JAC HFC7151M1V-U221B Workshop Manual
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JAC HFC7151M1V-U221B Workshop Manual

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WORKSHOP MANUAL
HFC7151M1V-U221B
Engine
Version No：JAC-201511030415001
江淮汽车
部门：客户服务部

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Summary of Contents for JAC HFC7151M1V-U221B

  • Page 1 WORKSHOP MANUAL HFC7151M1V-U221B Engine Version No：JAC-201511030415001 江淮汽车 部门：客户服务部...
  • Page 2 During the process of maintaining JAC vehicle, if genuine parts that are not from JAC or disqualified oil, the vehicle may be damaged.
  • Page 3 Engine 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. 2015.11 江淮汽车 部门：客户服务部...

  • Page 4: Table Of Contents

    Contents Engine Contents Chapter I Mechanical Part of Engine Section I Engine Body General Precautions Preparation III. Engine Assembly Drive Belt Air Filter and Air Duct Intake Manifold and Exhaust Manifold VII. Exhaust System VIII. Timing sprocket mechanism Cylinder head Valves Cylinder Body Assembly XII.
  • Page 5 Contents Fuel Filter Fuel Pump Assembly VII. Fuel Tank Assembly Section V Emission Control System of Engine Fuel Evaporation Control System Forced Ventilating System of Crankcase Chapter II Electrical Part of Engine Section I Ignition System Ignition coil Diagnosis of Common Troubles III.

  • Page 6: Chapter I Mechanical Part Of Engine

    Mechanical Part of Engine Chapter 1 Mechanical Part of Engine Section 1 Engine Body General Precautions Precautions on Discharging Engine Coolant Discharge coolant after engine has cooled down. Precautions on Disconnecting Fuel Pipeline Before the operation, ensure that the operating area is free of objects which may cause combustion or sparks.
  • Page 7 Make sure that the surfaces of threads and pedestal are clean and coated with engine oil. Precautions on Sealant Fig.1.1.001 Removal of Sealant JAC-T1F017 After dismounting fixing nuts and bolts, use the scraper to detach the matching faces and remove old sealant.
  • Page 8 Mechanical Part of Engine Position sealant with the specified size. Fig.1.1.003 ■ Put the sealant into the groove for it (if any). ■ Generally, the sealant is put inside the bolt hole; however, it is occasionally put outside the bolt hole. ■...

  • Page 9: Preparation

    Tools for Maintenance List of Special Tools Tool Appearance Code Description Fix camshaft End forked clamp timing sprocket JAC-T1D001 Used together with the end forked clamp Used to install Locating tool for and dismantle piston pin the piston pin JAC-T1F005...
  • Page 10 Mechanical Part of Engine Used to install Oxygen sensor and dismantle JAC-T1F015 socket the oxygen sensor Used to Dismantlement dismantle the JAC-T1F017 tool for oil pan oil pan Used to install Installer for valve the valve oil JAC-T3F001 oil seal...
  • Page 11 Mechanical Part of Engine List of Auxiliary Materials for Assembling Engine List of Auxiliary Materials for Assembling Engine Name Application Specification and Grade Factory filled oil: SAE10W-30 Ambient temperature: -25℃-35℃ Engine Used during filling and assembly User must select the appropriate according to the local temperature Quality level: SJ or above Silica...

  • Page 12: Engine Assembly

    Mechanical Part of Engine III. Engine Assembly 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.
  • Page 13 Mechanical Part of Engine Dismantlement of Related Elements in Engine Compartment ① Disconnect the following pipelines and put them aside. Attention: Use plugs to prevent leakage when disconnecting the pipelines. ■ Inlet pipe of fuel injector. See “Fuel Injector”. ■ Vacuum hose of braking vacuum booster on engine side.
  • Page 14 Mechanical Part of Engine ③ Dismount the engine supporting beam. See “Engine Supporting Beam”. Dismantlement ① Attach the lifting device hook to the hanging lug of the engine Fig.1.1.004 Fig.1.1.005 ② Lift the engine and fix it in place. ③ Use the manual lifting stand or equivalent to firmly support the bottom of engine and transmission assembly;...
  • Page 15 Mechanical Part of Engine Make sure that all engine suspensions have been properly fixed. Then, tighten the nuts and bolts. 8. Check after Installation Check for any leakage. The steps for checking oil and fluid leakage, lubricating oil leakage and the exhaust leakage are as follows: ■...

  • Page 16: Drive Belt

    Mechanical Part of Engine IV. Drive Belt Check Drive Belt Warnings Be sure to operate only when engine stopped. ■ Check belt for aging, crack, wear and oil stain. Replace as required. Check the belt tension at the mid-point between pulleys. ■...
  • Page 17 Mechanical Part of Engine Generator Belt Loosen the generator adjusting nuts and supporting nuts. Then adjust the tension by using the adjusting bolt. Fig. 1.1.006 Fig. 1.1.007 Tighten generator adjusting and supporting nuts. ■ Tightening torque: Generator adjusting nuts: 22.5 ± 2.5 Nm Generator supporting nuts: 47±5 N.m Belt of Power Steering Pump Loosen the power steering pump adjusting and supporting bolts.

  • Page 18: Air Filter And Air Duct

    Mechanical Part of Engine Air Filter and Air Duct Intake Pipe Dismantlement ① Dismount the fixing bolt of front intake pipe, take off the front intake pipe assembly. ■ Tightening torque: 17-19 N·m ② Dismount the locking bolt on upper cover of air filter.

  • Page 19: Intake Manifold And Exhaust Manifold

    Mechanical Part of Engine Attention: ■ Properly mount every joint and tighten the clamp. Replacement of Air Filter element Dismantlement Fig.1.1.015 ① Loosen the locking bolt on upper cover of air filter and lift the upper cover. ② Dismount air filter element. Fig.
  • Page 20 Mechanical Part of Engine Decomposition Diagram of Intake and Exhaust Manifolds Intake Manifold Dismantlement Caution: ■ Do not discharge the engine coolant when the engine is hot, otherwise you would be scalded. ① Discharge the engine coolant. See “Engine Coolant”. ②...
  • Page 21 Mechanical Part of Engine ■ Vacuum hose of braking vacuum booster on intake manifold side ■ Vacuum hose on carbon canister solenoid side ■ Small circulating water hose for throttle valve body ⑥ Dismount fixing bolts and valve body, take off valve Fig.1.1.018 body assembly.
  • Page 22 Mechanical Part of Engine Check after Dismantlement Check whether there is any crack or other damage on intake manifold and whether the matching face is distorted. If this is the case, repair or replace the intake manifold. Check for any abnormal condition of rubber rings.

  • Page 23: Exhaust System

    Mechanical Part of Engine ② Unscrew the fixing bolt for heat shield of exhaust Fig.1.1.023 manifold, and then take off heat shield. ■ Tightening torque: 5-10N·m ④ Unscrew bracket bolt to remove the exhaust manifold Fig.1.1.024 bracket. ■ Tightening torque: 20±1.0 N·m ⑤...
  • Page 24 Mechanical Part of Engine Diagram of Exhaust System 1- Rear muffler; 2- Lug; 3- Front muffler; 4- Front exhaust pipe; 5-Three-element Catalytic Converter; 6- Bellow; 7-Rear oxygen sensor Inspection of Exhaust System Check whether the exhaust pipe, the three-way catalytic converter, the muffler and the fixing devices are properly installed and whether there is any leakage, crack, damage or aging.
  • Page 25 Mechanical Part of Engine whether there is any intervention between parts, and then tighten the parts to specified torque. ■ When install the fixing rubber, avoid excessive upward/downward and leftward/rightward twist or stretch. Check after Installation ■ Verify clearance between rear muffler and rear bumper. ■...

  • Page 26: Timing Sprocket Mechanism

    Mechanical Part of Engine VIII. Timing sprocket mechanism Parts Timing sprocket mechanism diagram Dismantlement and Installation of Timing Fig.1.1.026 chain Dismantlement ① Dismount the fixing 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.
  • Page 27 Mechanical Part of Engine Dismantle damping wheel Fig.1.1.028 ■ Tightening torque: 160-170 N·m Dismantle generators and power steering pump bracket Fig.1.1.029 Fig.1.1.030 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.
  • Page 28 Mechanical Part of Engine Timing mark of sprocket coolant Timing mark of sprocket Timing mark of sprocket Timing mark of sprocket Dismantle tensioner and set/dynamic tracks of the automatic timing chain. Check for any abnormalities. ■ Tightening torque: Automatic tensioner: 9 - 11 N • m Set track: 10-12 N·m Dynamic track: 19-28 N·m Fig.1.1.032...
  • Page 29 Mechanical Part of Engine Dismantle intake cam timing controller Fig.1.1.035 ± ■ 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 Camshaft decomposition diagram 江淮汽车...
  • Page 30 Mechanical Part of Engine Disassembly and installation 1） Disassembly ① Remove cylinder cover. See "Intake Manifold." ② Remove high-voltage ignition coil. See "Ignition Coil." ③ Disconnect PCV hose and air hose of respirator. ④ Remove the cylinder head cover from the cylinder head. ⑤...
  • Page 31 Mechanical Part of Engine Assembly of camshaft machenism: All parts camshaft assembly should be assembled according to grouped drawings. ① The mechanical tappet at the intake side will be grouped and assembled as per the following table to ensure the intake valve clearance. Distance between intake camshaft base circle Top end thickness of Mechanical tappet...
  • Page 32 Mechanical Part of Engine ② The mechanical tappet at the exhaust side will be grouped and assembled as per the following table to ensure the intake valve clearance. Distance between exhaust camshaft base circle Top end thickness of Mechanical Valve clearance (mm) and valve tappet L2 mechanical tappet tappet label...
  • Page 33 Mechanical Part of Engine Installation precautions: ■ Mechanical tappet should be applied with proper amount of oil evenly; after the cylinder head is assembled, it should turn flexibly without sticking or other abnormalities. ■ Before assembling camshaft, proper amount of oil should be evenly applied on each contact surface;...
  • Page 34 Mechanical Part of Engine speed. Perform these steps to check other cylinders. ■ Standard pressure: 1500kPa ■ Minimum pressure: 1200kPa ■ Tolerable pressure difference between cylinders: ≤150kPa Attention: ■ It is required to obtain the specified engine speed always by the battery which is fully charged.
  • Page 35 Mechanical Part of Engine Dismantlement and Installation Dismantlement ① Discharge engine coolant and oil. See “Change Engine Coolant” and “Change Engine Oil”. Attention: ■ Perform these steps after engine cooled down. ■ Do not splash engine coolant or oil onto the drive belt. ②...
  • Page 36 Mechanical Part of Engine Measure the planeness in six directions at Fig.1.1.38 several positions on bottom surface of cylinder head. Standard value: below 0.03mm Height of cylinder head (new): 113±0.1mm If the the standard value is exceeded, grind or replace the cylinder head according to the specification.
  • Page 37 Mechanical Part of Engine ■ When the two tightening angles are above 184 °, completely loosen the bolt and re-tighten per the initial sequence. If the old cylinder head bolts are replaced during the maintenance, operation should be performed in sequence from “a”...

  • Page 38: Cylinder Head

    17 - intake valve guide 18 - exhaust valve guide 19 -intake valve seat 20 - exhaust valve seat 21 - cylinder head Disassembly and Assembly Fig.1.1.041 JAC-T1F001 Disassembly ① Dismount the spark plug with the special socket. ② Dismount the valve cotter, valve spring and spring seat.
  • Page 39 Mechanical Part of Engine ■ Label the dismounted valve, valve spring Fig.1.1.042 JAC-T1F012 and other parts, and write down their corresponding cylinder numbers positions ■ Store the parts reliably. ③ Dismount the valve oil seal. Fig.1.1.043 ④ See “Replacement of Valve Seat” to replace the valve seat, if required.
  • Page 40 Mechanical Part of Engine ■ Use the valve spring compressor during the installation. ■ After installation, lightly knock the edge of valve stem with a rubber hammer to check the mounting condition. ⑧ Install spark plug with the spark plug socket. Check after Disassembly Fig.1.1.045 Valve...
  • Page 41 Mechanical Part of Engine Valve guide Fig.1.1.047 ■ Check the gap between the valve guide and the valve stem. Replace the corresponding parts if the measurement is out of limit. Valve guide Valve guide Standard value: 0.020-0.036mm Outer Diameter of Valve Stem Limit: 0.10mm Inner Diameter of Valve Conduit ■...
  • Page 42 Mechanical Part of Engine End Face of Standard values: Fig.1.1.049 Valve Stem For intake valve: 53.21mm Valve Protrusion For exhaust valve: 54.10mm Height Limits: Surface of Valve For intake valve: 53.71mm Spring Seat For exhaust valve: 54.60mm ■ Renew valve seat. Before renewing the valve seat, check the clearance between valve guide and valve.

  • Page 43: Cylinder Body Assembly

    Mechanical Part of Engine XI. Cylinder Body Assembly Parts Disassembly Diagram of Cylinder Body Assembly 1 - flywheel bolt 2 - signal wheel screw 3 -flywheel 4 - crankshaft oil seal bolt 5 - crankshaft oil seal housing 6 - bearing cap bolt 7 - bearing caps 8 – upper main bearing shell 9 - crankshaft 10 - lower main bearing shell 11 - crankshaft thrust 12 - crankshaft signal wheel 13 - cylinder block Disassembly and Assembly Disassembly...
  • Page 44 Mechanical Part of Engine ■ Drive belt ■ Generator, power steering pump, compressor and related supports ■ Intake and exhaust manifolds ■ Water pump and its components ■ Ignition coil ■ Cylinder cover, damping wheel, oil pan ■ Engine timing sprocket mechanism ⑥...
  • Page 45 Mechanical Part of Engine Attention: ■ Be careful not to damage the big bonnet and connecting rod fitting surface ■ Do not damage the cylinder wall and the crankshaft journal with the big end of the connecting rod. ■ Maintain the connecting rod big end and the connecting rod body match sequentially and maintain the connecting rod big end serial number in consistency ⑩...
  • Page 46 Mechanical Part of Engine Loosen the bolts of crankshaft bearing cap in the Number of Bearing Fig.1.1.054 following sequence. ■ Tightening torque: 35±2 N·m＋60°～64° Be aware of the number and forward mark of bearing cap. ■ In Fig.1.1.065: For the upper row, 4→8→10→6→2 For the lower row, 1→5→9 →7→3 During the dismantlement, it is allowable to jiggle Fig.1.1.055...
  • Page 47 Mechanical Part of Engine Measure the gap between the connecting rod and Fig.1.1.057 the crankshaft by using feeler gauge. Standard value: 0.10-0.3mm Limit: 0.4mm If the limit is exceeded, replace the connecting rod and measure again. Replace the crankshaft if measurement is still out of the limit.
  • Page 48 Mechanical Part of Engine For 1 piston ring, 0.8mm For 2 piston ring, 0.8mm If the measurement exceeds the limit, replace the piston ring, and then measure again. Extend cylinder bore through grinding and use the corresponding piston and piston ring if the measurement is still over the limit.
  • Page 49 Mechanical Part of Engine Standard value: 0.02-0.04mm If the calculated value exceeds the limit, replace piston and piston ring assembly. ⑨ Boring Cylinder The piston with extended size to be used should be determined in accordance with the cylinder which has the highest bore. Pistons of the following extended sizes, i.e.
  • Page 50 Mechanical Part of Engine Put the plastic divider on the connecting rod Fig.1.1.063 journal, and asset it to a length equal to bearing shell width. The plastic divider must be placed at the center of connecting rod journal and be parallel with the axial line of connecting rod.
  • Page 51 Mechanical Part of Engine Measure the pressed portion of plastic divider Fig.1.1.065 Plastic Wire at the widest point by the scale which is Gauge printed on the plastic wire gauge bag. Standard values: 0.02-0.04mm Limit:0.1mm Attention: Round-angle Rolling Area Fig.1.1.066 ■...
  • Page 52 Mechanical Part of Engine below). If the crankshaft can not be identified, measure the diameter of crankshaft, and then select the corresponding bearing shell to match the crankshaft. Crankshaft group marking Main bearing Hole group marking (up / down) Black／Black Black／Yellow Black／Red Black／White...
  • Page 53 Mechanical Part of Engine ⑥ Install piston onto the connecting rod with following instructions. Fig.1.1.069 Measure the following lengths (See right Figure). A： Distance from piston flange to piston flange Connecting outside B： Distance from piston flange to piston flange inside C：...
  • Page 54 Mechanical Part of Engine upper and lower blades. ■ Lining ring and blade size coloring scheme. Table of lining ring and blade size coloring scheme Size Color Standard Colorless Extended by 0.50mm Blue Extended by 1.00mm Yellow To install the blade, install one end of blade into the groove (as shown in the diagram) before pressing the other areas to place.
  • Page 55 Mechanical Part of Engine center of bottom. ■ Apply sufficient engine oil onto cylinder bore, piston and crankshaft journal. ■ Align air ring opening with oil ring opening. See Fig.1.1.097. Schematic Diagram for Piston Ring Location Opening direction of first gas ring Opening direction of combined oil ring lower blade Opening direction of lining ring of combined oil ring...
  • Page 56 Mechanical Part of Engine Before installing nut, apply engine oil on its thread and seat. ⑪ Install rear oil seal housing of crankshaft with rear oil seal assemble to the cylinder block. ⑫ Installation of knock sensor, Hall sensors, oil pressure switch. Attention: ■...

  • Page 57: Diagnosis Of Common Troubles

    Mechanical Part of Engine XII. Diagnosis of Common Troubles Diagnosis List of Common Troubles Trouble Possible Cause Resolution The cylinder gasket is leaky. Replace cylinder gasket. The piston ring is damaged or worn. Replace the piston ring. Low cylinder pressure The cylinder or the piston is worn.
  • Page 58 Mechanical Part of Engine Trouble Possible Cause Resolution The sensor is at fault. Repair or replace. The fan is at fault. Repair or replace. The coolant is insufficient. Replenish The thermostat is at fault. Replace. Low temperature of coolant The sensor or the wire harness is at fault. Repair or replace.

  • Page 59: Parameters For Maintenance

    Mechanical Part of Engine XIII. Parameters for Maintenance List for Technical Parameters of Engine Technical Parameters list of Engine Item Standard Value Limits Camshaft Camshaft base circle diameter (mm) — Diameter of camshaft journal (mm) 32.033-32.082 — Cylinder head and valve ＜0.03 Planeness of cylinder gasket surface (mm) Total height of cylinder head (mm)
  • Page 60 Mechanical Part of Engine Item Standard Value Limits Oil pump and oil pan Addendum gap of oil pump 0.06-0.18 — Side clearance of oil pump(mm) 0.04-0.11 — Clearance of oil pump housing 0.10-0.18 0.35 Piston and connecting rod Reference outer diameter of piston 75.0 —...
  • Page 61 Mechanical Part of Engine Tightening Torques List of fastener tightening torque Name Specification Qty. Tightening Torques (Nm) High strength bolt Main bearing cap bolt M9×1.25×74.5 35±2Nm +60°-64° (Synchronous fastening machine) 5Nm → 13Nm +90 ° - 94 ° Connecting rod bolts tightening M6×0.75×33 torque (Manual) 5Nm →...
  • Page 62 Mechanical Part of Engine Other bolts Set track bolts M6×1×12 10±2 Dynamic track bolts M8×1.25×15 23.5±4.5 Starter bolt M8×55 24±3 Oil pressure switch R 1/8 10±2 Spark plug 34±4 Exhaust manifold stud M8×1×12 22±2.5 Q1840830 (exhaust manifold M8×30 See "Standard parts and threaded connections not bracket bolt) mentioned in table above"...

  • Page 63: Section Ii Engine Lubrication System

    Mechanical Part of Engine Section II Engine Lubrication System Precautions Application Steps of Sealant: 1. Remove any old sealant on the seal gasket by using scraper. Fig. 1.2.001 Scraper Attention: ■ Thoroughly remove old sealant from grooves, fixed bolts and bolt holes on sealant application surface.

  • Page 64: Preparation

    Mechanical Part of Engine Preparation Repair Tools List of repair tools Tool Outline Drawing Explanation Oil pressure gauge Measure oil pressure Connect oil pressure Hose gauge to cylinder body Oil pressure switch Dismount and mount socket oil pressure switch 江淮汽车 部门：客户服务部...

  • Page 65: Lubrication System Schematic Diagram

    Mechanical Part of Engine III. Lubrication system schematic diagram 1.3L发动机润滑系统油路示意图 Lubrication System Diagram of Engine 主 油 道 Main oil gallery Main oil gallery of 缸盖主油道 cylinder head VVT screen VVT滤网 Bearing hole of first air intake 第一道进气凸轮轴轴承孔 Filter 滤清器 主轴承...
  • Page 66 Mechanical Part of Engine ■ Oil pan ■ Oil drainage bolt on oil pan ■ Oil pressure switch ■ Oil filter ■ Matching surface of cylinder body and cylinder head ■ Front and rear oil seals of crankshaft ■ Matching surface of oil pump and cylinder body Inspect oil pressure Attention: ■...
  • Page 67 Mechanical Part of Engine ■ Please use the specified sealant: LT5699 or equivalent. ■ Tightening torque: 8-12N·m After the engine is warmed up, make sure there is no oil leakage during normal operation of engine. 2. Change Oil Attention: ■ As the temperature of engine oil is high, please protect yourself from being hurt.
  • Page 68 Dismantlement and Installation Dismantlement Dismount the oil filter with an oil filter spanner. Attention: ■ Use original oil filter provided by JAC or equivalent. ■ As the temperatures of engine and engine oil are high, please proetct yourself from being hurt. ■...

  • Page 69: Oil Pan And Engine Oil Pump

    Mechanical Part of Engine Oil Pan and Engine Oil Pump Parts Breakdown drawing of oil pan and oil pump 1 - oil filter bracket gasket 2 - oil filter bracket bolt 3 - oil filter 4 - oil pan bolt 5 – oil pan assembly 6 - oil pickup 7 - oil pickup bolt 8 - oil filter bracket 9 –...
  • Page 70 Mechanical Part of Engine Dismount oil pan. Fig. 1.2.007 First, use loosening agent for sealants in order to prevent oil pan sealing surface from deformation. Loosen the fixed bolts according to following sequence: center-both sides. ■ Tightening torque:7.6±0.6 N·m Knock the special tool into the space between Fig.
  • Page 71 Mechanical Part of Engine Install external generator, power steering pump, cylinder head cover and other parts on the oil pump assembly. Install oil filter. ■ Clean the oil filter mounting surface on oil pump housing. ■ Apply some oil on O-ring of oil filter. ■...
  • Page 72 Mechanical Part of Engine Install oil drainage bolt on oil pan Fig. 1.2.011 ■ The oil drainage bolt gasket for the oil pan is a one-time product, new one should be used after removal. ■ Install the oil drainage bolt washer of oil pan shown in the figure.

  • Page 73: Section Iii Cooling System Of Engine

    Mechanical Part of Engine Section III Cooling System of Engine Cooling Circuit Cooling Circuit Diagram Heater water returning pipe bolts II Heater water returning pipe Spacer of heater water returning pipe Thermost subassembly Water pump feeder Water pump inlet bolt Cooling circuit diagram Principle Diagram of Cooling Radiator...

  • Page 74: Engine Coolant

    Mechanical Part of Engine Engine Coolant Check Level check After the engine cooled, check whether coolant level in reservoir is between MIN and Max marks. ■ Adjust level if necessary. Fig. 1.3.005 Leakage check Apply pressure to cooling system with leak Fig.
  • Page 75 Attention: ■ The original engine coolant provided by JAC must be used. Please refer to “Recommended Oil and Lubricant”. ■ Disconnect when engine coolant overflows from warm water pipe, and then reconnect and continue to fill engine coolant.
  • Page 76 Mechanical Part of Engine ■ Fill coolant in radiator through the filler if necessary. ⑩ Fill engine coolant in reservoir to the MAX position. ⑪ Install the radiator cap and repeat steps ③-⑨ more than twice until the engine coolant level does not lower any more.
  • Page 77 Mechanical Part of Engine ③ Dismount air intake pipe and take it off. ④ Disconnect the harness connector of radiator fan motor and move it aside. ⑤ Dismount the inlet and outlet hoses of radiator and returning hose of coolant reservoir. ⑥...

  • Page 78: Radiator Cooling Fan

    Mechanical Part of Engine methods. ■ Be careful not to bend or damage the radiating fin. ■ When washing the radiator without dismantling it, please dismount all accessories such as cooling fan, wind collection cover and horn. Then wrap up the harness connectors with adhesive tape to prevent water from flowing in.

  • Page 79: Water Pump

    Mechanical Part of Engine IV. Water Pump Dismantlement and Installation Attention: ■ Be careful not to splash the engine coolant onto the drive belt while dismantling the water pump. ■ If the water pump can not be disassembled, it should be replaced as a whole. ■...

  • Page 80: Thermostat Sub-Assembly

    Mechanical Part of Engine Install belt pulley of water pump. Install drive belt and adjust it in accordance with specified tension. Please refer to “Drive Belt”. Fill engine coolant. Please refer to “Refill engine coolant”. Check after Installation ■ Check if there is any coolant leakage with leak detector for radiator cap. Please refer to “Leakage Check”.
  • Page 81 Mechanical Part of Engine Check after Dismantlement Fig. 1.3.014 ① Thermostat ■ Inspect opening of thermostat valve at normal room temperature. Temperature of thermostat (ON): 82℃ (initially open) 95℃ (fully open) Maximum lift of valve stem: ≥8mm Please replace the thermostat when the measurement exceeds the specified range. ②...

  • Page 82: Water Piping Sub-Assembly

    Mechanical Part of Engine ⑤ If the engine coolant temperature sensor Fig. 1.3.017 needs to be reused, apply specified sealant to its thread. ■ Specified sealant: LT648 or equivalent. Check after Installation ■ Check for any coolant leakage with leak detector of radiator cap.

  • Page 83: Trouble Analysis

    Mechanical Part of Engine VII. Trouble Analysis Table for Overheating Cause Analysis Symptom Item should be inspected Water pump Worn or loosening of drive malfunction belt Stuck of thermostat at closed position Blockage due to dust or Improper heat radiation —...

  • Page 84: Parameters For Maintenance

    Mechanical 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 >8mm 江淮汽车 部门：客户服务部...

  • Page 85: Section Iv Fuel Supply System Of Engine

    Start the engine, increase its speed and check each connection for fuel leakage. ■ Only the original fuel filler cap provided by JAC can be used. ■ Please refer to “Fuel Evaporative Emission System” for maintenance of parts of the system.

  • Page 86: Preparation

    List of Special Tools S.N. Tool Outline Diagram Explanation Fuel pressure Measure fuel JAC－T1F018 gauge pressure III. Fuel System Check Fuel Pipe Check the fuel pipeline, fuel filler cap and fuel tank for proper installation, leakage, crack, damage, loose connection, worn and aging.

  • Page 87: Fuel Injector And Guide Rail

    Mechanical Part of Engine Check for the following matters. Blockage of fuel hose and fuel pipe. Blockage of fuel filter. Fuel pump and its control circuit. IV. Fuel Injector and Guide Rail Dismantlement Caution: ■ Do read the “General Precautions” before dealing with fuel system. Please refer to “General Precautions”.
  • Page 88 Mechanical Part of Engine ■ Avoid the naked flame and spark. ■ Please keep any parts away from heat source. Special attention must be paid when welding around them. ■ Do not expose the parts to the electrolyte of battery or other fluid. ■...
  • Page 89 Mechanical Part of Engine Fuel Guide Rail ■ Check the fuel inspection hole for damage and jamming. If any, please replace. ■ Check if there is residuum in guide rail. If any, please clean. Installation Be aware of following precautions when mounting new O-ring on fuel injector. ■...
  • Page 90 Mechanical Part of Engine Make sure the fuel injector will not move or fall off. Installation is completed. Install fuel pipe guide rail and fuel injector assembly inside intake manifold. Attention: ■ Be careful not to make fuel injector nozzle contact with other parts. For the following steps, install with steps contrary to dismantlement.
  • Page 91 Mechanical Part of Engine Disconnect the fuel pipe joint 1 (at fuel pump Fig. 1.4.007 side), joint 2 (at fuel filter side) and grounding end 3 of fuel filter. Attention: The fuel filter should be wrapped up with towel or equivalent, so as to avoid injection of residual fuel.

  • Page 92: Fuel Filter

    Mechanical Part of Engine Fuel filter ■ Be aware of correct installation direction of Fig. 1.4.010 fuel filter. towards fuel inlet pipe side Connector Connect the connector of fuel supply hose according to following methods: ① Check the connection for foreign substance or damage. ②...

  • Page 93: Fuel Pump Assembly

    Mechanical Part of Engine VI. Fuel Pump Assembly Figure of fuel pump assembly Dismantlement Caution: ■ Do read the “General Precautions” before dealing with fuel system. See “General Precautions”. Check fuel level indicated on fuel meter. If the meter indicates “full” or “to be full”, discharge the fuel from tank until the meter indicates that the fuel level is lower than position “E”.
  • Page 94 Mechanical Part of Engine Disconnect the harness connector of fuel Fig. 1.4.013 pump and fuel pipe joint. ① Fuel pipe joint of fuel pump ② Harness connector of fuel harness Disconnect the joint with following methods: ■ Hold the side edge of joint and press the raised position of joint to pull out the pipe. ■...
  • Page 95 Mechanical Part of Engine Take off the Y-ring. Fig. 1.4.015 Attention: ■ Tilt the fuel pump when it is taken out, so as to avoid broken of fuel level sensor. ■ To avoid residual fuel from being polluted, wrap the Y-ring with cloth to pull it out straightly.
  • Page 96 Mechanical Part of Engine Fuel pump assembly ■ The Y-ring must fully fit with fuel tank during installation. ■ Tilt the fuel pump to facilitate its installation and pay attention to its direction. ■ There should be no turn-up on Y-ring during the installation. ■...

  • Page 97: Fuel Tank Assembly

    Mechanical Part of Engine VII. Fuel Tank Assembly Breakdown diagram of fuel tank assembly -Filler cap -Filler tube -Fuel tank -Fastening band of fuel tank Service lid -Locknut -Y-ring -Fuel pump -Fuel filter -Thermal baffle Dismantlement and Installation 1） Dismantlement Caution: ■...
  • Page 98 Mechanical Part of Engine ⑥ Dismount fastening band of fuel tank. ■ Tightening torque: 30-40N·m Fig. 1.4.017 ⑦ Manually support the tank and carefully lower the jack to dismount fuel tank. Attention: ■ Make sure all connections have been disconnected. ■...

  • Page 99: Section V Emission Control System Of Engine

    Mechanical Part of Engine Section V Emission Control System of Engine Fuel Evaporation Control System Description Intake manifold Air cleaner EVAP carbon canister solenoid valve Fuel evaporation EVAP carbon canister Fuel tank Schematic diagram of fuel evaporation system The fuel evaporation system is used to reduce hydrocarbon compositions emitted into ambient air from fuel system.
  • Page 100 Mechanical Part of Engine Diagram of Fuel Evaporative Emission Pipeline Diagram of fuel evaporative emission pipeline 1-Carbon canister assembly 2-Fuel inlet hose of engine 3-Pipe connecting carbon canister with solenoid valve 4-Hose connecting carbon canister with solenoid valve 5-Fuel inlet pipe of engine 6-Fuel filter Note: Fig.
  • Page 101 Mechanical Part of Engine slip-joint pliers, pull out the vacuum hose. 江淮汽车 部门：客户服务部...
  • Page 102 Mechanical Part of Engine ③ Dismount the carbon canister Lift the carbon canister and dismount it from the Fig. 1.5.002 左前车架 Left front frame bracket on inner lining of left fender. EVAP carbon canister solenoid valve The air flow rate is controlled by the opening of evaporation by-pass passage in EVAP carbon canister solenoid valve.
  • Page 103 Mechanical Part of Engine Disconnect the harness connector of EVAP Fig. 1.5.004 carbon canister solenoid valve. Take off EVAP carbon canister solenoid valve Fig. 1.5.005 from the bracket. 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 evaporation to ambient air.

  • Page 104: Forced Ventilating System Of Crankcase

    Mechanical Part of Engine Forced Ventilating System of Crankcase System Illustration The forced ventilating system of crankcase is used to bring the cylinder blow-by gas in crankcase back to intake manifold. It is the forced ventilating valve (PCV) which brings the cylinder blow-by gas in crankcase back to intake manifold.
  • Page 105 Mechanical Part of Engine Inspection of Element Check the PCV (forced ventilation of crankcase) valve as shown below: Operation principle Operation principle list of PAV valve High vacuum No vacuum Valve chamber cover side Valve chamber cover side Operating state of engine Out of work Operating state of engine Idling or deceleration...
  • Page 106 Mechanical Part of Engine Dismantlement and Installation ① Dismantlement Disconnect the PCV valve hose from cylinder cover. Fig. 1.5.006 Remove the PCV valve from cylinder Fig. 1.5.007 cover. Check after Dismantlement ① PCV valve: Hissing may be produced during normal working of valve with air flows through. Fig.

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