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Engine
EM Engine Structure
Precautions
Precaution for Draining Engine Coolant:
■ Drain engine coolant after the engine is in cooling condition.
Precautions for Disconnecting Fuel Pipe:
■ Before starting to work, make sure there is no article which may cause combustion
or spark in working area.
■ Before disconnecting and dismantling, first release fuel pressure. For methods to
release fuel pressure, please refer to "the release of fuel pressure in fuel pipe".
■ After disconnecting pipe, plug the opening to avoid fuel leakage.
Precaution of Dismantling and Disassembly:
■ If it is required to use special repair tools, please use special repair tools. Always
keep safe operation, and do not force to do or conduct improper operation.
■ Be careful not to damage the matching surface or sliding surface.
■ If necessary, use adhesive tape or equivalent to seal the opening of engine system,
to avoid foreign matters from entering.
■ Methodically mark and arrange the dismantled parts, to facilitate troubleshooting
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 the specified sequence.
Precaution of Inspection, Repair and Replacement:
■ Before repairing or replacing, completely inspect parts. Use the same methods to
inspect the replaced parts. If necessary, please replace.
Precaution of Assembly and Installation:
■ The basic principles for tightening bolts and nuts are to first tighten middle with the
same tightening torque, and then tighten exterior diagonal position. If the tightening
sequence is specified, please follow the specified sequence.
■ Cushion, oil seal or rubber sealing ring are easy to be damaged during dismantling.
If necessary, replace them.
■ Completely flush, clean and blow each part to dry condition. Carefully inspect
whether engine oil or engine coolant pipe is blocked.
■ When refilling engine coolant after drain it out, it is necessary to release air from
pipe.
■ After repairing, start the engine and increase engine rotation speed to inspect
whether the engine coolant, fuel, engine oil and tail gas have leakage.
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S5 Workshop Manual
EM-1
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Engine
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Table of Contents
Related Manuals for JAC S5
Summary of Contents for JAC S5
- Page 1 S5 Workshop Manual Engine Engine EM Engine Structure Precautions Precaution for Draining Engine Coolant: ■ Drain engine coolant after the engine is in cooling condition. Precautions for Disconnecting Fuel Pipe: ■ Before starting to work, make sure there is no article which may cause combustion or spark in working area.
- Page 2 S5 Workshop Manual Engine Parts to be tightened according to the Specified Angle: ■ Use angle wrench to finally tighten the following engine parts: —— Cylinder head bolt —— Main bearing cover bolts —— Connecting rod cap nut —— Crankshaft belt pulley bolts (it is unnecessary to use angle wrench, because bolt flange is used for fixing groove tightened according to fix angle).
- Page 3 S5 Workshop Manual Engine ■ If there is a groove to place sealant, please put the sealant into this groove. ■ For bolt holes, generally apply sealant into the holes. Sometimes, apply sealant outside of the hole. ■ Install binding parts within 5mins after applying sealant.
- Page 4 S5 Workshop Manual Engine Preparation Work Special Tool Table Tools Overall diagram Code Purpose Name It is used for dismantling engine valve Valve spring JAC-T1F001 and relevant compressor parts when it is unnecessary to dismantle. Install engine Camshaft oil...
- Page 5 S5 Workshop Manual Engine Mounting bearing used Handle JAC-T1F007 Handle with relevant installer. Handle Crankshaft Install Installer of rear oil seal of rear oil seal JAC-T1F008 crankshaft rear crankshaft installer oil seal Special It is used for socket for...
- Page 6 S5 Workshop Manual Engine Balance It is used for shaft oil seal installing oil JAC-T1F014 installing seal on engine tool balance shaft. It is used for Oxygen dismantling and sensor JAC-T1F015 installing wrench oxygen sensor. It is used for...
- Page 7 S5 Workshop Manual Engine Auxiliary Material Table of Engine Assembly Name Application Specification Brand 5W-30 (in winter of northern areas) 15W-40 (in summer of Oil filling, oil for assembly northern areas and full year in southern areas) quality grade is SJ or above.
- Page 8 S5 Workshop Manual Engine Structure Overview 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 EM-8 www.cargeek.ir...
- Page 9 S5 Workshop Manual Engine Structure Parameter of Engine: Structure Parameter Table of Engine Model HFC4GA3.1D Type L4/16.DOHC.MPI Cylinder number Fuel chamber Pentroof type Total displacement (CC) 1997 Cylinder bore mm 85.0 Stroke mm 88.0 Compression ratio Valves and drive mechanism...
- Page 10 S5 Workshop Manual Engine Engine No. Position Drive Belt Engine Drive Belt Schematic Diagram EM-10 www.cargeek.ir...
- Page 11 S5 Workshop Manual Engine Inspection before Dismantling: 1. Inspect whether the pulley has crack, abrasion and oil stain. If yes, please replace it. 2. Inspect whether the pulley is correctly installed in the groove of belt pulley. 3. Inspect the deflection of belt in the middle point of the pulley.
- Page 12 S5 Workshop Manual Engine Air Filter and Air Pipe Component Position Schematic Diagram 1-PCV hose 2-Air intake hose 3-Air filter assembly Dismantling: 1. Loosen intake hose locking clamp and PCV hose clamp. 2. Dismantle upper cover buckle of air filter.
- Page 13 S5 Workshop Manual Engine Inspection and Replacement of Air Filter Element: Dismantling: 1. Loosen upper cover locking buckle of EM006 air filter, and rise up upper cover. 2. Dismantling air filter element. EM007 Inspection after Dismantling: EM008 ■ Regularly clean and replace air filter element according to the recommended time.
- Page 14 S5 Workshop Manual Engine Engine Cylinder Block 1. Component Cylinder block 2. Dismantling Dismantle cylinder head, oil pump housing, timing belt, flywheel, piston and crankshaft. For detailed information, please refer to relevant section. 3. Inspection: 1) Inspect whether cylinder body has scratch, rusting and corrosion. Meanwhile, inspect whether there is crack or other defect.
- Page 15 S5 Workshop Manual Engine 3) If the cylinder exceeds the specified cylindricity or roundness after inspection, or cylinder wall has serious abrasion or scratch, re-bore the cylinder and grind cylinder body. And install new piston and piston ring. Standard Value: Cylinder Bore:85 + 0.03 mm...
- Page 16 S5 Workshop Manual Engine 3) Inspect clearance between piston and cylinder. Notes: When repairing cylinder, 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:...
- Page 17 S5 Workshop Manual Engine Camshaft 1. Component Engine hood front bracket components Engine hood rear bracket components Cover plate components of Cylinder head protective cylinder head protective cover cover component Sealing ring of cylinder head protective cover Sealing ring of spark plug...
- Page 18 S5 Workshop Manual Engine 4) Dismantling air filter. 5) Dismantling timing belt shield. 6) Dismantle rocker arm and crankshaft position sensor. 7) Loosen fixing bolt of camshaft chain wheel, and then dismantle camshaft chain wheel. 8) Loosen camshaft bearing cover bolts, and remove bearing cover, camshaft, rocker arm and hydraulic tappet.
- Page 19 S5 Workshop Manual Engine Limiting Value Air intake : 34.993 mm Air exhaust : 34.704 mm 3. Installation 1) Install camshaft onto cylinder head, but do not install rocker arm. Notes: ■ Apply oil onto the journal and cam of...
- Page 20 S5 Workshop Manual Engine 5) Tighten bearing cover to the specified torque in two or three times according to the figure. Notes: EM018 Front end ■ Uniformly tighten rocker arm Tightening Torque Main bearing cover bolt: 19 ～ 21 N•m...
- Page 21 S5 Workshop Manual Engine 8) Install cylinder protective cover, and EM022 apply oil onto the shown position. Cylinder head Tightening torque Semi-circle plug Rocker arm cover bolt: 8 ～ 10 N•m Center cover bolt: 4 ～ 5 N•m Sealant A position: Threebond No.10 or...
- Page 22 S5 Workshop Manual Engine Connecting Rod 1. Component piston ring piston ring Oil ring Piston Piston pin Connecting rod Upper connecting rod bearing Lower connecting rod bearing Connecting rod bearing cover Connecting rod nut 2. Dismantling Notes: Press relevant tie rods (according to cylinder number), and place bushings in sequence to facilitate correct re-installation.
- Page 23 S5 Workshop Manual Engine 2) Push each piston connecting rod EM026 assembly to the top of cylinder. Cylinder No. Stopper port 3. Dismantle and reinstalling of piston EM027 Universal fork 1) Use special tool JACF105 to dismantle and re-install piston and connecting rod.
- Page 24 S5 Workshop Manual Engine Notes: ■Pin guide column should be aligned with the centre of connecting rod through piston. If it is installed properly, piston guide column is just located under the centre of the hole in tool arch arm and evenly placed on the fork piece. If wrong size of pin guide column is used, piston and pin can't be aligned with the support.
- Page 25 S5 Workshop Manual Engine Inspect the matching condition of piston pin in piston hole. Replace the defected piston and pin assembly. Piston pin must be pressed into pin hole stably with hands (at indoor temperature). 2) Piston Ring Measure the side clearance of piston ring. If the measured value exceeds repair limit value, insert a new ring into the ring groove.
- Page 26 S5 Workshop Manual Engine ■ If the thrust surface is damaged, replace connecting rod. If connecting rod thrush surface has abrasion in layer, or the surface of small end, inner bore are very rough, replace connecting rod. 1) Install cushion spring.
- Page 27 S5 Workshop Manual Engine 5) Use piston ring expander to install the EM036 second circle of piston ring. 6) Install top piston ring. Inner chamfer side Lower cutting type 7) Place each piston ring to make its opening away from the opening of its adjacent ring.
- Page 28 S5 Workshop Manual Engine 13) Inspect connecting rod side clearance. EM039 Connecting Rod Side Clearance: Standard value: 0.10 ～ 0.25 mm Limiting value: 0.4mm Crankshaft 1. Component Flywheel Flywheel Oil seal baffle Rear oil seal Manual gear bracket Dustproof cover...
- Page 29 S5 Workshop Manual Engine 2. Dismantling 1) Dismantle timing belt, oil pump housing, flywheel, cylinder head assembly and oil pan. 2) Dismantle rear oil seal support and rear oil seal. 3) Dismantle connecting rod cap. Notes: ■ Make marks on bearing cover so that it is facilitate re-installation according to original position and direction.
- Page 30 S5 Workshop Manual Engine 3) How to use plastic gauge Plastic gauge is normally used for measuring clearance. Remove oil, grease and any other dirt from bearing and journal. Cut the plastic gauge to make its length equal to the width of bearing. Keep away from oil hole, and place it on the position parallel to the journal.
- Page 31 8) Make sure that crankshaft rotates freely and inspect axial clearance of crankshaft. 9) Use special tool (JAC-F110) to install EM045 oil seal onto the oil seal bracket. It is necessary to use new oil seal. EM-31...
- Page 32 S5 Workshop Manual Engine 10) Install rear oil seal bracket onto the Rear oil seal support EM046 body. Contact with oil pan Tightening Torque Oil seal bracket: 10 ～ 12 N•m (100 ～ 120 kg/cm 11) Install flywheel baffle onto the body.
- Page 33 S5 Workshop Manual Engine Inspection of Air Exhaust System 1. Exhaust Pipe 1. Component Turbocharger Heat insulator bracket assembly Exhaust manifold Catalyst connecting elbow Turbocharger bracket assembly 2. Dismantling EM047 1) Dismantle heater insulator. 2) Dismantle air exhaust manifold.
- Page 34 S5 Workshop Manual Engine 3. Inspection 1) Inspect whether it has damage or crack. 2) Use a ruler and plug gauge to inspect the deformation of cylinder head matching surface. Standard value: 0.15 mm Maintenance limit: 0.3 mm 3) Inspect whether exhaust manifold has damage or crack.
- Page 35 S5 Workshop Manual Engine II. Turbocharger 1. Component O-ring Clamp joint Turbine housing Compressor cover Turbine core assembly Coupling 2. Inspection 1) Inspect whether the inner housing contacted with turbine has crack, tilting and other damage due to overdue.
- Page 36 S5 Workshop Manual Engine 4) If there is crack or breaking on turbine blade, the turbine and shaft assembly can't be used. If the blade only has slight bending, it can be used. But if there is serious bending, it can't be used.
- Page 37 S5 Workshop Manual Engine 2. Dismantling EM052 1) Dismantle breathing hose connecting to rocker arm. 2) Dismantle engine coolant hose and EM053 throttle valve body. 3) Dismantle crankcase forced vent valve (pcv) and brake boosting vacuum hose. 4) Disconnect vacuum hose connector.
- Page 38 S5 Workshop Manual Engine 8) Dismantle air intake manifold fixing EM056 bracket. 9) Dismantle air intake manifold. EM057 3. Inspection Air intake manifold and stable pressure box 1) Inspect whether part has damage or crack. 2) Inspect the connection of vacuum outlet or air pipe.
- Page 39 S5 Workshop Manual Engine 2) Install fuel supply pipe and injector EM059 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.
- Page 40 S5 Workshop Manual Engine 2. Dismantling 1) Dismantle condenser housing. 2) Dismantle fan motor and temperature switch connector. 3) Dismantle air hose. EM060 4) Dismantle condenser assembly. 5) Dismantle fan motor assembly. 6) Dismantle condenser support. 3. Inspection 1) Air temperature switch Put the sensor into the water.
- Page 41 S5 Workshop Manual Engine 2. Dismantling 1) Disconnect air flow sensor connector. 2) Dismantle air intake hose on the air filter and resonance box. 3) Dismantle three bolts connecting air filter mounting bracket. 4) Dismantle air filter EM061 5) Dismantle air flow sensor from air filter cover.
- Page 42 S5 Workshop Manual Engine 3) Inspect whether filter element is blocked, expanded or damaged. If the filter element has slight block, remove dust and scrap by using compressed air blowing into filter element. EM064 4. Installation Install air filter assembly according to the reverse order of dismantling.
- Page 43 S5 Workshop Manual Engine 2. Dismantling Forward EM065 1) Use special tool (JACF111) to dismantle cylinder head bolts according to the sequence shown in figure. 2) Use special tool (JACF115) to dismantle valve spring lock plate, and then dismantle upper spring seat, valve spring, and lower spring seat and valve.
- Page 44 S5 Workshop Manual Engine Inspect the flatness of cylinder head surface according to the direction shown in figure. If flatness in any direction exceeds repair limit value, replace cylinder head or slightly process cylinder head matching surface. Flatness of cylinder head washer surface.
- Page 45 S5 Workshop Manual Engine Valve Spring Verticality 2° EM071 Standard value Free height: 45.8 mm Load: 25.3 kg / 40 mm Height Verticality: 1.5° or below Limiting value Free height: 44.82 mm Verticality: 4° Valve Guide Pipe Inspect the clearance between valve rod and guide pipe. If the clearance exceeds repair limit value, replace it with a No.1 bigger valve guide pipe.
- Page 46 S5 Workshop Manual Engine 6) Replacement of Valve Race Clean the inner surface of valve seat ring hole. Heat the cylinder head to about 250℃ (480°F), and press and install a seat ring into the hole of cylinder head.
- Page 47 S5 Workshop Manual Engine Valve Guide Pipe Enlarged Dimensions Dimension Enlarged dimension valve duct hole dimension Enlarged dimension mm (inch) mark (inch.) ～ 0.05 (0.002 ) 12.050 - 12.068 ( 0.4744 0.4751) ～ 0.25 (0.010 ) 12.250 - 12.268 (0.4823 0.4830)
- Page 48 S5 Workshop Manual Engine Use special tool (JACF115) to EM078 compress spring and install lock latch. After installing valve, before loosening valve spring compressor, make sure that the locking latch is located at its proper position. Notes: ■ When the spring is compressed, inspect whether the sealing piece of valve rod isn't compressed onto the bottom of spring seat.
- Page 49 S5 Workshop Manual Engine Timing Belt 1. Timing Belt 1. Component Upper cover plate of protective cover of timing belt Timing belt Engine belt adjuster Water pump Water pump pulley Left rear cover of timing belt Compound bracket cushion plate...
- Page 50 S5 Workshop Manual Engine 2. Dismantling Notes: ■ Rotate crankshaft in clockwise and align timing mark, to set No.1 cylinder piston onto T.D.C. At this moment, the timing marks of camshaft chain wheel and cylinder head cover are just aligned. Positioning pin of camshaft chain wheel is located upper side.
- Page 51 S5 Workshop Manual Engine 4) Dismantle timing belt. EM080 5) Dismantle camshaft sprocket. EM081 Notes: ■ When using wrench, do not damage valve cylinder head and camshaft sprocket. 6) When dismantling oil pump chain wheel nuts, first dismantle inspection bolt of left balance shaft on the left of cylinder body, and insert a pair of screwdrivers to keep the position of left balance shaft.
- Page 52 S5 Workshop Manual Engine 3. Inspection 1) Chain wheel, tensioner belt pulley and idler wheel. Inspect whether camshaft chain wheel, crankshaft chain wheel, tensioner pulley and idler wheel have abnormal abrasion, crack or damage. If necessary, replace them. Inspect whether tensioning wheel and idler wheel rotate freely and smoothly, and inspect their free play and noise.
- Page 53 S5 Workshop Manual Engine Use a pair of soft pliers to slowly press automatic tensioner rod. If it is easy to be compressed, replace automatic tensioner. When pushing the rod, you should feel that there is too much resistance. It is necessary to press into for several times.
- Page 54 S5 Workshop Manual Engine Descriptions Defect Condition 1. Hardening of the rubber back The back side is smooth without elasticity, so hard that it leaves no mark even pressing it with fingers. 2. Crack of the rubber back Crack 3.
- Page 55 S5 Workshop Manual Engine Descriptions Defect Condition 4. The teeth is worn seriously Canvas exposed in force borne surface (preliminary) (canvas has burrs, rubber grinds into white, and texture of canvas is unclear. Side abrasion of the 5. Belt tooth is worn seriously (late tooth (on force period).
- Page 56 S5 Workshop Manual Engine 4. Installation 1) Install crankshaft chain wheel "B" onto the crankshaft. Notes: ■ For flange direction, if this direction is Secondary chain EM089 wheel of crankshaft wrong, it may cause belt damage. Crankshaft 2) Apply a little amount of oil onto the...
- Page 57 S5 Workshop Manual Engine Secondary timing belt “B” Tensioning side Secondary tensioning wheel “B” Bolt centre 6) Rise up tensioning wheel "B" to EM092 tension timing belt "B" and tension its tensioning side. Under this condition, tighten bolt to fix tensioning wheel "B".
- Page 58 S5 Workshop Manual Engine 9) Flange and crank chain was installed on the crankshaft Make sure that the installation is conducted according to the instruction in figure. Notes: EM094 Secondary chain wheel ■ Pay attention to flange direction. If it is of crankshaft"B"...
- Page 59 S5 Workshop Manual Engine 14) Install automatic tensioner. EM098 Keep installed locating pin in the auto-tensioner Locating pin Notes: ■ If the automatic tensioner rod on its full extension position, reset it according to the following: Clamp it into the bench clamp on horizontal position by using the soft pliers.
- Page 60 S5 Workshop Manual Engine 2) If it is necessary to rotate camshaft EM101 Camshaft chain chain wheel, first rotate crankshaft chain Positioning wheel wheel counterclockwise based on timing Intake Exhaust mark. After the camshaft chain wheel is correctly timed, return crankshaft to the upper stop point.
- Page 61 S5 Workshop Manual Engine After inspecting timing mark, install inspection bolt of left balance shaft. Tightening torque: 2.7 ～ 3.4 kg/ (Apply liquid sealant: Threebond NO.1212B or equivalent) 18) Pull out locating pin 19) Rotate crankshaft for 6 circles in clockwise and keep for 5mins. And then measure the projection section "A"...
- Page 62 S5 Workshop Manual Engine Fault Diagnosis Engine is Difficult to Start: Fault Phenomenon and Reason Troubleshooting Tightening or 1. Battery doesn't rotate. charging The starter doesn't rotate 2. Electric circuit is broken. Inspection and repair 3. Starter has damage.
- Page 63 S5 Workshop Manual Engine Bushing has abrasion, and cam of camshaft Replace and rocker arm have abrasion. There is Crankshaft , connecting rod journal diameter Replace or repair cylinder and piston pin worn seriously striking sound inside the Piston ring damaged Replace engine.
- Page 64 S5 Workshop Manual Engine Maintenance Data and Specification Engine Overhaul Data List Item Specification Parameter Limiting Value Type In-line, dual overhead cam, 16-valve, turbocharging Cylinder numbers 83 mm Cylinder bore 83 mm Stroke 1.795 L Discharged 8.5:1 Compression ratio...
- Page 65 S5 Workshop Manual Engine Valve Valve length Air intake 109.5 mm Air exhaust 109.7 mm Outer diameter of valve rod ～ Air intake 6.565 6.580 mm Air exhaust ～ 6.530 6.550 mm Taper angle 45º ± 10’ Width (edge) of valve head Air intake 0.7 mm...
- Page 66 S5 Workshop Manual Engine Item Specification Parameter Limiting Value Piston ring Side clearance ～ No.1 0.04 0.075 mm No.2 0.1 mm ～ 0.02 0.06 mm Oil ring ～ 0.06 0.15 mm End play No.1 0.8 mm ～ 0.25 0.35 mm No.2...
- Page 67 S5 Workshop Manual Engine Safety spring Free length 46.6 mm When loading [61 N], 40.1 mm Item Specification parameter Limiting value Left balance shaft ～ Rear journal diameter 18.467 18.480 /41.959 - 41.975 Rear journal diameter ～ Clearance 40.951 40.967 mm...
- Page 68 S5 Workshop Manual Engine Fastening Torque Specification Table Name Specification Fastening Torque (N•m) Forced bolt 63 N•m + loosening + (20 ± 2 Cylinder head bolt N•m) + 90º+ 90º subassembly 25 ± 2 N•m + (90º~94º) Main bearing cover bolts Fixing bolt components of 20~30 N•m...
- Page 69 S5 Workshop Manual Engine assembly 15 ~ 20 N•m Air intake pipe bolt 18 ~ 25 N•m subassembly 8 ~ 12 N•m Water pipe fixing bolt M6×12 15 ~ 22 N•m Camshaft signal wheel bolt M85×0 Fastening bolts( air intake 18 ~ 25 N•m...
- Page 70 S5 Workshop Manual Engine 40 ~ 50 N•m Oxygen sensor Spark plug M14×1.25 20 ~ 30 N•m Thermostat valve seat long 19 ~ 28 N•m M8×20 bolt Thermostat valve seat short 19 ~ 28 N•m M8×20 bolt Hexagon flange with teeth 19 ~ 28 N•m...