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JAC J2 Maintenance Manual

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This manual is intended to help the
professional maintenance technicians
authorized by JAC Passenger Car Sales
Company provide effective and correct
maintenance and service for JAC J2
Sedan series models. The warm service
and
professional maintenance technicians of
JAC passenger cars are essential for
ensuring customer satisfaction to JAC
passenger car products. Therefore, the
maintenance
understand this manual fully. This
manual should be placed in a handy
place for your convenient reference.
All contents of this manual including
pictures and technical parameters are
latest. In case maintenance works are
affected due to product improvement,
JAC Passenger Car Sales Company will
provide
supplementary volumes. Therefore, you
should use this manual and pay close
attention to obtaining latest update
relevant information.JAC Passenger Car
Sales Company reserves the rights to
change, add or improve designs of its
products.
 No part of this manual is allowed to be
reproduced or modified in any form,
including but not limited to electronic
media, paper, sound and image, and
mechanical
authorization from JAC Passenger Car
Sales Company.
Use of non genuine spare parts for
JAC passenger cars or nonconforming
oils during maintenance and service
 processes
 products may cause vehicle damage.
Maintenance Manual for J2 Sedan
 
Maintenance Manual for J2 Sedan
Foreword  
proper
operation
from
technicians
technical
bulletins
media,
without
of
JAC
passenger
Master Table of Contents  
General
Maintenance
Chapter I General Description
the
Chapter II
Engine
must
Chapter I Engine mechanical system
Chapter II
Chapter III engine electronic control
system
Chassis
or
Chapter I
Transmission
Chapter II
Chapter III
Body Electrical & Structure
written
Chapter I
Chapter II Body Structure
Circuit Troubleshooting
car
 
Foreword  
Description
 
 
Maintenance
 
Engine electrical system
 
 
Clutch & Manual
 
 
 
Traveling system
 
 
Braking system
 
 
Body Electrical
 
&
 
 

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Summary of Contents for JAC J2

  • Page 1 This manual is intended to help the General Description & professional maintenance technicians Maintenance authorized by JAC Passenger Car Sales Company provide effective and correct maintenance and service for JAC J2 Chapter I General Description Sedan series models. The warm service   proper operation from  ...

  • Page 2: Table Of Contents

      Maintenance Manual for J2 Sedan Contents   Contents of Overview and Service Chapter I Overview......................1   Section I General Instructions ...................... 1 Summary ..........................1 Operations ..........................1 Section II  Vehicle Information ..................... 2 Identification Information Position ..................2 Nameplate ..........................

  • Page 3: Identification Information Position

      Maintenance Manual for J2 Sedan Overview   Chapter I Overview Section I General Instructi �� �� �� �� Summary This Manual provides the procedures required by service operations, including: Structure and composition Principles Dismantlement and installation steps Inspection methods Adjustment &...

  • Page 4: Vehicle Information

      Maintenance Manual for J2 Sedan Overview   Section II Vehicle Information Identification Information Position Position of vehicle ID 1- Name plate of vehicle 2- ID number of vehicle Nameplate Position of nameplate: at the firewall of engine compartment. Instructions of nameplate  ...
  • Page 5 Part 1: Word Manufacturer Identification (WMI), consists of 3 numbers according to GB16737, which should be applied, approved and filed. WMI for JAC is LJ1, which applicable for freight truck, incomplete vehicle, bus, passenger car, tractor and special vehicle of JAC. Word Manufacturer Identification (WMI) is shown in table below.

  • Page 6: Engine Number

      Maintenance Manual for J2 Sedan Overview   ①   Vehicle type ： 2 Means passenger cars F: 3 chambers & 4 doors ②   Body type G: 2 chambers & 5 doors ③   Max. Gross Weight: K: >1000-2000 ④...
  • Page 7   Maintenance Manual for J2 Sedan Overview   Meaning of Engine Number Fig. 2.1.002 3GB4.C – Engine model: 1.0 3-cylinder gasoline engine ☆  A3408769 ☆ :  A – the year of 2010 3 - engine type (petrol, local parts) 408769– Production SN...

  • Page 8: Lifting, Protection And Towing Of Vehicle

      Maintenance Manual for J2 Sedan Overview   Section III Lifting, Protection and Towing of Vehicle Lifting of Vehicle Vehicle’s Supporting Points The positions of vehicle’s supporting points are shown in figure below. Attention:   Don’t lift the vehicle by using the point other than those specified; otherwise vehicle body ...
  • Page 9   Maintenance Manual for J2 Sedan Overview   III. Towing of Vehicle If vehicle needs to be towed, please contact the local authorized after-sales service center or a special vehicle towing service company. Towing with tractor Caution:   No passenger allowed in the vehicle being towed;...

  • Page 10: Chapter Ii Service

    These service items are very important, for normal operation performance of vehicle. The owners can perform these inspections by themselves, or go to a JAC franchised store for assistance. Followed is content of general service: Exterior of Vehicle The following inspection and maintenance items should be frequently conducted.

  • Page 11: Regular Service

      Maintenance Manual for J2 Sedan Service   Vehicle lamps Verify that headlamps, brake indicators, tail lamps, turning signal indicator and other lighting units work normally and have been stably fixed. Meanwhile, inspect focusing function of headlamp. Interior of Vehicle The following inspection and maintenance items should be performed regularly.

  • Page 12: Service Of Engine

      Maintenance Manual for J2 Sedan Service   Service operational code: I-examination; R-replacement; C-washing Service cycle (odometer readings and the number of months, whichever comes first) Item 1000km Month  — I: every 10,000 km or 6 months Driving belt R: every 60,000 km or two years...

  • Page 13: Recommended Oil And Lubricant

    ⑨  At a temperature below 30 ℃ , driving at 120km/h or higher speed limits for more than 50% of the total travel time.   ⑩ Overloaded traveling. IV. Recommended Oil and Lubricant Which listed below are the types of oil and lubricant recommended by JAC: List of Recommended Oil and Lubricant Item Capacity (L)
  • Page 14 ⑤   Fill coolant into radiator and coolant reservoir to specified level; the engine coolant must be filled slowly, such as to gradually bleed air from the system. Attention: ■ Please mix the original JAC engine coolant or equivalent product with water. See “Recommended Oil and Lubricant”.
  • Page 15   Maintenance Manual for J2 Sedan Service   ■ If coolant overflows from the heater outlet pipe, disconnect pipe and reconnect and then continue the filling of coolant. ⑥   Install air filter upper cover and intake hose. Please refer to “Air Filter Assembly”.
  • Page 16   Maintenance Manual for J2 Sedan Service   1) Inspection of cooling system hose ■ Check the hose for incorrect installation, crack, damage, loose connection, worn or ageing. ■ Please repair or replace the damaged components as required. 2) Inspection of radiator cap ①...
  • Page 17   Maintenance Manual for J2 Sedan Service   ④   Blow the back of radiation core with compressed air vertically from top to bottom. The pressure of compressed air should be less than 490 KPa, and a distance of more than 30 cm should be kept.
  • Page 18   Maintenance Manual for J2 Sedan Service   Fig. 2.2.006 ②   Take off air filter element. Inspection After Dismantlement ■ The air filter must be regularly cleaned or replaced according to recommended schedule. Please refer to “Regular Service”. ■...
  • Page 19 Dismantlement ①   Use oil filter wrench to dismount the filter. Attention: ■ JAC original engine oil or equivalent product should be used. ■ Be careful not to be scalded since engine and oil are hot. ■ During dismantlement, a cloth should be prepared to wipe up the leaked or splashed oil.
  • Page 20   Maintenance Manual for J2 Sedan Service   Dismantlement ①   Dismount the engine hood. See also “Intake manifold”. ②   Disassemble the ignition coil. Please refer to “Ignition Coil”. ③   Dismount the ignition plug with plug socket. Attention: ■...

  • Page 21: Service Of Chassis And Body

      Maintenance Manual for J2 Sedan Service   ②   Release pressure inside fuel tank. ③   Remove the rear seat cushion. See “Rear Seat”. ④   Dismount the fuel tank service cap. ⑤   Dismount the fuel filter and fuel pipe.
  • Page 22   Maintenance Manual for J2 Sedan Service   ■ In case any component is found damaged, Fig. 2.2.009 repair or replace. Inspection of Clutch Fluid Level and Leakage If the fluid level is low, check clutch system for any leakage.
  • Page 23   Maintenance Manual for J2 Sedan Service    weight is nearest to the calculated value, and install it to the specified outer side position, or at the specified angle relative to wheel. Attention: ■ The balance block of outer side should be installed before inner side.
  • Page 24   Maintenance Manual for J2 Sedan Service     ■ Allowable maximum unbalance: Tyre Exchange Fig. 2.2.012 ■ Tyre exchange should be performed every 8000 km. Tyre exchange should also be performed when the new tyre is put on. Note: As shown in the figure is the recommend method for tyre exchange.
  • Page 25   Maintenance Manual for J2 Sedan Service   Fig. 2.2.015 Insert the ethylene tube onto release valve. Press on the brake pedal to loosen the release valve, and then discharge brake fluid slowly. Wash the inner side of fluid reservoir and refill with new brake fluid.
  • Page 26   Maintenance Manual for J2 Sedan Service   Standard Specification Table of Brake Drum Type Leading trailing shoe brake Brake drum diameter 204 mm Brake drum Cylinder bore of brake slave cylinder 17.46 mm Clearance adjustment Automatically Circular runout < 0.05 mm Brake caliper Fig.
  • Page 27   Maintenance Manual for J2 Sedan Service   Fig. 2.2.020 Rear brake shoe Check the brake shoe thickness and its contact state with the brake drum. If it fails to meet the requirement, replace. ■ Standard thickness of brake shoe (A): 5 mm ■...
  • Page 28   Maintenance Manual for J2 Sedan Service   ■ Rock each wheel to check for proper clearance. Fig. 2.2.023 ■ Inspect operation conditions of wheel bearings. ■ Check axle, suspension nut and bolt for loosening. ■ Check shock absorber for oil leak or other damages.

  • Page 29: Maintenance Data

    In case the seat belt is broken, worn or damaged, don’t repair but replace the seat belt assembly. ■ Be sure not to lubricate the lock tongue and snap ring. ■ Use original seat belt assembly of JAC. ■ Check whether the anchorage is loose. ■...
  • Page 30   Maintenance Manual for J2 Sedan Service   Attention: ■ Tightening torques listed above are the standard values which are applicable for following conditions: Steel, plating nuts and bolts. Plated steel plain washers. All the dry nuts, bolts and gaskets.
  • Page 31   Maintenance Manual for J2 Sedan Contents   Engine Volume Chapter I Mechanical Part of Engine............33   Section I Engine Body....................33   General Precautions ....................33     Precautions on Sealant .................... 34     III. Preparation ........................ 36  ...
  • Page 32   Maintenance Manual for J2 Sedan Contents   Section IV Fuel Supply System of Engine............114   I.   General Precautions ....................114   II.   Preparation ......................115   III.   Fuel System ......................115   IV.   Fuel Injector and Guide Rail .................. 116  ...
  • Page 33   Maintenance Manual for J2 Sedan Contents   Section III Structural Principle and Inspection of Engine Electronic Components ..........................179   I.   Intake Manifold Absolute Pressure (MAP/MAT) Sensor ........179   II.   Engine Coolant Temperature (ECT) Sensor  ............181  ...

  • Page 34: Chapter I Mechanical Part Of Engine

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   Chapter I Mechanical Part of Engine Section I 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 35: Precautions On Sealant

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   Parts Needed to Be Tightened with Specified Angle Use the angle spanner to finally screw up following engine parts: Cylinder head bolt Bolt of main bearing cap Connecting rod bolt Please follow the specified tightening methods.
  • Page 36   Maintenance Manual for J2 Sedan 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 37: Preparation

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   III. Preparation Tools for Maintenance   List of Special Tools    No. Tool Appearance Code Description           Fix camshaft End forked clamp timing   sprocket...
  • Page 38   Maintenance Manual for J2 Sedan 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...
  • Page 39   Maintenance Manual for J2 Sedan Mechanical Part of Engine   List of Auxiliary Materials for Assembling Engine List of Auxiliary Materials for Assembling Engine  No. Name Application Specification and Grade Factory filled oil: SAE10W-30 Ambient temperature: -25 ℃ -35 ℃  ...

  • Page 40: Engine Assembly

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   IV. 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.
  • Page 41   Maintenance Manual for J2 Sedan 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. ■...
  • Page 42   Maintenance Manual for J2 Sedan Mechanical Part of 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 43   Maintenance Manual for J2 Sedan Mechanical Part of Engine   ■ Before starting engine, check oil and fluid levels (including engine oil and coolant). Refill to specified level as required.. Check for fuel leakage with following steps ：  ...

  • Page 44: Drive Belt

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   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.
  • Page 45   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Generator Belt   Loosen the generator adjusting nuts and supporting nuts. Then adjust the tension by using the adjusting bolt. Fig. 1.1.007 Fig. 1.1.006 Tighten generator adjusting and supporting nuts.

  • Page 46: Air Filter And Air Duct

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   VI. Air Filter and Air Duct Parts   Diagram of Positions   Intake Pipe Fig. 1.1.008 Dismantlement ①   Remove the fastening bolts and clamps of front intake pipe and remove the front intake  pipe assembly.
  • Page 47   Maintenance Manual for J2 Sedan Mechanical Part of Engine   ③   Disconnect the locking clamp of intake hose, and then take off upper cover and intake hose. ■ Tightening torque: 6-9 N·m Fig. 1.1.010 Fig. 1.1.011 ④   Dismount the fixing bolt of air filter base, and Fig.

  • Page 48: Intake Manifold And Exhaust Manifold

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   ②   Dismount air filter element. Fig. 1.1.014 Check after Dismantlement ■ Periodically clean or replace the filter element with recommended period. See “Periodical Maintenance”. ■ Blow the filter element from its back side with compressed air, till nothing is blown off.
  • Page 49   Maintenance Manual for J2 Sedan Mechanical Part of Engine   ①   Discharge the engine coolant. See “Engine Coolant”. ②   Dismount the engine trimming cover. ■   Tightening torque: 8-12 N·m ③   Dismount the air filter assembly. See “Air filter Assembly”.
  • Page 50   Maintenance Manual for J2 Sedan Mechanical Part of Engine   ⑧   Dismount the supporting bracket of intake manifold Fig. 1.1.017 and engine cylinder body. ■ Tightening torque: 10-20 N·m ⑨   Dismount the fixing bolt and nut of intake manifold.
  • Page 51   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Caution: ■ Perform this operation after the exhaust system has completely cooled down. ①   Disconnect the wire harness connectors of front Fig. 1.1.019 oxygen sensor. Special tools should be used if necessary.

  • Page 52: Exhaust System

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   Check after Dismantlement Check whether the matching face of exhaust manifold is distorted. 3) Installation Install with steps contrary to the dismantlement. Attention: ■ Do not reuse the non-reusable parts.
  • Page 53   Maintenance Manual for J2 Sedan Mechanical Part of Engine   2) Installation ■   Install with steps contrary to dismantlement. ■   Tightening torque: 38-52 N·m ■   Replace the exhaust pipe gasket when reassembling the exhaust system each time.

  • Page 54: Timing Sprocket Mechanism

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   IX. Timing sprocket mechanism Parts Balance shaft gear    Timing sprocket mechanism diagram 1 – Timing chain 2 – Movable rail bolt subassembly 4. Movable rail subassembly 5 – Automatic tensioner bolt 5 –...
  • Page 55   Maintenance Manual for J2 Sedan Mechanical Part of Engine    Note: permissible perform dismantlement by means of the friction force of drive belt before drive belt is removed.   Dismantle drive belt to check whether the Fig. 1.1.024 drive belt has wearing, aging, cracking, etc.;...
  • Page 56   Maintenance Manual for J2 Sedan Mechanical Part of Engine     Dismantle oil pump assembly Fig. 1.1.028   Check timing Check the timing point shown in the diagram for compliance. Timing mark of primary chain Timing mark for camshaft...
  • Page 57   Maintenance Manual for J2 Sedan Mechanical Part of Engine     Dismantle tensioner and set/dynamic tracks of Fig. 1.1.029 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...
  • Page 58   Maintenance Manual for J2 Sedan Mechanical Part of Engine     Remove bolts secondary chain Fig.1.1.033 tensioner and remove the secondary chain tensioner. ■ Tightening torque: 10±2 N·m   Remove the bolts of balance shaft chain wheel Fig.1.1.034 and remove the balance shaft chain wheel.

  • Page 59: Camshaft And Balance Shaft Assembly

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   X. Camshaft and balance shaft assembly   1. Parts   Breakdown diagram for camshaft and balance shaft 1 – Intake camshaft subassembly 2 – Intake camshaft chain wheel 3 – Chain wheel bolts 4 –...
  • Page 60   Maintenance Manual for J2 Sedan Mechanical Part of Engine    Attention: ■ Handle with care to avoid collision or damage. ⑦   Remove the camshaft from cylinder head. 2 ）   Disassembly of balance shaft Fig.1.1.035 On the basis of above-mentioned disassembly  procedure of camshaft, proceed as below:...
  • Page 61   Maintenance Manual for J2 Sedan Mechanical Part of Engine   3 ）  Inspection after removal Fig.1.1.038 ①   Camshaft ■ Measuring camshaft base circle diameter and the maximum lifting strokes of intake and exhaust. Base circle diameter: 36mm Maximum lifting stroke of intake ： 8.7054mm exhaust  ：...
  • Page 62   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Distance between intake camshaft base circle Top end thickness of Mechanical tappet Valve clearance and valve tappet L1 mechanical tappet label (mm) 3.13 ＜ L1≤3.15 2.92 0.19-0.25 3.15 ＜...
  • Page 63   Maintenance Manual for J2 Sedan 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...
  • Page 64   Maintenance Manual for J2 Sedan 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.

  • Page 65: Cylinder Head

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   XI. Cylinder head On-vehicle Maintenance Inspect the cylinder pressure: ①   Thoroughly warm up the engine and then stop it. ②   Release the fuel pressure. See “Release of Fuel Pressure”.
  • Page 66   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Parts Diagram of Cylinder head 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.
  • Page 67   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Check after Dismantlement ①   Cylinder head Bolt Measure the length of cylinder head bolt. ■ Limit: 143.5±0.7mm. Replace the cylinder head bolt if this Limit is exceeded. ②   Cylinder head ■...
  • Page 68   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Apply a film of engine oil onto washer, which is at the threaded portion of bolt. Tighten cylinder head bolts in sequence, until each bolt torque is 24.5 ± 2 N • m.

  • Page 69: Valves

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   XII. Valves Parts Diagram of Valve parts 1 - cylinder head bolts 2 - cylinder head bolt washer 3 - cylinder head assembly 4 - Cylinder gasket 5 – intake valve cotter...
  • Page 70   Maintenance Manual for J2 Sedan Mechanical Part of Engine   compressor. Attention: ■ Pay attention to the position of upper dead point of piston.   ■ Label the dismounted valve, valve spring Fig.1.1.045 JAC-T1F012 and other parts, and write down their...
  • Page 71   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Note: The parts with paint mark should be installed upwards. ⑥   Install retaining seat for valve spring. ⑦   Install valve cotter. ■ Use the valve spring compressor during the installation.
  • Page 72   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Valve guide Fig.1.1.050 ■ 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...

  • Page 73: Cylinder Body Assembly

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   End Face of Standard values: 图 图 图 图 1.1.052   Valve Stem For intake valve: 53.21mm Valve Protrusion For exhaust valve: 54.10mm   Height Limits: Surface of Valve For intake valve: 53.71mm...
  • Page 74   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Parts Disassembly Diagram of Cylinder Body Assembly Disassembly and Assembly 1) Disassembly ①   Dismount the engine assembly from the vehicle, and then detach the transmission from engine. See “Engine Assembly”...
  • Page 75   Maintenance Manual for J2 Sedan Mechanical Part of Engine   ■ Water pump and its components ■ Ignition coil ■ Cylinder cover, damping wheel, oil pan ■ Engine timing sprocket mechanism ⑥   Dismount the flywheel assembly. Fix the flywheel by the special tool to dismount the fixing bolt.
  • Page 76   Maintenance Manual for J2 Sedan Mechanical Part of Engine   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 77   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Loosen the bolts of crankshaft bearing cap in the Fig.1.1.057 following sequence. Tightening torque: 35±2 N·m ＋ 60° ～ 64° ■ Be aware of the number and forward mark of bearing cap.
  • Page 78   Maintenance Manual for J2 Sedan Mechanical Part of Engine   ③   Side clearance of Piston Ring Fig.1.1.061   Measure the side clearance between piston ring and piston ring groove top land by the feeler gauge. Feeler   Gauge Standard values:  ...
  • Page 79   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Attention: ■ Be careful to prevent gasket materials from falling into the engine oil or coolant.   Measure planeness of cylinder body in different Ruler  Fig.1.1.063 directions at six positions using ruler and feeler gauge.
  • Page 80   Maintenance Manual for J2 Sedan Mechanical Part of Engine    piston diameter should be measured at the position shown in Figure. Calculate the boring size based on the piston diameter. [Boring size] ＝   [outer diameter of piston] ＋   [clearance between piston and cylinder (0.02-0.04mm)] －...
  • Page 81   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Standard value: 0.02 - 0.04mm + (0.01mm) expansion Limit:0.1mm ⑬   Roundness and Cylindricality of Crankshaft Measure sizes of each main crankshaft journal and Fi .1.1.067 main connecting rod journal at four different  positions as shown in the figure.
  • Page 82     Maintenance Manual for J2 Sedan Mechanical Part of Engine   ⑮   Flywheel Check whether the flywheel and the signal disk are distorted or cracked. Attention: ■ Do not disassemble the flywheel. ○   Crankshaft signal wheel Fig.1.1.070 ����...
  • Page 83   Maintenance Manual for J2 Sedan Mechanical Part of Engine   ③   Add oil to bearing surface Install crankshaft on cylinder block. When rotating the crankshaft by hand, check whether the rotation of crankshaft is smooth. ④   Install main bearing cap.
  • Page 84   Maintenance Manual for J2 Sedan Mechanical Part of Engine   mark side. Screw in the guide sleeves, clearance between Fig.1.1.073 the two sleeves should be 3mm plus the calculated L in Step 2. With the front mark facing downwards, install piston and connecting rod on mounting base of piston pin.
  • Page 85   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Install first and second piston rings. Install first and second piston rings with the identification marks facing upwards (on the piston top side) by using expander.  Notes: Piston ring opening direction...
  • Page 86   Maintenance Manual for J2 Sedan Mechanical Part of Engine   ■ Make the piston ring with front mark facing Fig.1.1.075 the front end of engine by the piston ring compressor or other suitable tool, then install  piston ring onto piston head.

  • Page 87: Diagnosis Of Common Troubles

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   XIV. 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.
  • Page 88   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Trouble Possible Cause Resolution The belt skids. Adjust or replace. The water pump is at fault. Replace. The sensor is at fault. Repair or replace. The fan is at fault.

  • Page 89: Parameters For Maintenance

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   XV. 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...
  • Page 90   Maintenance Manual for J2 Sedan 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...
  • Page 91   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Tightening Torques List of fastener tightening torque Tightening Torques  (Nm) Name Specification Qty. High strength bolt Main bearing cap bolt M9×1.25×74.5 35±2Nm +60°-64° (Synchronous fastening machine) 5Nm → 13Nm +90 °...
  • Page 92   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Other bolts Bolts of balance shaft gear M8×15×1.25 23.5±4.5 Bolts of balance shaft chain wheel M8×18×1.25 45±5 Set track bolts M6×1×12 10±2 Dynamic track bolts M8×1.25×15 23.5±4.5 Starter bolt M8×55...

  • Page 93: Section Ii Engine Lubrication System

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   Section II Engine Lubrication System Precautions Application Steps of Sealant:   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 94: Preparation

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   II. Preparation Repair Tools List of repair tools  No. Tool Outline Drawing Explanation Oil pressure gauge Measure oil pressure Connect oil pressure Hose gauge to cylinder body Oil pressure switch...

  • Page 95: Engine Oil

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   III. Engine Oil Check Engine oil level  Note: Before starting the engine, park the vehicle steadily to check oil level. If engine has been started, stop engine and check it after 10min.
  • Page 96   Maintenance Manual for J2 Sedan Mechanical Part of Engine   ①   Check oil level. Please refer to “Engine oil Fig. 1.2.003 level”. ②   Lift the vehicle, disconnect harness connector at oil pressure switch and remove the oil  pressure switch.

  • Page 97: Oil Filter

    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. ■ During dismantlement, prepare a cleaning cloth to absorb leaked or splashed oil.
  • Page 98   Maintenance Manual for J2 Sedan Mechanical Part of Engine   2) Installation ①   Remove any foreign substances attached on Fig. 1.2.006 mounting surface of oil filter. ②   Apply a film of engine oil on oil seal surface of new oil filter.

  • Page 99: Oil Pan And Engine Oil Pump

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   Oil Pan and Engine Oil Pump Parts Breakdown drawing of oil pan and oil pump 1 – Engine oil pump assembly 2 – Automatic tensioner sight hole cover 3 – Front crankshaft oil seal 4 –...
  • Page 100   Maintenance Manual for J2 Sedan 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.
  • Page 101   Maintenance Manual for J2 Sedan Mechanical Part of Engine   assembly. Install oil filter. ■ Clean the oil filter mounting surface on oil pump housing. ■ Apply some oil on O-ring of oil filter. ■ Tighten oil filter until the O-ring seating on the installation surface; re-tighten the oil filter by 0.75 lap or get the tightening torque to 11 ±...
  • Page 102   Maintenance Manual for J2 Sedan 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.

  • Page 103: Section Iii Cooling System Of Engine

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   Section III Cooling System of Engine Cooling Circuit Cooling Circuit Diagram    I    t   s    l   y   o    l   e    l    b   u   e   p    i   p   p Heater water returning pipe bolts II    l   y...

  • Page 104: Engine Coolant

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   II. 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. 1.3.001...
  • Page 105  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 106: Radiator

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   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 107   Maintenance Manual for J2 Sedan Mechanical Part of Engine   ⑤   Dismount the inlet and outlet hoses of radiator and returning hose of coolant reservoir. ⑥   Dismount bracket of radiator and take off the radiator and fan subassembly.

  • Page 108: Radiator Cooling Fan

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   ■ 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 109   Maintenance Manual for J2 Sedan Mechanical Part of Engine   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 110: Thermostat Sub-Assembly

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   a ） . Install belt pulley of water pump. b ） . Install drive belt and adjust it in accordance with specified tension. Please refer to “Drive Belt”. c ） . Fill engine coolant. Please refer to “Refill engine coolant”.
  • Page 111   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Fig. 1.3.010 Check after Dismantlement ①   Thermostat ■ Inspect opening of thermostat valve at normal room temperature. ℃ Temperature of thermostat (ON): 82 (initially open)   ℃ (fully open)  ...

  • Page 112: Water Piping Sub-Assembly

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   ⑤   If the engine coolant temperature sensor Fig. 1.3.013 needs to be reused, apply specified sealant to its thread. ■ Specified sealant: LT648 or equivalent. Check after Installation ■...

  • Page 113: Trouble Analysis

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   VIII. Trouble Analysis Table for Overheating Cause Analysis Symptom Item should be inspected Water pump malfunction Worn or loosening of drive belt Stuck of thermostat at closed position Blockage due to dust or Improper heat radiation  —...

  • Page 114: Parameters For Maintenance

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   Parameters for Maintenance Technical specification for cooling system ℃ ℃ Temperature of thermostat opening (Initiall  y open) 95 (Fully open)   Maximum lift of thermostat valve stem >8mm...

  • Page 115: 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 116: Preparation

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   II. Preparation The special tools are listed in the table below: List of Special Tools S.N. Tool Outline Diagram Explanation Fuel pressure － Measure fuel pressure T1F018 gauge III. Fuel System...

  • Page 117: Fuel Injector And Guide Rail

      Maintenance Manual for J2 Sedan 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: ■...
  • Page 118   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Attention: ■ Please prepare the container and cleaning cloth in advance as fuel leakage may take place. ■ Avoid the naked flame and spark. ■ Please keep any parts away from heat source. Special attention must be paid when welding around them.
  • Page 119   Maintenance Manual for J2 Sedan Mechanical Part of Engine   ■ Check the injection hole of fuel injector for blockage. If any, please wash or replace by using special instrument. Fuel Guide Rail ■ Check the fuel inspection hole for damage and jamming. If any, please replace.

  • Page 120: Fuel Filter

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   ■ Insert the snap slice C into the raised position B of fuel pipe. ■ Make sure the flange A of fuel pipe is properly mounted in the fixing groove on snap flange.
  • Page 121   Maintenance Manual for J2 Sedan 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 122   Maintenance Manual for J2 Sedan 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...

  • Page 123: Fuel Pump Assembly

      Maintenance Manual for J2 Sedan 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 124   Maintenance Manual for J2 Sedan 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: ■...
  • Page 125   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Fig. 1.4.015 Take off the Y-ring. 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...
  • Page 126   Maintenance Manual for J2 Sedan Mechanical Part of Engine   ■ 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 127: Fuel Tank Assembly

      Maintenance Manual for J2 Sedan 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  ...
  • Page 128   Maintenance Manual for J2 Sedan Mechanical Part of Engine   ■ 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 129: Section V Emission Control System Of Engine

      Maintenance Manual for J2 Sedan 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    Air   ...
  • Page 130   Maintenance Manual for J2 Sedan 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  ...
  • Page 131     Maintenance Manual for J2 Sedan 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 左前车架 左前车架 左前车架 Left front frame   bracket on inner lining of left fender.
  • Page 132   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Disconnect the harness connector of EVAP Fig. 1.5.004 carbon canister solenoid valve. Remove EVAP carbon canister Fig. 1.5.005 electromagnetic valve. 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 133: Forced Ventilating System Of Crankcase

      Maintenance Manual for J2 Sedan Mechanical Part of Engine   II. 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 134   Maintenance Manual for J2 Sedan 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...
  • Page 135   Maintenance Manual for J2 Sedan Mechanical Part of Engine   Dismantlement and Installation ①   Dismantlement Disconnect the PCV valve hose from cylinder Fig. 1.5.006 cover. Remove the PCV valve from cylinder Fig. 1.5.007 cover.   Check after Dismantlement ①...

  • Page 136: Chapter Ii Electrical Part Of Engine

      Maintenance Manual for J2 Sedan Electrical Part of Engine   Chapter II Electrical Part of Engine Section I Ignition System Ignition coil Parts Ignition coil Dismantlement & Installation Dismantlement Attention:   Fig. 3.1.001 ■ Be sure that the ignition switch is in the “OFF”...
  • Page 137   Maintenance Manual for J2 Sedan Electrical Part of Engine   ③   Remove high-voltage ignition coil bolt to Fig. 3.1.002 remove coil. ■ Tightening torque: 6-8N·m ④   Dismount the spark plug with special socket. Tightening torque: 25-30N·m Attention: Please do not drop or shake it.

  • Page 138: Diagnosis Of Common Troubles

      Maintenance Manual for J2 Sedan Electrical Part of Engine   Inspect clearance of spark plug by using feeler. Standard value: 0.7-0.8 mm If the clearance is beyond the standard value, replace. ■ Check sparking ability of spark plug. Connect spark plug to high voltage circuit.

  • Page 139: Section Ii Starting And Charging System

        Maintenance Manual for J2 Sedan Electrical Part of Engine   Section II Starting and Charging System Principle Diagram of Starting and Charging System 中央电器盒 Central electric 120 A box   熔断片 熔断片 20 A fuse link   30 A fuse link  ...
  • Page 140   Maintenance Manual for J2 Sedan Electrical Part of Engine   ■ If the vehicle is not used for a long time, the cathode terminal of battery should be disconnected. ■ Check charging condition of battery. Check Visual inspect ■...
  • Page 141   Maintenance Manual for J2 Sedan Electrical Part of Engine   Check after dismantlement ①   Bracket of battery ■ Check for erosion. If there is, clean with warm clean water. ②   Battery harness ■ Check for erosion and damage. Replace if there is any.

  • Page 142: Starting System

      Maintenance Manual for J2 Sedan Electrical Part of Engine   III. Starting System System Description Closed solenoid switch of starter provides a closed circuit between battery and starter. The starter is connected with engine body for grounding. After the power supply and grounding are provided, the starter can turn the crankshaft, and thus engine is started.
  • Page 143   Maintenance Manual for J2 Sedan Electrical Part of Engine   ②   Disconnect the harness connector of starter. Fig. 3.2.005 ③   Dismount the fixing bolts of starter, then take off the starter. 2) Installation Install with steps contrary to dismantlement.
  • Page 144   Maintenance Manual for J2 Sedan Electrical Part of Engine   Disassembly and Assemblage 1) Disassembly Exploded View of Starter 1-Screw 2-Front support 3-Stop ring 4-Snap ring 5-Pinion 6-Gear ring 7-Solenoid switch 8-Plantery gear   9-Planetary gear 10-Ball 11-Gasket 12-Stator 13-Rotor 14-Electric brush retainer 15-Rear support  ...
  • Page 145   Maintenance Manual for J2 Sedan Electrical Part of Engine   2) Check ①   Solenoid switch ■ Before check, disconnect negative terminal of battery. ■ Disconnect the “M” port of starter. Test electrical connectivity between “S” port Connecting from Fig.
  • Page 146   Maintenance Manual for J2 Sedan Electrical Part of Engine   ③   Electric brush Fig. 3.2.008 ■ Check brush wearing with a caliper. if excessive worn, replace. Vernier caliper Electric brush ④   Electric brush spring Fig. 3.2.009 ■...
  • Page 147   Maintenance Manual for J2 Sedan Electrical Part of Engine   ⑦   Inspection of Rotor Fig. 3.2.012 Check connectivity between adjacent fillets with ohmmeter. ■ If open, replace. Check conductivity between each copper  plate shaft commutator with ohmmeter. ■...
  • Page 148   Maintenance Manual for J2 Sedan Electrical Part of Engine   3) Assemblage When assembling the starter, the bearing, the gear and the friction surface should be lubricated by adding high temperature grease. And then conduct the following operations. ①...
  • Page 149   Maintenance Manual for J2 Sedan Electrical Part of Engine   Diagnosis flow chart of Common Troubles (if there is any abnormity found, disconnect negative  pole of battery at once.) Inspection Flow Chart of Common Troubles of Starting System Replace the solenoid switch.  ...

  • Page 150: Charging System

      Maintenance Manual for J2 Sedan Electrical Part of Engine   IV. Charging System System Description The generator is used to provide DC voltage to vehicle electric system and keep charged condition of battery. The voltage output is controlled by IC adjuster.
  • Page 151   Maintenance Manual for J2 Sedan Electrical Part of Engine   Fig. 3.2.019 Fig. 3.2.020 ④   Dismount the belt of generator. Please refer to the “Drive Belt” section. ⑤   Take off the generator from the vehicle. 2) Installation ■...
  • Page 152   Maintenance Manual for J2 Sedan Electrical Part of Engine   Disassembly and Assembly Exploded View of Engine 1-Lock nut 2-Belt pulley 3-Spacer 4-Front end cover 5-Front bearing 6- Bearing cap 7-Bolt 8-rotor  commutator   9-Rear bearing 10-Stator 11- gasket  ...
  • Page 153   Maintenance Manual for J2 Sedan Electrical Part of Engine   1) Disassembly Disassemble in the following order. ①   Belt pulley ②   Rear cover ③   Commutator assembly ④   Separate front and rear cover assembly. Attention: ■...
  • Page 154   Maintenance Manual for J2 Sedan Electrical Part of Engine   ③   Stator a. Inspect continuity between terminals. Lead Fig. 3.2.023 ■ If not, replace. b. Grounding test Lead Fig. 3.2.024 ■ If electrically continued, replace the stator. Stator...
  • Page 155   Maintenance Manual for J2 Sedan Electrical Part of Engine   Trouble Diagnosis for Charging System Be sure that the battery has been sufficiently charged before test of generator. A 30 V volt meter and a  proper test probe should be used in test. Inspection chart is helpful for inspection of generator.

  • Page 156: Chapter Iii Electronic Control System Of Engine

    Caution: ■ All maintenance operation should be carried out by JAC authorized franchised stores in order to avoid increasing risk of personal injury and death due to the SRS system failure. ■ Improper maintenances, including incorrect dismantlement and installation of SRS system, may cause wrong action of the system resulting in personal injury and death.
  • Page 157   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Even with engine stopped, there is high pressure in fuel pipelines. Therefore, the fuel pipe should not be dismantled casually during the course of maintenance. In case that it is necessary to repair fuel system, pressure in fuel system should be released before dismantlement of fuel pipe.

  • Page 158: Common Tools For Diagnose

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine IV. Common tools for diagnose ■ Description of tool: diagnose tool of electronic controlled injection system Function: reading/clearing DTC of electronic injection system, view data flow, test actions of parts, etc..
  • Page 159   Electronic Control System Maintenance Manual for J2 Sedan   of Engine ■ Description of tool: digital universal meter Function: measure characteristic parameters such as voltage, current and resistance of electronic injection system Fig. 4.1.003   ■ Description of tool: vacuum gauge Function: inspect air pressure of intake manifold Fig.
  • Page 160   Electronic Control System Maintenance Manual for J2 Sedan   of Engine ■ Description of tool: cylinder pressure gauge Function: inspect pressure in each cylinder Fig. 4.1.005   ■ Description of tool: fuel pressure gauge Function: inspect pressure of fuel system, determine working states of fuel pump and fuel pressure regulator.

  • Page 161: Precautions For On-Board Diagnose (Obd) System Of Engine

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine Precautions for On-board diagnose (OBD) system of engine The electronic control module (ECM) has an OBD system. The malfunction indicator lamp (MIL) of OBD system will be lit to indicate the driver that there is malfunction caused by aging of the exhaust system.
  • Page 162   Electronic Control System Maintenance Manual for J2 Sedan   of Engine ■ When connecting the ECM harness connectors, push the deflector rod (1) downward mostly to lock securely. ■ When Inserting the contact pin into the ECM Fig 4.1.008 or pulling it out, be aware to avoid damaging Bent  ...
  • Page 163   Electronic Control System Maintenance Manual for J2 Sedan   of Engine ■ Tighten clamp of fuel hose to specified torque. Fig 4.1.009 ■ Don’t step on accelerator pedal when starting the vehicle. ■ Don’t increase speed engine immediately after starting the vehicle.

  • Page 164: Section Ii Structural Principle And Inspection Of Engine Control System

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine Section II Structural Principle and Inspection of Engine Control System System Description Generally, the engine management system is mainly composed of three parts, namely sensors, micro-processor (ECU), and actuators, to control the intake volume, fuel injection amount, and ignition advance angle during the running of the engine.

  • Page 165: Multiple-Point Fuel Injection System

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine Illustration of Engine Control System  Note: This diagram is the control diagram, if the sensor location doesn’t match with  physical parts, actual conditions should prevail.   II. Multiple-point Fuel Injection System  ...
  • Page 166   Electronic Control System Maintenance Manual for J2 Sedan   of Engine cancelled. In starting work conditions, spark advance are also adjusted and vary with the engine temperatures, intake air temperatures and engine speeds. Warming-up and Heating Control of Three-way Catalyst With engine started at low ambient temperature, intake quantity of cylinder, fuel injection and electronic ignition are all adjusted to compensate the higher requirement of the engine torque;...
  • Page 167   Electronic Control System Maintenance Manual for J2 Sedan   of Engine maintain higher idling speed. Sum of all these required output torque is delivered to the torque coordinator to carry out the calculation to get the corresponding intake density, gas mixture composition and ignition timing.

  • Page 168: On-Board Diagnosis System

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine related to the sensor and actuator can be read with the diagnosis apparatus, and the actuator may be driven forcibly in some cases. 12. Other Control Functions Fuel Injection Pump With relay connected, the fuel injection pump will be energized when the crankshaft starts to rotate or with engine running.
  • Page 169   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Function Function diagnosis Electronic diagnosis control unit Data Control command collection Sensors  Actuators Engine Schematic Diagram for Malfunction Diagnosis of Electronic Injection System Control strategy of malfunction indicator lamp When no malfunction is present: ★...
  • Page 170   Electronic Control System Maintenance Manual for J2 Sedan   of Engine   Turn on “ignition switch”.   Read the trouble information (trouble code, freeze frame): inquire in maintenance manual to confirm the trouble component and type: draw up maintenance solution with trouble information and experiences.
  • Page 171   Electronic Control System Maintenance Manual for J2 Sedan   of Engine List of Common Control System Malfunction Codes of ECU 1.0 Table of Common Malfunction Codes for UAES Control System of 3-Cylinder Engine Information Introduction of Malfunction Codes (UAES)
  • Page 172   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Information Introduction of Malfunction Codes (UAES) P0267 Short-circuit of 3# cylinder fuel injector control circuit to ground P0268 Short-circuit of 3# cylinder fuel injector control circuit to power supply...
  • Page 173   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Information Introduction of Malfunction Codes (UAES) P1651 Malfunction of SVS lamp drive circuit P2177 Out-of-upper-limit of air-fuel ratio closed-loop control self-learning (Medium load zone) P2178 Out-of-lower-limit of air-fuel ratio closed-loop control self-learning (Medium load zone)

  • Page 174: Engine Trouble Diagnosis

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine IV. Engine Trouble Diagnosis   Trouble diagnosis general for engine control system In case of failure with Engine Electronic control system components (such as sensor, ECM, injector), fuel may be cut off or insufficient fuel will be supplied resulting in following conditions:  ...
  • Page 175   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Trouble Diagnosis Flow Chart The check starts   1. Acquire the symptom information  Ask the user for more information associated with symptom   2.Check the DTC User described the...
  • Page 176   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Trouble Symptom Check Table List of Trouble Symptom Inspection Symptoms Check Order No. Unable to communicate with Unable to communicate with all the systems diagnosis apparatus Unable to communicate with ECM only...
  • Page 177   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Symptom List Symptom List   Items Symptoms Starter drags the engine, but there is no combustion in cylinder and the engine Failure of starting does not start. Start Extinguishment after There is combustion in cylinder, but the engine extinguishes immediately.
  • Page 178   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Inspection of Idling Speed 1) Conditions  Attention: ■ Check the regular items including spark plug, fuel injector and compression pressure of the cylinder at beginning of inspection. ①   The engine coolant temperature is 80-95 .
  • Page 179   Electronic Control System Maintenance Manual for J2 Sedan   of Engine ■ During inspection of fuel pressure, always to make sure whether there is fuel leakage in fuel  pipeline. If the measured fuel pressure is more than the standard value, analyze the possible reasons referring the following table and repair as required.

  • Page 180: Section Iii Structural Principle And Inspection Of Engine Electronic Components

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine Section III Structural Principle and Inspection of Engine Electronic Components Intake Manifold Absolute Pressure (MAP/MAT) Sensor Description Intake absolute pressure sensor (MAP) is a pressure sensitive variable resistor. Diaphragm inside of sensor is connected with a magnet core placed through the coil.
  • Page 181   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Diagnosis   Sensor short circuit (to ground, to power supply);    Sensor circuit open;     Sensor detects the intake pressure exceeds the upper limit;  ...

  • Page 182: Engine Coolant Temperature (Ect) Sensor

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine ■ Apply a small amount of engine oil on seal ring of sensor in order to facilitate the installation.  tighten the self-tapping screw ■ Make sure that adhesive of sensor and intake manifold is well,  ...
  • Page 183   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Coolant temperature sensor Diagnosis   Water temperature signal higher than the limit;    Water temperature signal lower than the limit;    Water temperature sensor short circuit, open circuit.

  • Page 184: Throttle Position Sensor

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine Dismantlement ①   Discharge coolant from radiator. Please refer to Fig. 4.3.005 "Change Engine Coolant". ②   Disconnect the wire harness connector of the engine coolant temperature sensor.
  • Page 185   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Installation Position Fig. 4.3.006 It’s installed on throttle body. throttle position sensor   Wiring diagram of Pin18: 5V power supply Pin26: Throttle position sensor signal Pin39: 5V grounding Throttle Position Sensor ...

  • Page 186: Crankshaft Position Sensor

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine the throttle. The resistance measurement shall vary linearly following the opening of the throttle. The measurement on 2# and 3# pins shall be on the contrary. Note: While observing the variation of resistance, pay attention to observe for presence of high resistance leap.
  • Page 187   Electronic Control System Maintenance Manual for J2 Sedan   of Engine dead center information in the ignition system. It’s composed of a permanent magnet and a coil enwinding the magnet. The crankshaft signal wheel is one toothed disc, which originally has 60 teeth, but with two missing teeth.
  • Page 188   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Speed sensor    Diagnosis ECU real-time monitoring of the sensor and circuit   Sensor open circuit;    Internal short-circuit of sensor;    Sensor unit short-circuit to ground ...

  • Page 189: Camshaft Phase Sensor

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine Fig. 4.3.010 ②  Unscrew fixing bolts, remove the sensor. Fig. 4.3.011 2 ）  Installation Be aware of following precaution to install with steps contrarily. ■ Be aware of installation gap.
  • Page 190   Electronic Control System Maintenance Manual for J2 Sedan   of Engine �� �� �� �� Theory of Hall sensor: When a current IS flows through a semi-conductor chip, one Hall voltage is generated in the right-hand direction of the...
  • Page 191   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Phase sensor    Diagnosis ECU real-time monitoring of the sensor and circuit   Sensor open circuit;    Internal short-circuit of sensor;    Sensor unit short-circuit to ground ...

  • Page 192: Oxygen Sensor

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine Fig. 4.3.014 2 ）  Installation Be aware of following precaution to install with steps contrarily. ■ Be aware of installation gap. Standard: 0.5 - 1.5mm ■ Tightening torque: 7.8 - 9 N • m...
  • Page 193   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Installation position Fig.4.3.015   Front (upstream) oxygen sensor is installed on the exhaust manifold before three-way catalyst converter and the rear (downstream) oxygen sensor is installed behind the three-way catalytic converter.
  • Page 194   Electronic Control System Maintenance Manual for J2 Sedan   of Engine   Injector drive-level fault  Oxygen sensor fault indication is set, with the fuel cycle quantitative control cut off; use the basic fuel injection time stored in the ECU for the quantitative fuel control.

  • Page 195: Fuel Injector (Inj)

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine Be aware of following items to install with steps contrary to dismantlement. ■ Be aware of routing of oxygen sensor wire harness. ■ Tightening torque: 30-40N·m ■ After replacement of oxygen sensor, oxygen sensor should be coated with a layer of anti-rust oil to  prevent rust which impede removal.

  • Page 196: Knock Sensor

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine To main relay   1# cylinder fuel injector 2# cylinder fuel injector 3# cylinder fuel injector Inspection  Attention: ■ Please clean the fuel injector and analyze with special cleaning and analysis instrument for fuel inject at certain interval..
  • Page 197   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Description Knock sensor is installed in the cylinder block side usually between the 2, 3-cylinder, it is helpful for engine knock balance; the ECU uses the knock sensor output vibration frequency signal to judge whether there is knock with ECU internal filtering.

  • Page 198: Air-Conditioning Switch And Relay

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine   Cylinder judging signal not reliable;    Sensor circuit failure.  After knock sensor fault flagging out the failure position, knock set control loop is Disconnect and the advance angle of ignition stored in the ECU will be fixed to a safe angle by the software program.

  • Page 199: Canister Solenoid Valve

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine With engine idling, use fault diagnostic apparatus to check air-conditioning switch for normal working. Air conditioning switch Checklist Items Air conditioning switch Normal direction Air conditioning switch Off (compressor clutch does not work)

  • Page 200: Ignition Coil

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine   Short circuit of sensor with ground    Short circuit of sensor with power line    Open circuit of sensor  Trouble Solution   Check sensor signal for short circuit, open circuit;...
  • Page 201   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Description Ignition coil converts the low voltage of the primary winding into the high voltage of secondary winding and discharged at spark plug to ignite the fuel air mixture in cylinder.

  • Page 202: Electric Fuel Pump

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine Diagnosis ECU does not function to diagnose ignition coil failures. Therefore, if there is any failure of ignition coil, no DTC is set. Only by checking the ignition coil resistance can the proper working of the ignition coil be determined;...
  • Page 203   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Fuel pump relay   Fuel pump Inspection Check internal resistance of fuel pump. Internal resistance should not be zero or infinity. Check the fuel pressure Refer to “Fuel System”.

  • Page 204: Electronic Control Module (Ecm) Of Engine

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine XIII. Electronic Control Module (ECM) of Engine System description The greatest characteristic in the electronic control system of the M7 engine is the adoption of torque-based control strategy. The torque-based control strategy is mainly intended to link a great amount of different control objectives.
  • Page 205   Electronic Control System Maintenance Manual for J2 Sedan   of Engine 2 ）  ECM pin definitions: ECM pin definition list Function Function Reserved terminal Reserved terminal Heating of upstream oxygen sensor Reserved terminal Ignition coil 1 Phase terminal C of stepping motor...
  • Page 206   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Installation Position Fig. 4.3.026 Installation position is shown in the figure right. Inspection Read the engine trouble record with the data wire K. Check whether the connecting wire of ECM for normal conditions and put the focus on the ECM  power supply and grounding line.

  • Page 207: Section Iv Trouble Diagnosis Procedures For Engine Control System

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine Section IV Trouble Diagnosis Procedures for Engine Control System Diagnosis with DTC Instruction The following Repair can be carried out only after the current stable trouble has been identified, otherwise the diagnosis will be wrong.
  • Page 208   Electronic Control System Maintenance Manual for J2 Sedan   of Engine DTC Diagnosis ■ ECM pins referred to below should be subject to the actual wire harness diagrams. Fault code: P0107 “the intake pressure sensor is short to ground”...
  • Page 209   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Fault code: P0112 “the signal voltage of intake temperature sensor is too low” Step Check result Subsequent step Connect the diagnosis device and adapter, and turn the ignition switch  Next step...
  • Page 210   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Fault code: P0117 “the circuit voltage of engine coolant temperature sensor is too low” Step Check result Subsequent step Connect the diagnosis device and adapter, and turn the ignition switch  Next step...
  • Page 211   Electronic Control System Maintenance Manual for J2 Sedan   of Engine...
  • Page 212   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Fault code: P0122 “the circuit voltage of throttle position sensor is at the extremely low limit” Step Check result Subsequent step Connect the diagnosis device and adapter, and turn the ignition switch  Next step...
  • Page 213   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Fault code: P0130 “the signal of upstream oxygen sensor is unreasonable” Step Check result Subsequent step Connect the diagnosis device and adapter, and turn the ignition switch  Next step to ON position.
  • Page 214   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Fault code: P0134 “the upstream oxygen sensor signal is in trouble” Step Check result Subsequent step Connect the diagnosis device and adapter, and turn the ignition switch  Next step to ON position.
  • Page 215   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Step Check result Subsequent step Connect the diagnosis device and adapter, and turn the ignition switch  Next step to ON position. Start the engine and run the engine idly till the coolant temperature Next step reaches to the normal value.
  • Page 216   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Fault code: P0202 “the control circuit of fuel injector of Cylinder 2# is open” Step Check result Subsequent step Connect the diagnosis device and adapter, and turn the ignition switch  Next step...
  • Page 217   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Fault code: P0327 “the circuit voltage of knocking sensor signal is too low” Step Check result Subsequent step Connect the diagnosis device and adapter, and turn the ignition switch  Next step...
  • Page 218   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Step Check result Subsequent step To Step 6 Check if the voltage between Pin 2# of phase sensor and the negative pole of power source is about 9.9V.
  • Page 219   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Step Check result Subsequent step To Step 6 Check if the voltage between Pin 2# of phase sensor and the negative pole of power source is about 9.9V.
  • Page 220   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Step Check result Subsequent step ℃ valve at 20 is between 22Ω and 30Ω by the multimeter.   Replace the  No control valve Check if the voltage between Pin 1# of the canister control valve Diagnosis help connector and the negative pole of power source is about 3.7V by the...
  • Page 221   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Step Check result Subsequent step Repair or replace Check if the circuit connecting Pin 2# of canister control valve the harness connector to Pin 37# of ECU is short to power source.
  • Page 222   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Fault code: P0501 “the vehicle speed signal is unreasonable” Step Check result Subsequent step Connect the diagnosis device and adapter, and turn the ignition switch  Next step to OFF position.
  • Page 223   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Next step Do the necessary Check if the working condition of idle regulator is good.  No repair and maintenance Do the necessary A. Check if the system leaks air check and repair B.
  • Page 224   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Fault code: P0560 “the voltage signal of system battery is unreasonable” Step Check result Subsequent step Connect the diagnosis device and adapter, and turn the ignition switch  Next step to OFF position.
  • Page 225   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Step Check result Subsequent step always between 9V and 16V within different rotation speed ranges. Replace the  No generator Diagnosis help Check if the grounding point of engine harness is good.
  • Page 226   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Step Check result Subsequent step  No To Step 2 Check if the voltage between the control side of A/C compressor Replace the relay relay (namely Pin 86# of relay) and the negative pole of power source  No...

  • Page 227: Diagnosis By Trouble Phenomena

      Electronic Control System Maintenance Manual for J2 Sedan   of Engine Step Check result Subsequent step Repair or replace Check if the circuit of power supply side of engine malfunction lamp the harness is open or short to ground.
  • Page 228   Electronic Control System Maintenance Manual for J2 Sedan   of Engine  phenomenon still exists at this point, reinstall the original ECM and repeat the procedures again to carry out the Repair. Trouble phenomenon 1: during the start-up, the engine does not run or runs slowly General trouble position: Battery;...
  • Page 229   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Trouble phenomenon 2: Engine start to run but can not be started successfully during the start-up General trouble position: No fuel in the fuel tank; 2. Fuel injection pump; 3.Crankshaft position sensor; 4.Ignition coil;...
  • Page 230   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Trouble phenomenon 3: Difficulty in warm start General trouble position: Poor quality of fuel; 2.Fuel injection pump; 3.Coolant temperature sensor; 4.Ignition coil General diagnosis procedure: Detection  No. Operating Steps...
  • Page 231   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Trouble phenomenon 4: Difficulty in cold start General trouble position: Poor quality of fuel; 2. Fuel injection pump; 3.Coolant temperature sensor; 4.Fuel injector; 5.Ignition coil; 6.Air throttle body and idle bypass air passage; 7.Mechanical part of engine General diagnosis procedure:  No.
  • Page 232   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Trouble phenomenon 5: Engine speed is normal, but it is difficult to start all the time General trouble position: Poor quality of fuel; 2. Fuel injection pump; 3.Coolant temperature sensor; 4.Fuel injector;...
  • Page 233   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Trouble phenomenon 6: Normal start-up but unstable idling at any time General trouble position: Poor quality of fuel; 2.Fuel injector ; 3.Spark plug; 4.Throttle body and idle bypass air passage;...
  • Page 234   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Trouble phenomenon 7: Normal start-up but unstable idling during the warming-up General trouble position: Poor quality of fuel; 2. Coolant temperature sensor; 3.Spark plug; 4.Throttle body and idle bypass air passage;...
  • Page 235   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Trouble phenomenon 8: Normal start-up but unstable idle speed after warmed-up General trouble position: Poor quality of fuel; 2. Coolant temperature sensor; 3.Spark plug; 4.Air throttle body and idle bypass air passage;...
  • Page 236   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Trouble phenomenon 9: Normal start-up but unstable idling speed or flameout with partially load (for example, when the air conditioner is on) General trouble position: Air conditioning system; 2. Idle adjustor; 3.Fuel injector...
  • Page 237   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Trouble phenomenon 10: Normal start-up but too high idling speed General trouble position: Throttle body and idle bypass air passage; 2.Vacuum pipe; 3.Idle adjustor; 4.Coolant temperature sensor; 5.Ignition timing...
  • Page 238   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Trouble phenomenon 11: Engine speed fails to increase or flameout occurs during acceleration General trouble position: Poor quality of fuel; 2. Intake pressure sensor and air throttle position sensor; 3.Spark plug; 4.
  • Page 239   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Trouble phenomenon 12: Slow response of acceleration General trouble position: Poor quality of fuel; 2. Intake pressure sensor and air throttle position sensor; 3.Spark plug; 4 .Throttle body and idle bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Fuel injector;...
  • Page 240   Electronic Control System Maintenance Manual for J2 Sedan   of Engine Trouble phenomenon 13: Powerlessness and poor performance during acceleration General trouble position: Poor quality of fuel; 2.Intake pressure sensor and air throttle position sensor; 3.Spark plug; 4.Ignition coil; 5. Throttle body and idle bypass air passage; 6.Intake passage; 7.Idle adjustor;...
  • Page 241   1.0 Table of Common Malfunction Codes for UAES Control System of 3-Cylinder Engine Information Introduction of Malfunction Codes (UAES) P0030 Open-circuit of upstream oxygen sensor heating control circuit P0031 Short-circuit of upstream oxygen sensor heating control circuit to ground P0032 Short-circuit of upstream oxygen sensor heating control circuit to power supply P0036...
  • Page 242   Information Introduction of Malfunction Codes (UAES) P0300 Detection of misfire in various cylinders P0301 Detection of misfire in 1# cylinder P0302 Detection of misfire in 2# cylinder P0303 Detection of misfire in 3# cylinder P0321 No detection of missing tooth BM signal after certain angle rotation of crankshaft P0322 No pulse signal of speed sensor (open-circuit or short-circuit) P0327...
  • Page 243   Information Introduction of Malfunction Codes (UAES) P2178 Out-of-lower-limit of air-fuel ratio closed-loop control self-learning (Medium load zone) P2195 Aged upstream oxygen sensor P2196 Aged upstream oxygen sensor P2270 Aged downstream oxygen sensor P2271 Aged downstream oxygen sensor...

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