страница 19: ...e cover are to identify air intake air exhaust I Air intake camshaft E Air exhaust camshaft 3 Inspect camshaft to make sure it can be rotated easily with hands After inspection dismantle bearing cover...

Страница 20: ...staller and guide rod JACF125 JACF126 Make sure to apply oil on the surface of oil seal and then insert oil seal along the front of camshaft Use a hammer to push the installer until the oil seal is in...

Страница 21: ...o 1212D or equivalent Bolt A 13EA B 4EA 9 Install spark plug and ignition coil Connect secondary guide wire and then install protective cover plate 10 After installing camshaft position sensor signal...

Страница 22: ...ct re installation 1 Dismantle connecting rod cover nuts and then dismantle lower cover and bushing under the big end Make marks for re installation 1st piston ring 2nd piston ring Oil ring Piston Pis...

Страница 23: ...4 Dismantle piston pin from piston When the connecting rod is fixed on the fork piece put piston into the support Detaching tool goes through the top of the support This can be used to press piston p...

Страница 24: ...sure until the pin guide column can fall freely and installer tool is just aligned with the top of arch arm Notes When installing centre shaft lining the pressure exerted on the arch arm should not ex...

Страница 25: ...0 15 mm Measure the end play of piston ring Put a piston ring into the cylinder hole Press piston slight to push the ring downwards until the ring perpendicular to the cylinder wall Use a clearance ga...

Страница 26: ...se finger to press it down to insert it into the groove as shown in figure When installing blade do not Use piston ring expander 3 Install lower blade according to the same sequence shown in step 2 4...

Страница 27: ...cting rod toward the front of engine 10 When installing connecting rod cover make sure the cylinder number is aligned with mark made on the connecting rod cover when dismantling it 11 When installing...

Страница 28: ...iting value 0 4mm Crankshaft 1 Component EM039 Manual gear Flywheel Flywheel baffle Dustproof cover Oil seal Rear oil seal bracket Main bearing upper Thrust bearing Crankshaft Main bearing lower Main...

Страница 29: ...epair or replace any defected part Inspect the roundness and cylindricity of crankshaft journal Standard value Outer diameter of crankshaft journal 56 982 57 000 mm Outer diameter of crankshaft pin 44...

Страница 30: ...e small size of bearing When installing new crankshaft make sure to use standard size of bearing If the standard clearance still can t be achieved after replacing bearing it is necessary to grind jour...

Страница 31: ...journal and install crankshaft 5 Install bearing cover by making the arrow direction towards the front of the engine Cover number must be correct 6 Tighten cover bolt to the specified torque Tighteni...

Страница 32: ...l flywheel assembly and tighten bolts to the specified torque Tightening Torque Flywheel bolt 130 140 N m 1300 1400 kg cm2 13 Install connecting disc onto the body 14 Install drive disc and tighten bo...

Страница 33: ...smantling 1 Dismantle heater insulator 2 Dismantle air exhaust manifold 3 Dismantle air exhaust manifold gasket EM048 EM047 Turbocharger Heat insulator bracket assembly Exhaust manifold Turbocharger b...

Страница 34: ...surface Standard value 0 15 mm Maintenance limit 0 3 mm 3 Inspect whether exhaust manifold has damage or crack 4 Installation 1 Install exhaust manifold with washer Tightening torque Air exhaust manif...

Страница 35: ...lting and other damage due to overdue 2 Make sure that exhaust gas valve rod can be pushed freely with hands 3 Make sure that the inner housing surface contacted with compressor has no damage Contact...

Страница 36: ...oreign matter blocked oil pipe in turbine core assembly 6 Exhaust gas valve Inspection Under the following pressure inspect the operation of waste gas valve rod Normal value 77 5 KPa 0 79 kgf cm2 3 Ai...

Страница 37: ...um hose 4 Disconnect vacuum hose connector 5 Release pressure from fuel pipe to avoid fuel splashing and then disconnect high pressure hose 6 Disconnect fuel injector wire harness connector 7 Dismantl...

Страница 38: ...r crack 2 Inspect the connection of vacuum outlet or air pipe 3 Use a ruler and plug gauge to inspect flatness Standard value 0 15 mm or below Maintenance limit 0 2 mm 4 Installation 1 Install intake...

Страница 39: ...Connect fuel injector connector and wire harness and then install the cover 5 Connect with vacuum hose Tightening Torque Intake manifold fixing seat and cylinder body 18 25 N m 6 Connect PCV valve and...

Страница 40: ...switch Put the sensor into the water Heat the water and inspect whether it is conducted Temperature Normal Condition 50 C or below Disconnect 60 C or below Connectivity Condenser fan motor At speed of...

Страница 41: ...et 4 Dismantle air filter 5 Dismantle air flow sensor from air filter cover Notes Do not drag air flow sensor wire and connect the connector to air filter cover 3 Inspection 1 Inspect whether air filt...

Страница 42: ...rder of dismantling Cylinder Head Cover Assembly 1 Cylinder Head 1 Component EM064 Camshaft oil seal Front lug Intake connecting pipe bracket bolt assembly Cylinder head protective cover bolt Cylinder...

Страница 43: ...ate re installation according to their original position 3 Use a pair of pliers to dismantle valve lifter sealing piece Notes Do not use the used valve lifter sealing piece 3 Inspection 1 Cylinder Hoo...

Страница 44: ...ry replace it If rod end surface A has depression or abrasion repair the surface according to actual condition This repair must be limited to the minimum valve range Meanwhile re process valve surface...

Страница 45: ...lve seat overheats and whether valve surface has nonuniform contact If necessary repair or replace valve seat Before repairing valve seat inspect whether valve guide pipe has abrasion If valve guide p...

Страница 46: ...e pipe Press valve guide pipe by special tool JACF116B It is necessary to press valve guide pipe from the top of cylinder head Attention should be paid that the length of intake valve pipe and exhaust...

Страница 47: ...il seal by special tool in the correct position Notes Do not use old valve oil seal Improper installation of valve oil seal may cause oil leakage of valve guide pipe Apply oil onto each valve Valve wa...

Страница 48: ...ket surface of engine body and cylinder cover Confirm identification mark on the cylinder cover gasket When installing washer make the marked surface upwards cylinder head Notes Inspect and measure th...

Страница 49: ...absorption pulley Compound bracket cushion plate Left rear cover of timing belt Right balance shaft chain wheel Secondary chain wheel of crankshaft B Secondary timing belt B Secondary tensioning wheel...

Страница 50: ...ley 2 Dismantle timing belt with shield 3 Dismantle auto tensioner Notes If timing belt is to be used again make an arrow mark showing rotation direction or front side of engine to ensure that it has...

Страница 51: ...an 60 mm 2 36 inch 7 Dismantle oil pump placket 8 Unscrew mounting bolt of left balance shaft chain wheel until it can be loosened with hands 9 Next dismantle secondary tensioning wheel B and secondar...

Страница 52: ...freely and smoothly and inspect their free play and noise If necessary replace it If there is grease flowing out of bearing replace tensioning wheel 2 Auto tensioner Inspect whether automatic tensioni...

Страница 53: ...horizontal position A pair of soft pliers should be used to avoid damage automatic tensioner 3 Timing belt Inspect whether there is deposited oil or dust on the belt If necessary replace it For a litt...

Страница 54: ...g of the rubber back 2 Crack of the rubber back 3 Crack or separation of canvas The back side is smooth without elasticity so hard that it leaves no mark even pressing it with fingers Crack Crack Sepa...

Страница 55: ...cracks Canvas exposed in force borne surface canvas has burrs rubber grinds into white and texture of canvas is unclear Side abrasion of the tooth on force borne surface Side abrasion of the tooth an...

Страница 56: ...ing mark on oil pump housing with that of chain wheel 5 When installing timing belt B make sure that its tensioning side has no loosening condition Install tensioning wheel B to make the centre of bel...

Страница 57: ...rify tensioning force of timing belt Method 1 Use fingers to press the span centre on tensioning side according to the arrow direction This is to verify whether belt deflection is within the specified...

Страница 58: ...g Torque Crankshaft chain bolt 160 170 N m 11 Insert screwdriver into the inspection hole of left balance shaft on the left of cylinder body to keep the shaft stationary 12 Install oil pump chain whee...

Страница 59: ...automatic tensioner and rod 15 Install tensioning wheel onto tensioning rod Tightening Torque Tensioner 43 55 N m 16 Rotate camshaft chain wheel to make the positioning pin of camshaft chain wheel on...

Страница 60: ...chain wheel intake camshaft chain wheel tensioning wheel Notes Make sure that No 1 cylinder position is located on the upper stop position compression stroke When aligning timing mark of oil pump chai...

Страница 61: ...Pull out locating pin 19 Rotate crankshaft for 6 circles in clockwise and keep for 5mins And then measure the projection section A of automatic tensioner clearance between tensioning lever and automat...

Страница 62: ...shion has crack Replace 2 Valve clearance is improperly adjusted or damaged Adjust repair or replace 3 Intake manifold is loose or there is air flowing into it Tightening 4 Piston piston ring cylinder...

Страница 63: ...water pipe is blocked Supplement or clean Clearance of water pump is improper or damage Repair or replace Oil pump is insufficient Supplement Oil path is blocked or oil pump is damaged Clean or replac...

Страница 64: ...flatness The size of repaired valve seat hole is enlarged Air intake 0 3 mm O S 0 6 mm O S Air exhaust 0 3 mm O S 0 6 mm O S The size of repaired valve guide pipe hole is enlarged intake and exhaust 0...

Страница 65: ...45 5 0 1 mm 50 5 0 1 mm 0 05 0 25 0 50 mm Valve seat Seat contacting width Seat tapering angle Maintenance dimension 0 9 1 3 mm 44 44 5 0 2 mm 0 6 mm more than tolerance Valve spring Free length Bear...

Страница 66: ...aring clearance Clearance between main bearings of crankshaft No 1 2 4 5 journal No 3 journal 0 05 mm 0 1 mm 0 10 0 25 mm 125 50 N m 44 98 45 mm 0 015 0 048 mm 0 018 0 036 mm 0 024 0 042 mm 0 2 mm 0 1...

Страница 67: ...0 042 0 083 mm Cooling type Water cooling Cooling system capacity 4 0 L Thermostat Type Normal opening temperature Opening temperature range Full open temperature Paraffin type 82 80 84 95 Radiator co...

Страница 68: ...insulator plate bolt of main bearing cover M8 16 17 26 N m Left balance shaft check bolt M10 12 27 34 N m Hexagon flange bolt crankshaft rear oil seal support M6 14 10 12 N m Hex plug of right balanc...

Страница 69: ...20 27 N m Air filter support bolt M6 20 8 10 N m Oil pump cover bolt M8 20 15 18 N m Oil pump housing screw plug M20 1 5 20 27 N m Shaft end nut M10 50 60 N m Oil strainer bolt subassembly M8 20 15 2...

Страница 70: ...0 N m Long bolt of power steering pump M8 88 22 25 N m Short bolt of power steering pump M8 30 17 26 N m Generator support bolt M8 20 25 N m Outlet pipe installing bolt M8 20 10 15 N m Inlet pipe inst...

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