Manual Servicio Jac j2

Maintenance Manual for J2 Sedan Foreword
Maintenance Manual for J2 Sedan

Foreword Master Table of Contents

General Description &
Maintenance
Engine
Chassis
Body Electrical & Structure
Circuit Troubleshooting
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 proper operation from the
professional maintenance technicians of
JAC passenger cars are essential for
ensuring customer satisfaction to JAC
passenger car products. Therefore, the
maintenance technicians must
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 technical bulletins or
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 media, without written
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 of JAC passenger car
products may cause vehicle damage.
Chapter I General Description
Chapter II Maintenance
Chapter I Engine mechanical system
Chapter II Engine electrical system
Chapter III engine electronic control
system
Chapter I Clutch & Manual
Transmission
Chapter II Traveling system
Chapter III Braking system
Chapter I Body Electrical
Chapter II Body Structure

Contents

Contents of Overview and Service
Chapter I Overview..........................................................................................................1
Section I General Instructions ...................................................................................................... 1
I. Summary .............................................................................................................................. 1
II. Operations ............................................................................................................................ 1
Section II Vehicle Information..................................................................................................... 2
I. Identification Information Position ........................................................................................ 2
II. Nameplate ............................................................................................................................ 2
III. Vehicle Identification Number (VIN) ..................................................................................... 3
IV. Engine Number..................................................................................................................... 4
Section III Lifting, Protection and Towing of Vehicle.................................................................. 6
I. Lifting of Vehicle ................................................................................................................... 6
II. Protection of Vehicle............................................................................................................. 6
III. Towing of Vehicle ................................................................................................................. 7

Chapter II Service............................................................................................................8
Section I Service............................................................................................................................... 8
I. Prepara tools ........................................................................................................................ 8
II. General Service.................................................................................................................... 8
III. Regular Service.................................................................................................................... 9
IV. Recommended Oil and Lubricant....................................................................................... 10
V. Service of Engine ............................................................................................................... 11
VI. Service of Chassis and Body ............................................................................................. 19
VII. Maintenance Data .............................................................................................................. 27

Overview

1
Chapter I Overview
Section I General Instructio oo ons
I. Summary
This Manual provides the procedures required by service operations, including:
1. Structure and composition
2. Principles
3. Dismantlement and installation steps
4. Inspection methods
5. Adjustment & commissioning methods
6. Common trouble diagnosis procedures
7. Technical parameters
The simple operations that can be conducted through the observation of vehicle are left out in this
Manual. No description is given for the necessary basic skills of maintenance technicians in this Manual.

II. How to use
This Manual comprises four parts, i.e. engine volume, chassis volume, electrical appliance & structure
volume of vehicle body and electric circuit inspection volume. In front of each part is given a detailed
content index, in which you can find the section you want quickly.
This Manual provides following information:
1. Working principles;
2. Component position
3. Inspection and service specifications
4. Component dismantlement & installation steps
5. Common troubles and repair procedures
Such information are in compliance with current model at time published.

Overview

2
Section II Vehicle Information
I. Identification Information Position

Position of vehicle ID
1- Name plate of vehicle 2- ID number of vehicle
II. Nameplate
1. Position of nameplate: at the firewall of engine compartment.
2. Instructions of nameplate

Example of Nameplate
Made by China Anhui Jianghuai Automobile Co., Ltd.
Ex-factory no.
Ex-factory date Jan. 2010
Max. gross weight
Fixed number 5 persons
Engine Model
Rated power
Engine displacement
Model
Brand: Jianghuai
1
2

Overview

3
III. Vehicle Identification Number (VIN)
1) VIN position: on the nameplate or at the left bottom of windshield.
2) Illustration of VIN

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.
Table Worldwide Manufacturer Identification
ID Manufacturer Applicable Models
LJ1 JAC Co., Ltd, ANHUI
Freight truck, incomplete vehicle, bus, passenger car, tractor,
special vehicle
Part 2: vehicle description Code (VDS), as specified in GB 16737, this part should be made up with 6
digitals to presents basic features of vehicle model.
VDS making-up:

Inspection digit
Code of engine type and rated power
Max. gross weight

Body type

Vehicle type

Truck wheelbase / passenger cars, buses
and chassis length
Geographical region
Country
Manufacturer
Vehicle Description
Code
Check Character
Digitals
Order number
Assembled in
Model year
Representative letter
or number
Representative number
Digitals

Overview

4
Vehicle type2 Means passenger cars
F: 3 chambers & 4 doors
Body type
G: 2 chambers & 5 doors
Max. Gross Weight: K: >1000-2000
Truck wheelbase / passenger cars, buses and chassis length: R> 2390 - 2600
1: gasoline 70Kw
Code of engine type and rated power 2: gasoline >70-90Kw
3: gasoline >90-110Kw
Part 3: indication of vehicle, 8 digitals

4:General Assembling Workshop of Passenger Car Manufacture Company
Factory assembled
7:General Assembling Workshop of Passenger Car Manufacture Company
8: 2008
Year 9: 2009
A: 2010

IV Engine Number
1. Position of engine number
Engine number is stamped on the exhaust side of cylinder block (See figure below).

Production SN
Factory assembled
Year
Digitals
Fig. 2.1.001

Overview

5
2. Meaning of Engine Number

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

Fig. 2.1.002

Overview

6
Section III Lifting, Protection and Towing of Vehicle
I. Lifting of Vehicle
1. Vehicles Supporting Points
The positions of vehicles supporting points are shown in figure below.
Attention:
Dont lift the vehicle by using the point other than those specified; otherwise vehicle body
may be damaged.

Positions of Vehicles Supporting Points
2. Operation of Lifter
The lifter should be operated strictly in accordance with the specifications of manufacturer.
Caution:
The operation against the specifications may cause damage of vehicle or personnel injury or
even death.

II. Protection of Vehicle
1. Appearance Protection
Be sure to use the four protection appliances including seat cover, steering wheel cover, gearshift
lever cover, and foot mat before any operation. A protective pad must be applied on the fenders
when engine hood is opened for inspection.
2. Preventive Measures before Welding
Since electrical components are installed on the vehicle, the following procedures must be carried
out in order to avoid too large current through such components in welding:
1) Turn ignition switch to OFF position;
2) Disconnect negative pole of battery;
3) Ground the welding equipment carefully at a point nearby the welding area;
4) Cover other exposed equipment around the welding area to prevent solders from splashing on.
Supporting point

Overview

7
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.
1. Towing with tractor
Caution:
No passenger allowed in the vehicle being towed;
Dont allow the traction speed over the safety speed or the stated speed limit;
Make sure the vehicle being towed are fixed firmly;
Operation against above-mentioned precautions may cause personnel injury.
2. Towing with wheel lifter
1) Turn ignition switch to ACC (accessory) position;
2) Turn on the hazard warning indicator flashing;
3) Shift to neutral position;
4) Release parking brake;
5) Make sure the front wheels are away from ground.
Attention:
If it is necessary to tow the vehicle from the back, the supporting wheel of traction device
should be set under front wheels. Dont make front wheels in contact with ground in towing;
otherwise the transmission may be seriously damaged.
3. Emergency towing
If no towing vehicle is available under emergency, a rope may be fixed to the emergency towing
hole under the vehicle for temporary traction.
1) Front towing hole: It is under the front bumper. A driver is required in the vehicle for steering and
braking purposes in towing. Such traction method is applicable only on hard pavement with towing
distance and speed limited to certain extent. In addition, such parts as wheels, axles, drive system,
steering system, and brakes must be in good conditions.
Caution:
The vehicle may be damaged when towed by rope.
In order to minimize such damage,
If no other towing equipment is available, the towing hole must be used;
Always tow the vehicle from its forehead;
Keep the towing rope away from the bumper;
Check the towing rope by pulling it to make sure both ends are fixed firmly on the towing hole.
2) Rear towing hook: It can used to tow another vehicle only under emergency (when a vehicle is
trapped in a ditch, heavy snow or mud pit). When using the rear towing hook, always keep the rope
or chain perpendicular to hook. Dont apply force to the towing hook from any ohter directions. Dont
start towing sharply otherwise damage may be caused.

Service

8
Chapter II Service
Section I Service
I. Preparation
1. Maintenance Tools
List of Maintenance Tools
No. Tools Outside View Description
1 Power tool

For dismantlement and
installation of bolts and
nuts
2
Ignition plug
socket

For dismantlement and
installation of ignition
plug
II. General Service
General Service means the inspection and maintenance items which should be performed everyday
during normal use of vehicles. 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:
1. Exterior of Vehicle
The following inspection and maintenance items should be frequently conducted.
List of Items to be Frequently Inspected for the Exterior of Vehicle
Item Inspection
Tyre Use an air gauge to inspect the pressure of tyres (including spare tyre) in the service
station regularly; adjust pressure in accordance with technical data if necessary. Check
whether theres any damage, crack or excessive worn tear carefully.
Windshield Clean the windshield regularly. Check whether theres any crack or other damage of the
windshield every six months or more frequently. Repair as required.
Windshield
wiper blade
If the wiper doesnt work efficiently, check for worn or torn.
Door and
engine hood
Check whether all of the doors, engine hood, boot cover and tail door can be normally
opened and closed normally, whether all the door locks are locked closely. Lubricate as
required. Moreover, If the vehicle often travels on the salt-spread roads or in the areas
with corrosive substances, always inspect lubricating conditions.
Tyre exchange The tyre exchange should be conducted after each 8000 km traveling.

Service

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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.
2. Interior of Vehicle
The following inspection and maintenance items should be performed regularly.
List of Items to be Regularly Inspected for Interior of Vehicle
Item Inspection
Alarm light and
buzzer
Make sure all the alarm lights and buzzers are working normally.
Windshield wiper
and washer
Check whether the wiper and cleaner are working normally; check whether there
is any crack in the wiper.
Windshield defroster
Check whether the air can be correctly bled from the air outlet of defroster,
whether the heater or air conditioner can breathe enough air during operation of
heater or air conditioner.
Steering wheel
Check whether the free travel of steering wheel is in the standard range. Inspect
changes of steering performance, such as the free travel beyond range, hard
steering and abnormal noise etc.
Seat Belt
Check whether all the components of seat belt system are flexible and working
normally and fixed firmly and stably. Check seat belt for cracking, worn out or
other damage.
Throttle pedal
Check whether the pedal can be operated smoothly, make sure that the pedal
would not be seized or loaded unevenly. Keep floor pad away from the pedal.
Brake pedal and
booster
Check if the pedal can be operated smoothly; make sure the pedal still keeps an
appropriate distance from the bottom plate when it is completely pressed down.
Inspect the function of brake vacuum booster. Make sure that the bottom plate
pad is away from the pedal.
Parking brake Check travel of handle.
3. Engine and Vehicle Chassis
The following inspection and maintenance items should be regularly performed.
List of Items to be Regularly Inspected for the Engine and Vehicle Chassis
Item Inspection
Cleaning liquid for windshield Check whether there is adequate cleaning liquid in reservior.
Level of engine coolant Check the coolant level when the engine is cold.
Engine oil level Stop the vehicle on a level ground and turn off engine; check oil
level.
Levels of brake fluid and clutch fluid Make sure that the levels of brake fluid and clutch fluid are
between the MAX line and MIN marks on reservoir.
Battery Inspect conditions of voltage and battery poles.
Liquid leakage After the vehicle has been stopped for a while, check for any
leakage of fuel, engine oil, coolant or other liquid under the
vehicle. Water drop from the air conditioner which has just
been used is normal. In case of obvious leakage or petrol fume,
find out the causes and repair immediately.
III. Regular Service
Each item is expressed in travel distance and time (months), whichever comes first (distance or time)
should be used as the basis for inspection.

Service

10
Service operational code: I-examination; R-replacement; C-washing
Service cycle (odometer readings and the number of months, whichever comes first)
1000km 1 10 20 30 40 50 60 70 80 90 100 Item
Month 6 12 18 24 30 36 42 48 54 60
1 Driving belt
I: every 10,000 km or 6 months
R: every 60,000 km or two years
2
Check oil and gas control systems of
crankcase for normal working
I I
3 Spark plug I I R I I R I I R I
4 Change coolant R R R R R
General conditions of use C: every 5,000km R: 15,000km
5
Air filter
element
Harsh conditions of use C: every 3,000km R: 10,000km
General conditions of use R: every 5,000 km or 6 months
6
Oil and oil
filter
Harsh conditions of use R: every 3,000 km or 3 months
7 Carbon monoxide content with engine idling I I I I I I I I I I
8 Ignition timing I I I I I
9 Hose I I I I I I I I I I
10 Exhaust fittings leakage I I I I I I I I I I
11 Throttle body C C C C C
12 Injector C* C* C* C* C* C* C* C* C* C*
13 Valve clearance I I I I I I
Notes:
C *---For cleaning operation of fuel injector, it is recommended that dedicated fuel injector cleaning
analyzer is used; Check every 3 months or 5000km; if there are nozzle clogging or blockage failures and
they are non-product quality problems, they should be maintained at users expenses.
"Harsh conditions of use" specifications are only used in severe conditions of use of vehicles. Harsh
conditions of use include the following:
Driving in dusty areas or the vehicle is regularly exposed to salty air or sea water.
Driving on rugged road, road with water accumulation or on mountain roads.
Driving in cold areas.
In the cold season, the engine idles a long time or used frequently in short-distance traveling.
Frequent use of brakes, regular emergency braking. .
As tractor
As taxi or leasing
At temperatures above 32 , driving in urban heavy traffic for more than 50% of the total travel
time.

Service

11
At a temperature below 30 , driving at 120km/h or higher speed limits for more than 50% of the
total travel time.
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) Recommended oil / lubricant
Engine oil 3.8
Factory filled oil: SAE10W-30
Ambient temperature for use: -25 - 35
User must select the appropriate oil according to local ambient
temperature
Quality level: SJ or above
Cooling system 5.5 High-quality HF-C anti-freezing solution
Manual transmission gear oil 2.0 API GL-4, SAE 75W/90
Brake fluid and clutch fluid 0.560.05 DOT4 (Great Wall)
AC refrigerant 60025g R134a
Wiper cleaning liquid 3 Water
AC compressor lubricating oil 0.12 PAG56
V. Service of Engine
1. Inspection of Driving Belt
Warnings
Be sure to operate only with engine stopped.
1) Check for belt aging, crack, wear and oil stain. Replace as required.
2) Check the belt tension at the mid-point between both pulleys.
Inspection should be conducted in the engine cold state or when it has been stopped after 30min.
Range of tension force Alternator belt: 50050N Please be noted that the experience equation for
tensioning force of reused belt is as below: Tensioning force for new belt * 1.2/1.5
If the belt tension is out of range, adjust.
Attention
For checking belt tension installation, firstly adjust to the specified value, then turn the crank
for more than two laps to re-adjust to the specified value in order to avoid tension between
pulleys changing.
2. Adjustment of Tension

Service

12
Tension Adjustment Table
Part Adjusting Method
Generator belt Turn adjusting bolt of generator belt
Attention:
After replaced with new belt, adjust the belt tension so as to meet requirements.
During installation of belt, make sure that the belt is in correct engagement with the pulley
groove.
Dont spill any engine oil or engine coolant on the belt.
Do not over wind or bend belt; for used belt, be aware of mounting direction.
3. Change Coolant of Engine
Caution:
In order to avoid scald, never change coolant with engine hot.
Wrap the radiator cap with thick cloth and unscrew it carefully. Release the pressure inside
the radiator at first, and then completely unscrew it to open the radiator.
Be aware not to spill the engine coolant on the driving belt.
1) Drain engine coolant
Dismount the right deflector of engine. See Engine Deflector.
Open the water drain plug at the bottom of radiator, and then open the cap of radiator.
If necessary, please dismount coolant reservoir, drain the engine coolant, and reinstall it after
cleaned.
Check if theres any foreign matter such as rust or any color change in the discharged engine
coolant.
In case it is polluted, please wash the engine cooling system. See Washing the Cooling System
please.
2) Refill engine coolant
Reinstall dismantled coolant reservoir and the drain plug of radiator.
Attention:
The drain screw plug must be cleaned, a new O-ring must be installed.
Make sure that all the hose clamps have been stably tightened.
Dismount the upper cover of air filter and the intake hose. Please refer to Air Filter Assembly.
Disconnect outlet tube of heater pipe. Please lift the hose as high as possible.
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.

Service

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If coolant overflows from the heater outlet pipe, disconnect pipe and reconnect and then
continue the filling of coolant.
Install air filter upper cover and intake hose. Please refer to Air Filter Assembly.
Install radiator cap.
Warm up the engine until the thermostat is switched on.
Examine if theres warm water flowing out by touching the lower hose of radiator, such as to check
whether the thermostat has been switched on.
Attention:
Watch on engine temperature meter, such as to avoid overheating of engine.
Stop the engine, allow engine temperature drops.
The cooling time can be reduced by using fan.
Fill engine coolant in coolant until the MAX level reached.
Install radiator cap, and repeat steps - for more than two times until the level of engine coolant
doesnt go down any more.
Start engine, check for any leakage in the cooling system.
3) Wash cooling system
Install water drain plug of radiator and coolant reservoir removed above.
Attention:
The drain screw plug must be cleaned, a new O-ring must be installed.
Dismount air filter upper cover and the intake hose. Refer to Air Filter Assembly.
Disconnect outlet tube of heater pipe. Please lift the hose as high as possible.
Fill engine coolant into the radiator and coolant reservoir, install cap of radiator.
If coolant overflows from the heater outlet pipe, disconnect pipe and reconnect and then continue
filling of coolant.
Install air filter upper cover and intake hose. Refer to Air Filter Assembly.
Start the engine, warm up it to normal working temperature.
Speed up the engine for several times without load.
Stop engine, and wait till engine cooled down.
Discharge coolant inside system. Refer to Draining Engine Coolant.
Repeat steps - until the radiator starts to discharge clear water.
4. Inspection of Cooling System
Caution:
Never open the radiator cap with engine hot. The high temperature and high pressure liquid
overflowing from the radiator may cause severe scald.
Wrap the radiator cap with thick cloth and unscrew it for 1/4 circle to release the pressure
inside radiator at first, and then completely unscrew it to open radiator.

Service

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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
Check valve seat of radiator cap
Check whether the valve seat expands outward, i.e. when the plunger is vertically lifted from the top,
end of plunger is out of view.
Check valve seat for any dust or damage.
Pull out negative pressure valve to open it,
and upon the pressure is released, check
whether it can be completely closed.
Make sure there isnt any smudge or damage
on the valve seat.
Make sure that the valve seat can be normally
opened and closed.
Check the pressure released by radiator cap.
Standard: 78-98 KPa
Limit: 59 KPa
Connect the radiator cap to radiator leak
detector, paste engine coolant onto the
sealing face of cap.
If any failure is found in above-mentioned
three inspection items, replace radiator cap.

Attention:
For installation of radiator cap, please wipe the radiator filler carefully to clear away any
paraffin residue or foreign substance.
3) Inspection of radiator
Check for any mud or clogging situation in radiator. If any, clean with following method.
Be aware not to twist or damage the radiation fins.
In case of cleaning without dismounting the radiator, all accessories such as cooling fan, wind
collection hood and horn should be dismounted. Wrap connectors of wire harness with adhesive
tape for water proofing.
Wash back of radiator fins from the top to the bottom with water spraying normal to radiator.
Wash each surface of the radiator every other minute.
In case no dirt is washed away from the radiator, the washing work should be stopped.
Fig. 2.2.001
Fig. 2.2.002

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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.
Blow radiator core surface with compressed air every other minute until no water can be blown
away.
4) Check for leakage of cooling system
Check for leakage through applying pressure to the cooling system with a leakage detector of
radiator cap.
Test pressure: 157 KPa
Caution:
Never remove the radiator cap with engine hot;
otherwise the high temperature and high
pressure liquid overflowing from the radiator
may cause severe scald.
Attention:
A pressure exceeds the specified test
pressure may cause damage to the radiator.

In case the engine coolant is found decreased, please refill engine coolant into the radiator.
If any component is found damaged, repair or replace.
5. Inspection of Fuel Pipeline
Check the fuel pipeline, fuel filler cap and fuel tank for
incorrect installation, leakage, crack, damage, loose
connection, worn or aged.
Repair or replace damaged component as
required.

6. Replacement of Air Filter
1) Dismantlement
Unscrew lock bolt of air filter upper cover lift up the
cover.

Fig. 2.2.005
Fig. 2.2.004
Fig. 2.2.003
Engine
Fuel pipeline

Fuel tank

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16
Take off air filter element.
2) Inspection After Dismantlement
The air filter must be regularly cleaned or replaced
according to recommended schedule. Please
refer to Regular Service.

Blow back of air filter element with compressed air until nothing can be blown away.
3) Installation
Install with steps contrary to dismantlement.
7. Replacement of Engine Oil
Attention:
Be careful not to be scalded since oil temperature is high.
Long-time direct contact between skin and the used oil should be avoided. In case contacted,
wash with soap or detergent thoroughly as soon as possible.
1) Warm up the engine, and check for any oil leakage in the engine compartment. Refer to Leakage of
engine oil.
2) Stop engine and wait for ten minutes.
3) Loosen engine oil filler cap, and then remove the oil drain screw plug.
4) Discharge engine oil.
5) Install the oil drain screw plug with new gasket.
Attention:
Any dirt such as iron debris on oil drain screw plug must be cleaned, and new gaskets
should be installed.
Tightening torque of oil drain bolt: 34-44 Nm.
6) Refill new oil.
For specification and viscosity of engine oil, please refer to Recommended Oil and Lubricant.
Engine oil quantity: 3.8L
Attention:
During the filling of engine oil, please do not remove oil gage.
The filling amount of engine oil may vary according to oil temperature and oil drain time.
Quantity above is for reference only.
Fig. 2.2.006

Service

17
Oil rule should be used all the way to check whether the filling amount of engine oil is
proper.
7) Warm up the engine, check areas around the oil drain screw plug and oil filter for leakage.
8) Stop engine and wait for ten minutes.
9) Inspect oil level. See also Engine oil level.
8. Change Oil Filter
1) Dismantlement
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.
Please keep the driving belt free from engine oil.
Clean any oil splashed on engine and vehicle.
2) Installation
Clear any foreign substance on mounting
surface of oil filter.
Paste a film of engine oil onto the oil seal
surface of new filter.
Tighten.
Tightening torque: 10-12Nm

Attention:
The engine oil filter must be tightened with a filter wrench.
Manual tightening may cause oil leakage due to the inadequate tightening torque.
3) Post-installation inspection
Inspect oil level, and fill engine oil when it is inadequate. See also Engine Oil.
Start engine, check for any oil leakage.
Stop engine and wait for ten minutes.
Inspect oil level, and fill engine oil. See also Engine Oil.
9. Replacement of Ignition Plug
Fig. 2.2.007

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1) Dismantlement
Dismount the engine hood. See also Intake manifold.
Disassemble the ignition coil. Please refer to Ignition Coil.
Dismount the ignition plug with plug socket.
Attention:
Be aware not to drop or shock the ignition plug.
2) Inspection after the dismantlement
Generally, the standard ignition plug should be used.
In the following conditions, if carbon deposition frequently occurs with standard ignition plug, the hot
ignition plug should be used:
Engine is frequently started.
Ambient temperature is low.
In the following conditions, in case ignition knock frequently occurs with standard ignition plug, the cold
ignition plug should be used:
Long-time traveling on the expressway;
Engine is frequently running with high speed.
Attention:
Be sure not to drop or shock the ignition plug.
Steel brush should not be used for cleaning.
If theres carbon deposition on ignition plug end, remove with ignition plug cleaner.
During the replacement interval, the ignition plug gap should be checked when it is
necessary.
Ignition plug gap: 0.7-0.8 mm
3) Installation
Install with steps contrary to dismantlement. Tightening torque of ignition plug: 25-30 Nm.
10. Replacement of Fuel Filter
1) Dismantlement
Caution:
Be sure to read the General Precautions before any handling of fuel system. See General
Precautions.
Open the fuel filler cap.

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Release pressure inside fuel tank.
Remove the rear seat cushion. See Rear Seat.
Dismount the fuel tank service cap.
Dismount the fuel filter and fuel pipe.
For detailed information, please refer to Fuel Filter.
2) Installation
Be aware of following precautions to install with steps contrary to dismantlement.
Installation direction of fuel filter
Be aware of installation direction of fuel filter.
Towards inlet tube.
Installation of pipe fitting.
3) Post-installation inspection

Check for any fuel leakage with following steps.
Turn ignition switch to ON (with engine stopped), and then check for leakage at the joints of fuel
pipeline.
Start engine and run with increased speed, check again for fuel leakage at the joints of fuel pipeline.
11. Inspect the Evaporator passage of Fuel Evaporative Emission System (EVAP)
1) Visually check whether the installation position of EVAP evaporator pipeline is correct, and if it is
free from leakage, crack, damage, loose connection, scratching or ageing etc.
2) Check vacuum release valve of fuel tank cap for blockage or sticking etc. See Fuel Evaporative
Emission System.
VI. Service of Chassis and Body
1. Inspection of Exhaust System
Check for proper positions of exhaust pipe, muffler and fixed support, and anyleakage, crack, damage,
loose connection, worn or ageing.
Fig. 2.2.008

Service

20
In case any component is found damaged,
repair or replace.

2. Inspection of Clutch Fluid Level and Leakage
If the fluid level is low, check clutch system for any leakage.
3. Inspection of Clutch System
Check for correct installation positions of liquid pipelines and operation cylinders, and any crack,
damage, loose connection, worn or ageing.
4. Inspection of Manual Transmission Gear Oil
Inspect oil level and whether there is any leakage. For detailed information, refer to Inspection of
Manual Transmission Oil.
5. Change Manual Transmission Gear Oil
1) Thoroughly drain oil from drain plug, and then refill with new gear oil. For detailed information, refer
to Change Manual Transmission Oil.
2) Inspect oil level. For detailed information, refer to Inspection of Manual Transmission Oil Level.
6. Wheel Balance
1) Dismantlement
Dismount the wheel(s) need to be adjusted.
Dismount the old balance blocks from both sides of the wheel, clear any foreign matters from treads
of tyre.
Note: for new tyre(s), the tape on the tyre should be removed.
Attention:
During dismantlement, be careful not to scratch the tyre.
2) Adjusting wheel balance
Take the center hole as guide to install the wheel on balancer. Start the balancer.
When unbalance values of both inner side and outer side of tyre have been indicated on the display
of wheel balancer, multiply the unbalance value of outer side with 5/3, so as to define the weight of
balance blocks which will be actually applied. Then, select the outer side balance block of which
Fig. 2.2.009

Service

21
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.
Prior to the installation of balance block, fitting surface on wheel must be thoroughly
cleaned.
a. Install the balance block to the position indicated in figure below.
b. As shown in the figure, during installation of
balance block on the wheel, the balance block
should be placed in the groove area on the
wheel inner wall, and fix with its center
towards the position (or angle) indicated by
the wheel balancer.

Attention:
The balance block should not be reused; it should be replaced every time.
At most three balance blocks are allowed to be installed.
The original balance blocks should be used any time.
c. In case the calculated weight of balance block
is more than 50 g, the two balance blocks
should be installed in a line.
Attention:
Never install a balance block on another
one.
Restart the wheel balancer.
At position (or angle) indicated by the wheel
balancer, knock in the balance block at the
inner side of wheel.

Attention:
At most two balance blocks are allowed to be installed.
Start the balancer. Make sure the residual unbalance value of both inner side and outer side is only
5 g or less.
In case the residual unbalance value of either side is more than 5 g, please repeat the installation
steps for balance block.
Fig. 2.2.010
Fig. 2.2.011
Stuck weight
Towards the
groove
Position (or angle) indicated
by the wheel balancer
Center of gravity

Position (or angle) indicated
by the wheel balancer

Service

22
Allowable maximum unbalance:
7. Tyre Exchange
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.

8. Inspection for Brake Fluid Level and Leakage
If fluid level is low, please check brake system for
leakage.

9. Inspection of Brake System Pipeline and
Cable
Check for correct positions of brake pipeline and
parking brake cable, and any leakage, worn,
scratching or ageing etc.

10. Change Brake Fluid
Attention:
Refill brake fluid.
Discharged brake fluid must not be reused.
In order to keep the paintwork free from damage, be sure not to splash brake fluid onto the
paintwork. If the fluid is splashed onto the paintwork, please clean with water immediately.
Fig. 2.2.012
Fig. 2.2.014
Fig. 2.2.013
Highest line
Lowest line
N
o
r
m
a
l

Service

23
1) Insert the ethylene tube onto release valve.
2) Press on the brake pedal to loosen the
release valve, and then discharge brake fluid
slowly.

3) Wash the inner side of fluid reservoir and refill with new brake fluid.
4) Loosen the release valve, press down the
brake pedal slowly, and then release. Repeat this
operation every other 2 or 3 s until theres outflow
of new brake fluid, and then step on the brake
pedal to close the release valve. Repeat there
procedures for all wheels.

5) Bleed air. See also Air Bleeding of Brake Pipeline.
11. Inspection of Brake
1) Brake disc
Check for worn or damage.
List of Standard Specification of Brake Disc
Type Floating caliper type / ventilated disc
Brake disc diameter 241 mm
Brake disc thickness 19 mm
Friction block thickness 9 mm
Brake disc
Cylinder bore 51 mm
2) Brake drum
Check whether the inner diameter and circular runout of brake drum are in the scope of standard values.
If not, corresponding processing or replacement should be performed.
Fig. 2.2.015
Fig. 2.2.016

Service

24
Standard Specification Table of Brake Drum
Type Leading trailing shoe brake
Brake drum diameter 204 mm
Cylinder bore of brake slave cylinder 17.46 mm
Clearance adjustment Automatically
Brake drum
Circular runout < 0.05 mm

3) Brake caliper
Check for any oil leakage.

4) Rear brake slave cylinder
Check for any leakage.

5) Front brake shoe
Check for worn or damaged conditions.
Standard thickness: 9 mm
Limit thickness: 2 mm

Fig. 2.2.017
Fig. 2.2.018
Fig. 2.1.019

Service

25
6) 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
Allowable limiting thickness (A): 1 mm

12. Inspection of Steering Gear and Pull-rod
1) Steering gear
Check whether the steering gear housing and
dust boot are free from looseness, damage
and grease leakage.
Check whether its connection with the
steering column is loose.

2) Steering pull-rod
Check ball joint, dust boot and other components for loosening, worn, damage and grease leakage.
13. Check the pipeline.
Stop engine, check fluid level in reservior.
Attention:
Be sure not to fill steering fluid excessively.
Check for proper installation position of pipeline, and
any leakage, crack, damage, loose connection, worn
or ageing.

14. Axle and Suspension Components
Check for proper clearance between front/rear axles and suspension components and any crack,
damage, worn or other damages.
Fig. 2.2.020
Fig. 2.2.021
Fig. 2.2.022
Check the leakage of
lubricating grease
Check the tightening torque

Service

26
Rock each wheel to check for proper clearance.
Inspect operation conditions of wheel bearings.
Check axle, suspension nut and bolt for loosening.
Check shock absorber for oil leak or other damages.
Check the suspension ball joint for grease leakage;
check ball joint dust boot for crack or other damages.

15. Inspection of Drive Shaft
Check dust boot and drive shaft for any crack, worn,
damage or grease leakage.

16. Lubricating Door Lock, Hinge and Engine Hood Lock Pin

Lubricating Points of Door Lock, Hinge and Engine Hood Lock Pin
Fig. 2.2.023
Fig. 2.2.024
Fig. 2.2.025

Service

27
17. Inspection of Seat belt, Tuckle and Pre-tensioner
Attention:
The seat belt assembly including retractor and other accessories (such as fixing bolt, guide
rail device) should be inspected every time after collision.
We suggest that you should replace seat belt assembly after collision, unless it is free of any damage
after slight impact.
And the seat belt assembly which is not used during the accident should also be checked, please
replace any damaged seat belt assembly.
In case a front collision which activates both driver and passengers airbags happens, the seat belt
pre-tensioner should be replaced, even though the seat belt is not used at all.
If any component of seat belt assembly has problems, please do not repair it, but replace the seat
belt assembly.
In case the seat belt is broken, worn or damaged, dont 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.
Check whether the seat belt is damaged.
Check whether the motion of retractor is flexible.
While the snap ring open, check whether the snap ring and lock tongue function normally.
VII. Maintenance Data
1. Tightening Torque of Standard Parts
Tightening Torque List of Standard Parts
Torque (Nm) Nominal Diameter of
Thread
Pitch
Head mark 4 Head mark 7
M5 0.8 3-4 5-6
M6 1.0 5-6 9-11
M8 1.25 12-15 20-25
M10 1.25 25-30 30-50
M12 1.25 35-45 60-80
M14 1.5 75-85 120-140
M16 1.5 110-130 180-210
M18 1.5 160-180 260-300
M20 1.5 220-250 360-420
M22 1.5 290-330 480-550
M24 1.5 370-420 610-700

Service

28
Attention:
Tightening torques listed above are the standard values which are applicable for following
conditions:
a. Steel, plating nuts and bolts.
b. Plated steel plain washers.
c. All the dry nuts, bolts and gaskets.
The torques listed above are not applicable for following conditions:
a. When the component is to be tightened with spring or tooth washer;
b. Tightening of the plastic parts.
c. Self-tapping screw or self-locking nut.
d. Oiled thread and surface.
In following conditions, the torques listed above should be correspondingly reduced:
a. if a spring washer is used, the torque should be reduced to 85%.
b. If bolt surface is coated with oil, the torque should be reduced to 85%.

Maintenance Manual for J2 Sedan Contents

Engine Volume
Chapter I Mechanical Part of Engine........................................................ 33
Section I Engine Body...............................................................................................33
I. General Precautions ................................................................................................. 33
II. Precautions on Sealant ............................................................................................ 34
III. Preparation ................................................................................................................ 36
IV. Engine Assembly ...................................................................................................... 39
V. Drive Belt.................................................................................................................... 43
VI. Air Filter and Air Duct ............................................................................................... 45
VII. Intake Manifold and Exhaust Manifold ................................................................... 47
VIII. Exhaust System......................................................................................................... 51
IX. Timing sprocket mechanism................................................................................... 53
X. Camshaft and balance shaft assembly................................................................... 58
XI. Cylinder head............................................................................................................. 64
XII. Valves......................................................................................................................... 68
XIII. Cylinder Body Assembly.......................................................................................... 72
XIV. Diagnosis of Common Troubles.............................................................................. 86
XV. Parameters for Maintenance.................................................................................... 88
Section II Engine Lubrication System .....................................................................92
I. Precautions................................................................................................................ 92
II. Preparation ................................................................................................................ 93
III. Engine Oil................................................................................................................... 94
IV. Oil Filter...................................................................................................................... 96
V. Oil Pan and Engine Oil Pump .................................................................................. 98
Section III Cooling System of Engine..................................................................102
I. Cooling Circuit......................................................................................................... 102
II. Engine Coolant ........................................................................................................ 103
III. Radiator.................................................................................................................... 105
IV. Radiator Cooling Fan.............................................................................................. 107
V. Water Pump ............................................................................................................. 107
VI. Thermostat Sub-assembly ..................................................................................... 109
VII. Water Piping Sub-assembly................................................................................... 111
VIII. Trouble Analysis ..................................................................................................... 112
IX. Parameters for Maintenance.................................................................................. 113


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
V. Fuel Filter ................................................................................................................. 119
VI. Fuel Pump Assembly.............................................................................................. 122
VII. Fuel Tank Assembly ............................................................................................... 126
Section V Emission Control System of Engine ..................................................128
I. Fuel Evaporation Control System......................................................................... 128
II. Forced Ventilating System of Crankcase............................................................. 132
Chapter II Electrical Part of Engine...................................................... 135
Section I Ignition System......................................................................................135
I. Ignition coil .............................................................................................................. 135
II. Diagnosis of Common Troubles............................................................................ 137
III. Parameters for Maintenance.................................................................................. 137
Section II Starting and Charging System............................................................138
I. Principle Diagram of Starting and Charging System.......................................... 138
II. Battery ...................................................................................................................... 138
III. Starting System....................................................................................................... 141
IV. Charging System..................................................................................................... 149
Chapter III Electronic Control System of Engine ................................ 155
Section I Precautions............................................................................................155
I. Precautions of Supplemental Restraint System (SRS)....................................... 155
II. General Precautions ............................................................................................... 155
III. Precautions in Maintenance .................................................................................. 155
IV. Common tools for diagnose .................................................................................. 157
V Precautions for On-board diagnose (OBD) system of engine........................... 160
Section II Structural Principle and Inspection of Engine Control System.......163
I. System Description................................................................................................. 163
II. Multiple-point Fuel Injection System.................................................................... 164
III. On-board Diagnosis System.................................................................................. 167
IV. Engine Trouble Diagnosis...................................................................................... 173


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
III. Throttle Position Sensor ........................................................................................ 183
IV. Crankshaft Position Sensor................................................................................... 185
V. Camshaft phase sensor.......................................................................................... 188
VI. Oxygen sensor ........................................................................................................ 191
VII. Fuel Injector (INJ).................................................................................................... 194
VIII. Knock sensor........................................................................................................... 195
IX. Air-conditioning switch and relay ......................................................................... 197
X. Canister solenoid valve.......................................................................................... 198
XI. Ignition coil .............................................................................................................. 199
XII. Electric Fuel Pump.................................................................................................. 201
XIII. Electronic Control Module (ECM) of Engine........................................................ 203
Section IV Trouble Diagnosis Procedures for Engine Control System............206
I. Diagnosis with DTC ................................................................................................ 206
II. Diagnosis by Trouble Phenomena........................................................................ 226

Maintenance Manual for J2 Sedan Mechanical Part of Engine

33
Chapter I Mechanical Part of Engine
Section I Engine Body
I. General Precautions
1. Precautions on Discharging Engine Coolant
Discharge coolant after engine has cooled down.
2. Precautions on Disconnecting Fuel Pipeline
1) Before the operation, ensure that the operating area is free of objects which may cause combustion
or sparks.
2) Disconnect the piping, plug openings to prevent leakage of fuel.
3. Precautions on Dismantlement and Disassembly
1) Use special tools as required in Instruction. Always operate safely; any forcible operations and
operations other than that specified in Instructions are forbidden.
2) Take particular care not to damage the matching face or the sliding face.
3) Use the adhesive tape or equivalent to cover the opening of engine system so as to prevent the entry
of foreign bodies, if necessary.
4) For the purpose of troubleshooting and reassembly, methodically mark and neaten the disassembled
parts.
5) When loosening the bolts and nuts, follow this basic principle: outmost ones first, diagonal ones
second, and so on. Conduct the operation in compliance with the loosening sequence, if specified.
4. Precautions on Check, Repair and Replacement
Thoroughly check the parts before repair or replacement. Check the substitutive parts by the same
means, and then replace as required.
5. Precautions on Assembly and Installation
1) Use the torque spanner to tighten the nuts and bolts.
2) When tightening the nuts and bolts, follow this basic principle: screw up the central nuts and bolts
with the same torque in steps, and then carry out the same operation with the internal and external
diagonal ones. Perform the operation in accordance with the tightening sequence, if it is specified.
3) Replace gaskets, oil seal or O-ring with new ones.
4) Thoroughly rinse, clean and dry every part. Carefully check the engine oil pipeline or engine
coolant pipeline for obstruction.
5) Never damage the sliding face and the matching face. Completely eliminate the foreign bodies such
as cloth scraps or the dust. Before assembly, paste the sliding face with engine oil.
6) When refilling engine coolant after draining completely, release air from the pipes at first.
7) After repair, start the engine and run with high speed to check for any leakage of the engine coolant,
fuel, engine oil and exhaust gas.


34
6. Parts Needed to Be Tightened with Specified Angle
1) Use the angle spanner to finally screw up following engine parts:
- Cylinder head bolt
- Bolt of main bearing cap
- Connecting rod bolt
2) Please follow the specified tightening methods.
3) Make sure that the surfaces of threads and pedestal are clean and coated with engine oil.
II. Precautions on Sealant
1. Removal of Sealant
After dismounting fixing nuts and bolts, use the
scraper to detach the matching faces and remove
old sealant.
Attention:
Do not damage the matching faces.
Insert the scraper, and then knock its side
to slide it as shown in the figure.
For the positions where it is difficult to use
scraper, lightly knock the parts to dismount
them with a plastic hammer.
If you have no choice but to use the tools
such as a screwdriver, be careful not to
damage the matching faces.
2. Application Steps of Sealant
1) Remove the attached old sealant from the
application and matching faces of liner with
scraper.
Attention:
Thoroughly remove the old sealant from
the groove on surfaces, fixing bolts and bolt
holes where the sealant was applied.

2) Wipe sealant surface and matching surface clean with a special cleaner, remove water drops, grease
and foreign substances.
JAC-T1F017
Fig.1.1.001
Fig.1.1.002
Slide
Knock
Scraper


35
3) Position sealant with the specified size.

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.
Install the matching part in a certain period of time after applying sealant.
Eliminate any dirt from the sealant.
Do not re-tighten the bolts or nuts after installation in order to avoid failures of bolts or nuts.
Add engine oil and coolant 30min after the installation has been finished.
Attention:
Conduct the operation in accordance with the instructions specified in this manual.

Fig.1.1.003


36
III. Preparation
1. Tools for Maintenance
List of Special Tools
No. Tool Appearance Code Description
1 End forked clamp

Fix camshaft
timing
sprocket
2 Pin

JAC-T1D001
Used together
with the end
forked clamp
3
Locating tool for
piston pin

Used to
install and
dismantle the
piston pin
4 Guide sleeve

JAC-T1F005
Used together
with the
locating tool
for piston pin
5 Flywheel chock

JAC-T1F011
Used to fix
the flywheel
6
Valve spring
compressor

JAC-T1F012
Used to
compress the
valve spring
Install valve
cotter


37

7
Oxygen sensor
socket

JAC-T1F015
Used to install
and dismantle
the oxygen
sensor
8
Dismantlement
tool for oil pan

JAC-T1F017
Used to
dismantle the
oil pan
9
Installer for
valve oil seal

JAC-T3F001
Used to install
the valve oil
seal
11
Guide for front
oil seal of
crankshaft

JAC-T3F003
Functioning as
a guide during
the installation
of front oil seal
of crankshaft
12
Installer for front
oil seal of
crankshaft

JAC-T3F004
Used to install
the front oil
seal of engine
crankshaft
13
Installer for rear
oil seal of
crankshaft

JAC-T3F005
Used to install
the rear oil seal
of crankshaft


38
2. List of Auxiliary Materials for Assembling Engine
List of Auxiliary Materials for Assembling Engine
No. Name Application Specification and Grade
1
Engine
oil
Used during filling and assembly
Factory filled oil: SAE10W-30
Ambient temperature: -25-35
User must select the appropriate oil
according to the local temperature
Quality level: SJ or above
2
Silica
gel
Engine oil pump, water pump, oil pan
and rear oil seal housing of crankshaft
LT5699 or equivalent
3 Sealant
Oil pressure switch, draining screw plug
and flywheel bolt
LT243 or equivalent
4 Sealant
Coolant temperature sensor and water
temperature alarm switch
LT648 or equivalent
5 Petrol 93# unleaded petrol or above
6 Sealant Stud bolt LT271 or equivalent
3. List of Auxiliary Materials for Assembling Cylinder head
List of Auxiliary Materials for Assembling Cylinder head
No. Name Present Material and Model Assembly Position
1 Engine oil
5W-30 (winter) 15W-40
(summer),with SJ-class quality
level and above
Valve head, camshaft and camshaft oil seal
2 Sealant LT271 or equivalent Stud bolt
3 Sealant LT962T or equivalent
Guide sleeve of spark plug, bowl patch of
cylinder body/cover, connecting pipe nozzle


39
IV. Engine Assembly
1. 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.
Do not start before the exhaust system and engine coolant have completely cooled down.
If the necessary items or operations are not mentioned in the sections of Engine, see relevant
chapters.
Use the specified lifting points all the time and select appropriate lifters according conditions.
2. Preparation for Dismounting Engine and Transmission Assembly
1) General
Dismount the engine and transmission assembly from the vehicle, and then detach the engine from
transmission.
2) Preparation
Discharge the engine coolant from the radiator. See Change Engine Coolant.
Discharge the engine oil, transmission oil and clutch oil. See "Engine Oil", Transmission Oil and
Clutch Pipeline.
Collect the refrigerant in AC pipeline.
Attention:
Perform this step after the engine has cooled down.
Do not spill engine cooling fluid or brake fluid to the drive belt.
Dismount the following parts:
Engine trimming cover. See Intake Manifold.
Front wheels and tyres. See Wheels and Tyres.
Engine deflectors (left and right).
Air duct and air filter assembly. See Air Duct.
Battery, battery base and base support. See Battery.
Radiator assembly and radiator fan. See Radiator.


40
3. Dismantlement of Related Elements in Engine Compartment
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. See Braking Vacuum Booster.
PVC hose. See Fuel Evaporation Control System.
Oil inlet pipe joint of clutch. See Hydraulic Pipeline of Clutch.
Low and high-pressure pipes of air compressor. See Air Compressor.
Remove the brake fluid reservoir.
Remove the accelerator cable.
Disconnect the wire harness connectors and buckles of the following parts and then take them
away:
Oxygen sensor
Engine coolant temperature sensor
Crankshaft position sensor
Camshaft position sensor
Speed sensor
Throttle opening sensor
Absolute intake pressure sensor
Ignition coil
Fuel injector
Knock sensor
Generator
Starter
Air conditioner switch
4. Dismantlement of Components of Chassis
Dismount the front drive shaft. See Front Drive Shaft.
Remove the front exhaust pipe. Please refer to Exhaust System.
Dismount the engine supporting beam. See Engine Supporting Beam.
5. Dismantlement
Attach the lifting device hook to the hanging lug of the engine


41

Lift the engine and fix it in place.
Use the manual lifting stand or equivalent to firmly support the bottom of engine and transmission
assembly; adjust the lifting tension.
Attention:
A soft pad may be placed on the supporting surface so as to ensure a totally stable state.
Detach left, right, front and rear suspensions of engine. See Engine Suspension.
Carefully lower the engine and transmission assembly. Be aware of following items during
operation:
Make sure that the work will not affect the vehicle.
Make sure that all connecting parts have been disconnected.
In order to avoid falling due to changes of vehicle gravity, use the jack to support the rear lifting
point.
6. Detachment
Remove A/C compressor assembly from the engine and transmission assembly.
Dismount starter. See Starter.
Lift engine and transmission assembly with specified lifter, and then detach them.
Attention:
Before lifting, check whether each connection wiring harness has been disconnected.
7. Installation
Be aware of following items to install with steps contrary to dismantlement.
1) Do not damage the soft pad of engine suspension. Meantime, avoid spilling engine oil onto the soft
pad.
2) Make sure that all engine suspensions have been properly fixed. Then, tighten the nuts and bolts.
8. Check after Installation
1) Check for any leakage.
The steps for checking oil and fluid leakage, lubricating oil leakage and the exhaust leakage are as
follows:
Fig.1.1.004

Fig.1.1.005


42
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
- With ignition switch turned to the ON position, check whether there is fuel leakage at the
connecting positions.
- With engine started, recheck whether there is fuel leakage at the connecting positions during engine
increasing.
During running of engine, check for any abnormal noise and/or vibration.
With engine warmed up, verify that there are no leakage of fuel, exhaust gas or other oil and liquid
(including engine coolant and oil).
Bleed air and replenish by using specified ports and hoses.
After engine cooled down, recheck oil and liquid levels (including engine oil and coolant). If
necessary, refill them to the specified levels.
2) General of Check Items
List of Leakage Check Items
Item Before Startup During Engine
Operation
After Engine
Stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission oil, brake fluid, and clutch fluid Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust Leakage


43
V. Drive Belt
1. Check Drive Belt
Warnings:
Be sure to operate only when engine stopped.
1) Check belt for aging, crack, wear and oil stain. Replace as required.
2) Check the belt tension at the mid-point between pulleys.
Inspection should be conducted with cold state of engine or when it has been stopped for at least
30min.
Tension range - Generator belt: 50050N. Please be noted that the experience equation for
tensioning force of reused belt is as below: Tensioning force for new belt * 1.2/1.5
Adjust if tension is out of range.
Attention:
When checking belt tension after installation, firstly to adjust tension to specified value. Then
revolve the crankshaft for more than two laps to re-adjust in order to avoid tension between
pulleys changes.
2. Adjustment of Tension
List of Tension Adjustment
Part Method
Generator belt Screw adjusting bolt of generator
Attention:
After replacing with the new belt, adjust the tension so as to meet the requirements
When installing the belt, ensure the proper engagement with the belt pulley groove.
Do not splash the engine oil or engine coolant onto the belt.
Do not over wind or bend belt; for worn belt, pay attention to mounting direction.


44
3. Generator Belt
1) Loosen the generator adjusting nuts and supporting nuts. Then adjust the tension by using the
adjusting bolt.

2) Tighten generator adjusting and supporting nuts.
Tightening torque: Generator adjusting nuts: 22.5 2.5 Nm
Generator supporting nuts: 475 N.m
4. Dismantlement of Drive Belt
1) Completely loosen the alternator belt as per the instructions in Tension Adjustment.
2) Remove the alternator belt.
5. Installation of Drive Belt
1) Mount the belt onto the pulley with steps contrary to dismantlement.
Attention:
Make sure that the belt has properly engaged with the groove of pulley.
Make sure that no engine oil or coolant splashed onto any belt or pulley groove.
2) Verify that the tension of every belt is within the standard range. See Inspection of Drive Belt.
Fig. 1.1.006
Fig. 1.1.007


45
VI. Air Filter and Air Duct
1. Parts

Diagram of Positions
2. Intake Pipe
1) Dismantlement
Remove the fastening bolts and clamps of
front intake pipe and remove the front intake
pipe assembly.
Tightening torque: 17-19 Nm

Loosen the lock clips from the air cleaner
upper cover.

Fig. 1.1.009
Fig. 1.1.008


46
Disconnect the locking clamp of intake hose, and then take off upper cover and intake hose.

Dismount the fixing bolt of air filter base, and
then take down the base.

2) Check after Dismantlement
Check whether there is any crack or wearing on the air duct assembly. If any, replace.
3) Installation
Attention:
Properly mount every joint and tighten the clamp.
3. Replacement of Air Filter element
1) Dismantlement
Loosen the lock clips of air cleaner upper
cover and lift the upper cover.

Fig. 1.1.012
Fig. 1.1.011
Fig. 1.1.013
Fig. 1.1.010


47
Dismount air filter element.

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.
3) Installation
VII. Intake Manifold and Exhaust Manifold

Decomposition Diagram of Intake and Exhaust Manifolds
1. Intake Manifold
1) Dismantlement
Caution:
Do not discharge the engine coolant when the engine is hot, otherwise you would be scalded.
Fig. 1.1.014


48
Discharge the engine coolant. See Engine Coolant.
Dismount the engine trimming cover.
Dismount the air filter assembly. See Air filter Assembly.
Disconnect the wire harness connectors of the following parts:
Fuel injector
Throttle position sensor
Carbon canister control solenoid
Accelerator cable
Disconnect the following hose joints:
Water hose joint (insert a plug to prevent the engine coolant leakage)
PCV hose
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
Remove the fastening bolts of throttle body and
remove the throttle body assembly.

Dismount the fuel injector assembly. See Fuel
Injector.
Tightening torque: 18.41.4 Nm

Fig. 1.1.015
Fig. 1.1.016


49
Dismount the supporting bracket of intake manifold
and engine cylinder body.

Dismount the fixing bolt and nut of intake manifold.
Tightening torque: 181.0 Nm

Take off the intake manifold.
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.
3) Installation
Install with steps contrary to the dismantlement.
Attention:
Do not reuse the non-reusable parts.
Before starting the engine, check the level of engine coolant. If the level is lower, refill engine
coolant as specified.
Carry out the following steps to check whether fuel leakage is present.
With ignition switch turned to the ON position, check whether there is fuel leakage at the
connecting positions.
With engine started, recheck whether there is fuel leakage at the connecting positions during
engine increasing.
With engine warmed up, verify that there is no fuel and/or coolant leakage.
After engine cooled down, recheck the level of engine coolant. Refill to specified level as required.
2. Exhaust Manifold
1) Dismantlement
Fig. 1.1.017
Fig. 1.1.018


50
Caution:
Perform this operation after the exhaust system has completely cooled down.
Disconnect the wire harness connectors of front
oxygen sensor. Special tools should be used if
necessary.

Attention:
Do not damage the oxygen sensor.
It is forbidden to use any oxygen sensor which has dropped to the hard ground from a height
above 0.5m. Such an oxygen sensor should be replaced.
Unscrew the fixing bolt for heat shield of exhaust
manifold, and then take off heat shield.

Unscrew bracket bolt to remove the exhaust manifold
bracket.

Unscrew fixing bolt to remove the exhaust manifold.
Tightening torque: M8 352 Nm

Fig. 1.1.020
Fig. 1.1.019
Fig. 1.1.021
Fig. 1.1.022


51
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.
Do not excessively tighten oxygen sensor, otherwise it may be damaged.
VIII. Exhaust System
1. Parts

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
2. 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.
Repair or replace the damaged part as required.
3. Dismantlement and Installation
Attention:
Do not have you hand cut by the edge of heat shield.
Do use original exhaust system parts or equivalent products.
Perform the operation after the exhaust system has completely cooled down, for the temperature of
exhaust system remains hot when the engine has just stopped.
1) Dismantlement
Disconnect every joint and fixed part.
2
3
4
6
5
7
1


52
2) Installation
Replace the exhaust pipe gasket when reassembling the exhaust system each time.
Repair or replace the seriously distorted heat shield. Eliminate the accumulations from the heat
shield.
When install the heat shield, try to avoid wide clearance or blockage and intervention between the
heat shield and each exhaust pipe.
Eliminate the sediments from the sealed face of each joint. Such joints should be firmly connected
to avoid gas leakage.
Pre-tighten the fixing nuts and bolts on exhaust manifold side and those on vehicle side. Check
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.
3) Check after Installation
Verify clearance between rear muffler and rear bumper.
WIth engine running, check the connecting position of exhaust pipe for air leakage and abnormal
noise.
Ensure that the fixing support and the fixing rubber have been properly mounted. Do not subject
them to excessive force. Improper installation may result in considerable noise and shake.


53
IX. Timing sprocket mechanism
1. Parts

Timing sprocket mechanism diagram
1 Timing chain 2 Movable rail bolt subassembly 4. Movable rail subassembly
5 Automatic tensioner bolt 5 Automatic tensioner 6 Bolt 7 Balance shaft front cover plate
8 Balance shaft chain wheel fastening bolt 9 Balance shaft chain wheel 10 Secondary chain
11 Balance shaft idler gear 12 Secondary tensioner 13 Secondary tensioner torsion spring
14 Fixed gauge subassembly 15 Fixed gauge bolt subassembly
2. Dismantlement and Installation of Timing
chain
1) Dismantlement
a) Remove the water pump pulley and tensioner
fastening bolts.
Tightening torque: Water pump pulley bolts:
7~8.2N.m
Tensioner bolts: 40~58N.m
Fig. 1.1.023
Balance
shaft gear


54
Note: It is permissible to perform the
dismantlement by means of the friction force of
drive belt before drive belt is removed.
b) Dismantle drive belt to check whether the
drive belt has wearing, aging, cracking, etc.;
if any, replace drive belt.
c) Dismantle oil gauge assembly
Tightening torque: 7-8.2 Nm

d) Dismantle damping wheel

e) Remove the alternator bracket.

f) Dismantle oil pan and cylinder head cover
Attention: Only when oil pan and cylinder head
cover are disassembled can the oil pump
assembly be dismantled.
Remove the cylinder head shield as per the
illustrated sequence.

Fig. 1.1.024
Fig. 1.1.025
Fig. 1.1.026
Fig. 1.1.027
Tightening sequence for bolts
of cylinder head shield


55
g) Dismantle oil pump assembly

h) Check timing
Check the timing point shown in the diagram for compliance.

Fig. 1.1.028
Timing mark of primary chain
Timing mark of
secondary chain
Timing mark of
secondary chain
Timing mark for crankshaft
chain wheel
Timing mark for balance
shaft chain wheel
Timing mark of
primary chain
Timing mark
for camshaft
chain wheel


56
i) 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 Nm
Dynamic track: 19-28 Nm

j) Dismantle exhaust camshaft sprocket bolt
Tightening torque: 8810 Nm

k) Remove t he bolts of intake cam chain wheel

l) Remove the rear end cap of balance shaft and
secure the anti-rotation device of balance
shaft on the tail of the balance shaft.
Tightening torque for rear end cap of balance
shaft: 7.60.6 Nm

Fig. 1.1.029
Fig. 1.1.031
Fig. 1.1.030


57
m) Remove the bolts of secondary chain
tensioner and remove the secondary chain
tensioner.

n) Remove the bolts of balance shaft chain wheel
and remove the balance shaft chain wheel.

2 Installation
Reverse the above steps for installation. Be aware of timing and tightening torque during installation.

Fig.1.1.033
Fig.1.1.034


58
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 Exhaust camshaft chain wheel 5 Exhaust camshaft subassembly 6 Mechanical tappet
7 Balance shaft retaining bolt 8 Balance shaft gear 9 Balance shaft
10 Balance shaft rear end cap gasket 11 Balance shaft rear end cap
12 Balance shaft rear end cap bolts
2. Disassembly and installation
1 Disassembly of camshaft
Remove cylinder cover. See "Intake Manifold."
Remove high-voltage ignition coil. See "Ignition Coil."
Disconnect PCV hose and air hose of respirator.
Remove the cylinder head cover from the cylinder head.
Remove camshaft timing sprocket. Seethe "timing sprocket body."
Remove camshaft position sensor from rear end of the cylinder head.
Tightening torque: 9 - 11 N m


59
Attention:
Handle with care to avoid collision or damage.
Remove the camshaft from cylinder head.
2 Disassembly of balance shaft
On the basis of above-mentioned disassembly
procedure of camshaft, proceed as below:
Remove the bolts of balance shaft front end
cap and remove the balance shaft front end
cap.
Tightening torque for balance shaft front end
cap: 7.60.5N.m

Remove the balance shaft idler gear, remove
the bolts of balance shaft front gear, and
remove the balance shaft gear.
Tightening torque for bolts of balance shaft
front gear: 23.54.5N.m

Remove the bolts of exhaust bracket II and
balance shaft side cover and remove the
balance shaft.
Tightening torque for bolts of cover:
7.60.6N.m
Fastening bolts for exhaust pipe bracket II:
22.52.5N.m

Fig.1.1.037
Fig.1.1.036
Fig.1.1.035


60
3 Inspection after removal
Camshaft
Measuring camshaft base circle diameter and
the maximum lifting strokes of intake and
exhaust.
Base circle diameter: 36mm
Maximum lifting stroke of intake8.7054mm
Maximum lifting stroke of exhaust
8.2836mm
If specified value is exceeded, replace the
camshaft.

Mechanical tappet
Measure the top thickness of the mechanical
tappet
Measurement should be within: 2.70
2.30mm

4 Installation
Assembly of camshaft machenism: All parts camshaft assembly should be assembled according to
grouped drawings.
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
and valve tappet L1
Top end thickness of
mechanical tappet
Mechanical tappet
label
Valve clearance
(mm)
2.91L12.93 2.70 270 0.19-0.25
2.93L12.95 2.72 272 0.19-0.25
2.95L12.97 2.74 274 0.19-0.25
2.97L12.99 2.76 276 0.19-0.25
2.99L13.01 2.78 278 0.19-0.25
3.01L13.03 2.80 280 0.19-0.25
3.03L13.05 2.82 282 0.19-0.25
3.05L13.07 2.84 284 0.19-0.25
3.07L13.09 2.86 286 0.19-0.25
3.09L13.11 2.88 288 0.19-0.25
3.11L13.13 2.90 290 0.19-0.25
Fig.1.1.039
Fig.1.1.038


61
Distance between intake camshaft base circle
and valve tappet L1
mechanical tappet
Mechanical tappet
label
Valve clearance
(mm)
3.13L13.15 2.92 292 0.19-0.25
3.15L13.17 2.94 294 0.19-0.25
3.17L13.19 2.96 296 0.19-0.25
3.19L13.21 2.98 298 0.19-0.25
3.21L13.23 3.00 300 0.19-0.25
3.23L13.25 3.02 302 0.19-0.25
3.25L13.27 3.04 304 0.19-0.25
3.27L13.29 3.06 306 0.19-0.25
3.29L13.31 3.08 308 0.19-0.25
3.31L13.33 3.10 310 0.19-0.25
3.33L13.35 3.12 312 0.19-0.25
3.35L13.37 3.14 314 0.19-0.25
3.37L13.39 3.16 316 0.19-0.25
3.39L13.41 3.18 318 0.19-0.25
3.41L13.43 3.20 320 0.19-0.25
3.43L13.45 3.22 322 0.19-0.25
3.45L13.47 3.24 324 0.19-0.25
3.47L13.49 3.26 326 0.19-0.25
3.49L13.51 3.28 328 0.19-0.25
3.51L13.53 3.30 330 0.19-0.25
Table: Distance between intake camshaft base circle and top of valve tappet, top end thickness of the
mechanical tappet grouping and assembly


62
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
and valve tappet L2
mechanical tappet
Mechanical
tappet label
Valve clearance
(mm)
2.99L23.01 2.70 270 0.27-0.33
3.01L23.03 2.72 272 0.27-0.33
3.03L23.05 2.74 274 0.27-0.33
3.05L23.07 2.76 276 0.27-0.33
3.07L23.09 2.78 278 0.27-0.33
3.09L23.11 2.80 280 0.27-0.33
3.11L23.13 2.82 282 0.27-0.33
3.13L23.15 2.84 284 0.27-0.33
3.15L23.17 2.86 286 0.27-0.33
3.17L23.19 2.88 288 0.27-0.33
3.19L23.21 2.90 290 0.27-0.33
3.21L23.23 2.92 292 0.27-0.33
3.23L23.25 2.94 294 0.27-0.33
3.25L23.27 2.96 296 0.27-0.33
3.27L23.29 2.98 298 0.27-0.33
3.29L23.31 3.00 300 0.27-0.33
3.31L23.33 3.02 302 0.27-0.33
3.33L23.35 3.04 304 0.27-0.33
3.35L23.37 3.06 306 0.27-0.33
3.37L23.39 3.08 308 0.27-0.33
3.39L23.41 3.10 310 0.27-0.33
3.41L23.43 3.12 312 0.27-0.33
3.43L23.45 3.14 314 0.27-0.33
3.45L23.47 3.16 316 0.27-0.33
3.47L23.49 3.18 318 0.27-0.33
3.49L23.51 3.20 320 0.27-0.33
3.51L23.53 3.22 322 0.27-0.33
3.53L23.55 3.24 324 0.27-0.33
3.55L23.57 3.26 326 0.27-0.33
3.57L23.59 3.28 328 0.27-0.33
3.59L23.61 3.30 330 0.27-0.33
Table: Distance between the exhaust camshaft base circle and top of valve tappet, top end thickness of
mechanical tappet assembly grouping and assembling


63
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; after the camshaft bearing bolt is tightened, the camshaft should turn flexibly without
sticking or other abnormalities; axial clearance should be: 0.05 - 0.15mm. (Measurement
location)
Install the camshaft position sensor.
Attention:
Apply a film of sealant to the flange of rear end cover.
Tighten the fixing bolt after the support has been fully mounted.
Install camshaft timing sprocket
Install the timing chain wheel of balance
shaft. During installation, notice to align the
timing mark of balance shaft.
Backlash of balance shaft gear: 0.06-0.12mm
Backlash of balance shaft idler gear:
0.08-0.14mm

Before installing cylinder head cover, clear any sealant on cylinder head.
Make sure that cylinder head cover gasket is put into the installation slot.
Check for proper position of all parts installed.
Check the level of engine oil before starting the engine. If the engine oil is less than the required
volume, replenish to specified level.
With engine running, check for abnormal noise and vibration.
Be sure that there is no oil leakage after engine warmed-up thoroughly.
Recheck the level of engine oil with engine cooled down. Replenish the engine oil to the specified
level as required.

Fig.1.1.040
Timing mark of balance shaft gear
and idler gear


64
XI. Cylinder head
1. On-vehicle Maintenance
1) Inspect the cylinder pressure:
Thoroughly warm up the engine and then stop it.
Release the fuel pressure. See Release of Fuel Pressure.
Disconnect the fuse of fuel pump, otherwise the fuel may be sprayed out during measurement.
Use special ignition coil and spark plug removal tool. See "Ignition Coil" and the "Spark Plug."
Dismantle engine trimming cover. See Intake manifold.
Install a cylinder pressure gauge (with joint) on the spark plug hole.
Push the accelerator pedal to the end, then turn the ignition switch to the START position to start
the engine. After the instrument finger appears stable, read compression pressure and engine speed.
Perform these steps to check other cylinders.
Standard pressure: 1200100 kPa
Tolerable pressure difference between cylinders: 98kPa
Attention:
It is required to obtain the specified engine speed always by the battery which is fully
charged.
Inspect valve clearance and other relevant parts (such as valve, valve seat, piston, piston ring,
cylinder bore, cylinder head and gasket) if the compression pressure is less than the minimum
value. Repeat measurement of compression pressure after the check.
If the pressures in some cylinders are low, add some engine oil to the spark plug holes of such
cylinders and then inspect again.
The piston ring may be worn or damaged if the cylinder pressure rises after the engine oil is
added. Check the piston ring and replace if necessary.
The valve may have faulty if the compression pressure is still low after the adding of engine
oil. Check whether the valve is damaged. Replace the damaged valve or valve seat.
The cylinder gasket must be leaky if the compression pressures in two neighboring cylinders
are low and even keep low after adding engine oil. Replace cylinder gasket.
After inspection, remount the dismounted parts.
Start engine, confirm that the engine runs smoothly.


65
2. Parts

Diagram of Cylinder head
1) Dismantlement
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.
Dismount the following elements and the relevant parts:
Engine trimming cover. See Intake Manifold.
Drive belt. See Drive Belt.
Cylinder head cover. See "Camshaft Assembly."
Intake manifold. See Intake Manifold.
Exhaust manifold. See Exhaust Manifold.
Oil gauge tube.
Oil pump body assembly and timing mechanism. See the "Timing Sprocket Mechanism."
Loosen the cylinder head bolts with special tool.
Remove the cylinder gasket.


66
Cylinder head Bolt
Measure the length of cylinder head bolt.
Limit: 143.50.7mm. Replace the cylinder head bolt if this Limit is exceeded.
Cylinder head
Check whether there are cracks or other damages on the cylinder head.
Check whether there is any blockage in the coolant gallery and oil passage. If any, clean the coolant
gallery and oil passage.
Check planeness of cylinder head.
Note: Check the planeness of cylinder body as well when performing this check.
a. Wipe off the engine oil from the cylinder head, remove any sealant and the carbon deposit.
Attention:
Be careful to prevent impurities from falling into coolant gallery and oil passage of cylinder
head.
b. Measure the planeness in six directions at
several positions on bottom surface of
cylinder head.
Standard value: below 0.03mm
Height of cylinder head (new): 1130.1mm
If the the standard value is exceeded, grind or
replace the cylinder head according to the
specification.

Attention:
The total grindable margin of matching surface between cylinder head and cylinder body
should not be greater than 0.2mm.
3) Installation
Install new cylinder gasket.
Follow the numerical order as shown in the
diagram to tighten the cylinder head bolt and
follow the given steps to install cylinder head.
A: Intake side
B: Exhaust side
: Front end of engine
a. Install washer.
Fig.1.1.042
Fig. 1.1.041


67
b. Apply a film of engine oil onto washer, which is at the threaded portion of bolt.
c. Tighten cylinder head bolts in sequence, until each bolt torque is 24.5 2 N m.
d. Fully unscrew bolts.
e. Tighten the bolts until the torque of each bolt is 24.5 2N m.
f. Paint marks on the bolt head and the cylinder
head (see Fig.1.1.040).
g. Screw each bolt for more 90 with to the
tightening sequence.
h. Re-tighten each bolt by 90.
Attention:
When the two tightening angles are below
180 , tightening performance can not be
assured; be sure to reach 180 when
tightening.

When the two tightening angles are above 184 , completely loosen the bolt and re-tighten per
the initial sequence.
i. If the old cylinder head bolts are replaced during the maintenance, operation should be performed
in sequence from a to h.
j. If the old cylinder head bolts are not replaced during the maintenance, operation should be
performed in sequence a, b, e, f, g and h.
Then, perform the installation steps which are just contrary to dismantlement.
The steps for checking oil leakage, lubricant leakage and tail gas leakage are as following:
Before starting the engine, check the engine oil/coolant level. If the level is lower, replenish the
engine oil/coolant till the specified level is reached.
Perform the following steps to check whether the oil leakage occurs:
Turn the ignition switch to the ON position (when engine is stopped). With the oil pressure
acting on the oil pipe, check whether there is fuel leakage at the joint.
Start the engine. With the engine accelerating, recheck whether there is fuel leakage at the joint.
Run the engine to check whether the abnormal noise or vibration appears.
With engine warmed up completely, verify that there is no fuel leakage, tail gas leakage or any
oil/fluid (including engine oil and coolant) leakage.
After engine cooled down, recheck oil/fluid (including engine oil and engine coolant) level.
Replenish the oil/fluid to the specified level as required.
Fig.1.1.043
Painting Mark


68
XII. Valves
1. 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 6 - intake valve spring upper seat 7 - intake valve spring 8 - intake
valve
9 - exhaust valve cotter 10 - exhaust valve spring upper seat 11 - exhaust valve spring
12 - exhaust valve 13 - intake valve oil seal 14 - intake valve spring lower seat
15 - exhaust valve seal 16 - exhaust valve spring lower seat 17 - intake valve guide
18 - exhaust valve guide 19 -intake valve seat 20 - exhaust valve seat 21 - cylinder head
2. Disassembly and Assembly
1) Disassembly
Dismount the spark plug with the special
socket.
Dismount the valve cotter, valve spring and
spring seat.
Compress the valve spring with the special

Fig.1.1.044
JAC-T1F001


69
compressor.
Attention:
Pay attention to the position of upper dead
point of piston.
Label the dismounted valve, valve spring
and other parts, and write down their
corresponding cylinder numbers and
positions
Store the parts reliably.

Dismount the valve oil seal.
See Replacement of Valve Seat to replace
the valve seat, if required.
See Valve Guide to replace the valve guide,
if required.

2) Assembly
Install valve guide if it has been dismounted. See Valve Guide.
Install valve seat, if it has been dismounted. See Valve Seat.
Install valve oil seal.
a. Install the valve spring seat.
b. Install the new valve oil seal with the special
tool shown in Fig.1.1.044
Attention:
The valve oil seal should not be reused.
The valve oil seal must be installed with
the proper special tool.
Install valve.
Install valve spring.

Fig.1.1.045 JAC-T1F012
Fig.1.1.046
Fig1.1.047
JAC-T3F001


70
Note: The parts with paint mark should be installed upwards.
Install retaining seat for valve spring.
Install valve cotter.
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.
Install spark plug with the spark plug socket.
3) Check after Disassembly
1. Valve
Check whether the contact between valve
surfaces is proper. Renew the surface of valve
seat if the contact is uneven or incomplete.

Inspect thickness of valve edge. Replace the
valve if the measurement is less than the
specified value.
For intake valve: 1.35-1.65mm
For exhaust valve: 1.850.15mm

Inspect the total length of valve. Replace the valve if the measurement is less than specified value.
For intake valve: 89.51-90.01mm
For exhaust valve: 90.69-91.19mm
2. Valve Spring
Check free height of valve spring. Replace the valve spring if the measurement is less than
specified value.
Check perpendicularity of valve spring. Replace the valve spring if the measurement is out of
limit.
Standard value: 2
Limit: 4
Fig.1.1.048
Fig.1.1.049
Good
Bad Bad
Contact
(required to be
at the center of
surface)
Thickness of
edge


71
3. Valve guide
Check the gap between the valve guide and
the valve stem. Replace the corresponding
parts if the measurement is out of limit.
Valve guide
Standard value: 0.020-0.036mm
Limit: 0.10mm

Replacement of Valve guide
a. Push out the valve guide towards the cylinder side by the press.
b. Rebore mounting hole on the valve guide of cylinder head to make it match increased size of valve
guide to be installed.
Attention:
Do not install the valve guides with the same sizes of old ones. Re-boring mounting hole on
the valve guide of cylinder head
Outer diameter of valve guide:
For the hole with diameter of 10.655-10.665mm,
extend the size of valve guide by 0.05mm.
c. Press the valve guide till its protrusion height
reaches the specified value.

Standard value: 23.0mm
Attention:
Use cold pressing method to install valve guide from upper side of cylinder head. Check
whether there are cracks after press fitting.
After valve guide pressed in, insert a new valve to check for smooth sliding of valve.
4. Valve Seat
Check the valve protrusion height between the end face of valve stem and the surface of valve
spring seat. Replace the valve seat if the limit is exceeded.
Fig.1.1.050
Fig.1.1.051
Valve guide
Inner Diameter of Valve Conduit
Outer Diameter of Valve Stem
Protrusion
Height


72
Standard values:
For intake valve: 53.21mm
For exhaust valve: 54.10mm
Limits:
For intake valve: 53.71mm
For exhaust valve: 54.60mm

Renew valve seat.
a. Before renewing the valve seat, check the clearance between valve guide and valve. Replace the
valve guide if necessary.
b. Resurfacing the valve seat by the proper special tool or the valve seat grinder till specified seat
surface width and angle are met.
c. After renewing the valve seat, grind the valve and the valve seat by the grinding cream. Then,
check the protrusion height of valve stem (refer to the above mentioned check steps of valve seat)
Replacement of Valve Seat
a. Cut away the replaced valve seat from its
inner side in order to decrease the wall
thickness. Then remove the valve seat.

b. Rebore the valve seat hole on cylinder head
till the hole matches the selected valve seat
with a extended diameter. See Parameters
for Maintenance for the detailed size.
c. Do not have the cylinder head hole scratched
by the valve seat cooled by the liquid
nitrogen before it is pressed.
d. Renew the valve seat till its width and angle
meet the specifications (see the operation
instruction of valve seat correction).
e. leak testing must be conducted for
disassembly of valve related components.

XIII. Cylinder Body Assembly
1.1.052
Fig.1.1.053
Fig.1.1.054
End Face of
Valve Stem
Valve Protrusion
Height
Surface of Valve
Spring Seat
Cut Away
Valve Seat
Height
Inner Diameter of Extended Hole


73
1. Parts

Disassembly Diagram of Cylinder Body Assembly
1) Disassembly
Dismount the engine assembly from the vehicle, and then detach the transmission from engine. See
Engine Assembly for detailed dismantlement steps.
Fix whole engine.
Discharge engine oil. See Change Engine Oil
Dismount following engine accessories. See relevant chapters for detailed dismantlement steps.
Drive belt
Alternator, compressor and relevant brackets
Intake and exhaust manifolds


74
Water pump and its components
Ignition coil
Cylinder cover, damping wheel, oil pan
Engine timing sprocket mechanism
Dismount the flywheel assembly. Fix the flywheel by the special tool to dismount the fixing bolt.
Tightening torque: For flywheel: 95-105Nm
Attention:
Fixing bolts should be loosened in the diagonal orders.
Disassemble knock sensor, crankshaft position sensor, oil pressure switch.
Tightening torque: Knock sensor: 16 - 24 N m
Crankshaft position sensor: 7.8 - 9 N m
Oil pressure switch: 8 - 12 N m
Attention:
Do not drop or knock the sensor.
Remove crankshaft rear oil seal bracket
Tightening torque: 7.0-8.2Nm
Insert the screwdriver between the crankshaft and the rear oil seal housing to dismantle.
Attention:
Once dismounted, the rear oil seal must not be reused. It should be replaced by a new one.
Dismount the piston and connecting rod assembly:
Before dismounting the piston and connecting rod assembly, check the gap at the big end of connecting
rod. See Check after Disassembly below.
a. Rotate the crankshaft to place the journal side of crankshaft which is corresponding to the
connecting rod to be dismounted at the center of bottom.
b. Dismount the connecting rod cover.
Tightening torque: 131Nm + 90-94
Be aware that when tightening the "5Nm 10Nm 13Nm +45 +45 " alternate methods should be
followed to tighten.
c. Push out the piston and connecting rod assembly from the cylinder body by the rubber hammer or
equivalent.

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


75
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
Dismount bearing shell from the connecting rod and the connecting rod cover.
Attention:
Identify their mounting positions, and properly place them to avoid confusion.
Dismount ring from the piston.
Check the side clearance of piston ring before dismounting. See Check after Disassembly below.
Attention:
Use the piston ring expander.
Dismount the piston ring from the connecting
rod with method below:
a. Insert the push rod (special tool) from the
front side with a arrow mark, and then install
the guide sleeve D.
b. With the front mark of piston face upwards,
install piston and connecting rod assembly on
the mounting base of piston pin (special tool).
c. Push out the piston ring by the press.
d. Detach the connecting rod from piston.
Attention:
After dismounting piston pin, place it
together with the piston pin and the
connecting rod.
It is forbidden to place the pistons, piston
pins and connecting rods of different
cylinders together.

Dismount the crankshaft bearing cap.
Before loosening the crankshaft bearing cap, measure axial clearance of crankshaft. See Check after
Disassembly below.
Fig.1.1.055
Fig.1.1.056
Piston Ring
Expander
Push Rod

Guide Sleeve D
Base
Front
Mark


76
Loosen the bolts of crankshaft bearing cap in the
following sequence.
Tightening torque: 352 Nm6064
Be aware of the number and forward mark of
bearing cap.

During the dismantlement, it is allowable to jiggle
the crankshaft bearing cap forwards and
backwards by the bolts of crankshaft bearing cap.
See Fig.1.1.055.
Dismount the crankshaft.

2) Check after Disassembly
Axial clearance of Crankshaft
Detection methods are as shown in the figure

If measurement is not within the standard range, replace the thrust washer and repeat measurement. If it
is still over limit, replace the crankshaft.
Big End Clearance of Connecting Rod
Measure the gap between the connecting rod and
the crankshaft by using feeler gauge.
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.

Fig.1.1.058
Fig.1.1.057
Fig.1.1.059
Fig.1.1.060


77
Side clearance of Piston Ring
Measure the side clearance between piston ring
and piston ring groove top land by the feeler
gauge.
Standard values:
For 1
st
piston ring, 0.030.07mm
For 2nd piston ring, 0.040.06mm
Limits:
For 1
st
piston ring, 0.1mm
For 2
nd
piston ring, 0.1mm

If the measurement exceeds the limit, replace the piston ring, and then remeasure the gap. Replace the
piston if the measurement is still out of the limit.
End Gap of Piston Ring
Ensure that the inner diameter of cylinder stays
within the specified range.
See "Cylindricality of Cylinder"
Lubricate the piston and the piston ring with new
engine oil, then insert the piston ring till the piston
reaches the middle part of cylinder, measure end
gap of piston ring by the feeler gauge.

Standard values:
For 1
st
piston ring, 0.15-0.30mm
For 2
nd
piston ring, 0.30-0.50mm
Limits:
For 1
st
piston ring, 0.8mm
For 2
nd
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.
Planeness of Cylinder Body
Remove any gasket material and eliminate the engine oil, sediment, carbon or other contaminants on
surface of cylinder body.
Fig.1.1.062
Fig.1.1.061
Piston Ring
Feeler Gauge
Good
Feeler
Gauge
Bad
Feeler
Gauge
Piston
Piston
Ring
Piston
Ring
Measured Point
Pressed and Fixed


78
Attention:
Be careful to prevent gasket materials from falling into the engine oil or coolant.
Measure planeness of cylinder body in different
directions at six positions using ruler and feeler gauge.
Standard values: below 0.05mm
Limits: below 0.1mm
If the limit is exceeded, replace cylinder body.

Cylindricality of Cylinder
Measure the cylinder degree at 6 different points per cylinder by using micrometer.
Standard values:
For cylinder bore: 75.0mm
For cylindricality: below 0.07mm
Diameter of Piston Skirt
Use outside micrometer to check whether the
piston skirt is distorted.
Standard values:74.973mm

Clearance between Piston and Cylinder Bore
Calculate per the actual measurement of piston skirt and cylinder bore.
(Gap) (inner diameter of cylinder) (diameter of piston skirt)
If the calculated value exceeds the limit, replace piston and piston ring assembly.
Boring Cylinder
a. 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. 0.25mm, 0.50mm, 0.75mm and 1.00mm, are applicable.
b. Measure the diameter of piston to be used.
After boring cylinder, clearance between piston and cylinder bore must be within standard range. The
Fig.1.1.063
Fig.1.1.064
Feeler
Gauge
Ruler
Dial Indicator


79
piston diameter should be measured at the position shown in Figure.
c. Calculate the boring size based on the piston diameter.
[Boring size] [outer diameter of piston] [clearance between piston and cylinder (0.02-0.04mm)]
[grinding margin (0.02mm)]
d. Boring each cylinder till it obtains the calculated boring size.
Attention:
To avoid the distortion due to heat during the boring course, bore the cylinders in following
sequence: Cylinder 2 Cylinder 4 Cylinder 1 Cylinder 3
e. Grind the cylinder till it meets the final processing size (outer diameter of piston clearance
between piston and cylinder)
Diameter of Main Crankshaft Journal
Measure the main crankshaft journal by the outside micrometer.
Standard value: 48.0mm
If it exceeds the standard, please follow the rules of selection to replace.
Diameter of Main Journal of Connecting Rod
Measure the diameter of main journal of
connecting rod by using outside micrometer.
Standard values:43.0mm
Replace the connecting rod bearing shell if
measurement exceeds standard value.
Gap of Connecting Rod Bearing Shell
Note: Use the plastic divider to perform the
measurement.
a. Clean any engine oil from the connecting rod
journal and connecting rod bearing shell.

b. Put the plastic divider on the connecting rod
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.
c. Lightly put the connecting rod cover to
specified place, and screw the bolt to
specified torque.

d. Dismount the bolt, then take off the connecting rod cover slowly.
e. Measure the pressed portion of plastic divider at the widest point by the scale which is printed on
the plastic divider bag.
Fig.1.1.066
Fig.1.1.065
Dial Indicator


80
Standard value: 0.02 - 0.04mm + (0.01mm) expansion
Limit:0.1mm
Roundness and Cylindricality of Crankshaft
Measure sizes of each main crankshaft journal and
main connecting rod journal at four different
positions as shown in the figure.
The difference between X and Y of A
and B represents the roundness.
The difference between A and B of X
and Y represents the cylindricality.

Limits: For roundness: equal to or less than 0.05mm
For cylindricality: equal to or less than 0.05mm
Calibrate or replace the crankshaft if the measurements exceed the limits.
Clearance of Crankshaft
a. Wipe off oil from the crankshaft journal and the inner surface of bearing shell.
b. Mount the bearing shell.
c. Set the plastic divicer till its width equals to the width of bearing shell. Then put them on the
journal along the axial line of journal.
d. Lightly mount the crankshaft bearing shell cover, and screw the bolt till to specified torque.
e. Dismount the bolt and lightly take off the crankshaft bearing shell cover.
f. Measure the pressed portion of plastic divider at
the widest point by the scale which is printed on
the plastic wire gauge bag.
Standard values: 0.02-0.04mm
Limit:0.1mm

Attention:
The connecting rod journal and main
journal of crankshaft should be rolled but
needn't to be machined to the reduced size.

Fig.1.1.067
Fig.1.1.068
Fig.1.1.069
Plastic Wire
Gauge
Round-angle Rolling Area


81
Flywheel
Check whether the flywheel and the signal disk are distorted or cracked.
Attention:
Do not disassemble the flywheel.
16 Crankshaft signal wheel
Check whether the crank signal wheel has
distortions, cracks and other anomalies.
Check whether the bolts are loose

3) Assembly
Blow away any oil and coolant from the cylinder body, the cylinder bore and the crankcase.
Remove any foreign bodies.
Attention:
Use goggles to protect your eyes.
Install the upper and lower main bearings shells.
Attention:
Select the bearing shells by using the identification marks of crankshaft (See the table 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
1 2 3 4 5
0 (up / down) BlackBlack BlackYellow BlackRed BlackWhite BlackPurple
1 (up / down) YellowBlack Yellow
Yellow
YellowRed Yellow
White
YellowPurple
2(up / down) RedBlack RedYellow RedRed RedWhite RedPurple
a. Remove any dust, dirt and oil from the matching surfaces of cylinder body and main bearing cap.
b. Install intermediate and upper bearing shells on the cylinder body
c. Be aware of direction of bearing shell during the installation.
Bearings shells with oil holes and slots should be installed at block side; other shells should be
installed at the main bearing cap side.
For installation of bearings, clean before installation. Please apply engine oil to the bearing surface.
Do not use oil on the back, but to thoroughly clean it.
During installation, align the extrusion on bearing shell with the cut of cylinder body and main
bearing cap.

Fig.1.1.070


82
Add oil to bearing surface
Install crankshaft on cylinder block. When rotating the crankshaft by hand, check whether the rotation
of crankshaft is smooth.
Install main bearing cap.
The main bearing cap can be identified through
mark.
Install the main bearing cap starting from the
front of the engine according to the ordering
numbers.
Arrow must point to engine front.
Tighten the bolts of main bearing cap to
standard torque.

a. Apply new engine oil onto the thread and fixing surface of bolts of main bearing cap.
b. Tighten bolts for main bearing cap in steps.
Tightening torque: 352Nm
Screw all bearing cap bolts by 60-64 clockwise.
After installation of bolts of main bearing cap, verify that the crankshaft can be rotated smoothly by
hand.
Check the axial clearance of crankshaft. See Axial clearance of Crankshaft.
Install piston onto the connecting rod with
following instructions.
a. Measure the following lengths (See right
Figure).
A Distance from piston flange to piston flange
outside
B Distance from piston flange to piston flange
inside
C Length of piston pin.
D Thickness of small end of connecting rod.
b. Introduce the measurements into following
formula:

L = [(A-C)-(B-D)]2
c. Insert push rod (special tool) into the piston pin, and then install guide sleeve.
d. When mounting the piston and the connecting rod, keep the front marks at same side.
e. Apply the engine oil onto the outer circle of piston pin.
f. Starting from the guide sleeve, press the guide sleeve, piston pin and push rod into the piston front
Fig.1.1.072
Fig.1.1.071
P
i
s
t
o
n

P
i
n

P
i
s
t
o
n

Connecting
Rod


83
mark side.
g. Screw in the guide sleeves, clearance between
the two sleeves should be 3mm plus the
calculated L in Step 2.
h. With the front mark facing downwards,
install piston and connecting rod on mounting
base of piston pin.
i. Install piston pin by the press.

Attention:
If the pressing load exceeds specified value, replace the piston pin and piston assembly and/or
the connecting rod.
Standard value: 10854Nm
Install piston pin.
Attention:
When mounting the piston ring, do not damage the piston.
Do not damage the piston ring due to the excessive expansion.
a. Install oil ring
a) Install oil ring lining ring into the piston ring groove. Then install the upper and lower blades.
Attention:
Lining ring and blade can be installed in two directions There is no difference between
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
b) To install the blade, install one end of blade into the groove (as shown in the diagram) before
pressing the other areas to place.
Attention:
Do install blades by using piston ring
expander, otherwise, they may break.
c) After installation of the blades, check whether
they can move smoothly in both directions.

Fig.1.1.073
Fig.1.1.074
Guide
Sleeve B
Guide
Sleeve A
Piston Ring
Expander


84
b. 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

Install bearing shell onto the connecting rod and the connecting rod cover.
Apply engine oil onto bearing surface of shells before installation. Do not use engine oil on the
back but to thoroughly clean it.
Install piston and connecting rod assembly onto the crankshaft.
Place the crankshaft journal which is corresponding to the connecting rod to be mounted at the just
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.

Install piston rod assembly in corresponding cylinder according to marks on connecting rod.
Make sure that the front mark on piston top faces to timing belt, and then press the piston and
connecting rod assembly into the cylinder from the cylinder upside.
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
Opening direction of combined oil ring upper blade
Opening direction of second gas ring
Engine front-end
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
Opening direction of second gas ring
Opening direction of combined oil ring upper blade
Engine front-end


85
Make the piston ring with front mark facing
the front end of engine by the piston ring
compressor or other suitable tool, then install
piston ring onto piston head.
Attention:
Do not damage cylinder wall or crankshaft
journal by the big end of connecting rod.
Do not to damage big bonnet and
connecting rod fitting surface

Install connecting rod cover.
During installation, first use high pressure gas for
blowing the expansion sections.
When tightening connecting rod bolt, the order of
5Nm10Nm13Nm+45+45alternate
methods should be followed. After piston
connecting rod assembly is installed, verify that
clearance for the connecting rod big end is 0.10 -
0.30mm.

Attention:
Connecting rod bolts can only be used once..
Before installing nut, apply engine oil on its thread and seat.
Install rear oil seal housing of crankshaft with rear oil seal assemble to the cylinder block.
Installation of knock sensor, Hall sensors, oil pressure switch.
Attention:
Do not screw the nut when grasping the joint.
If the knock sensor is shocked, replace with a new one.
Note: Be sure that there is no foreign body at the matching surface of cylinder body or the back side of
knock sensor.
Be aware of following to install with steps contrary to dismantlement.
Flywheel
Alternately tighten bolts to specified torque.
Fig.1.1.075
Fig.1.1.076


86
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. Replace the piston ring.
The cylinder or the piston is worn. Repair or replace the piston or the
cylinder body.
Low cylinder
pressure
The valve seat is worn or damaged. Repair or replace the valve seat.
The volume of engine oil is insufficient. Check oil level.
The engine oil pressure sensor failed. Replace sensor.
The engine oil filter is blocked. Replace filter.
Oil pump rotor or cover damaged Replace.
The viscosity of engine oil is low. Check. Change oil as required.
The plunger of engine oil pressure switch is constantly
open.
Repair.
Low oil pressure
The bearing gap is high. Replace.
High engine oil
pressure
The plunger of engine oil pressure switch is constantly
closed.
Repair.
The engine supporting bolt loosened Tighten
The transmission mounting support loosened. Tighten
The engine support loosened Tighten
The heat shield for engine is damaged. Replace.
The engine support heat shield is damaged. Replace.
Engine quiver
The heat shield for transmission is damaged. Replace
The engine oil is thin (low oil pressure). Change oil.
Noise of valve
The valve or the valve guide is damaged or worn. Replace.
The oil is insufficient. Check the level of engine oil.
The engine oil is thin (the oil pressure is low). Change oil.
Noise from
connecting rod
bearing shell and the
main bearing shell
The bearing gap is wide. Check and then determine the cause.
The radiator or the radiating pipe is leaky. Repair or replace.
The water tank cover is not sealed. Tighten or replace the cover.
The thermostat is leaky. Replace the thermostat pad.
The radiator is leaky. Repair or replace.
Poor cooling
performance
The water pump is leaky. Replace.
Jam in radiator The coolant contains the impurities. Replace the coolant.
The water tank cover is not strictly sealed. Replace.
The cooling system is jammed. Rinse or replace.
High temperature of
coolant
The thermostat is at fault. Replace.


87
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. 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.
The sensor or the starter is at fault. Repair or replace.
Ineffective fan
The fan relay or the wire harness is damaged. Repair or replace.
The joint loosened. Tighten it
The exhaust pipe or the muffler is damaged. Repair or replace. Exhaust system leaks
Exhaust pipe gasket damaged Replace.
The muffler loosened Tighten it
The rubber pad cut off Replace.
The exhaust pipe or muffler contacts vehicle body. Correct
Abnormal noise
The exhaust pipe or the muffler is damaged. Repair or replace.


88
XV. Parameters for Maintenance
1. List for Technical Parameters of Engine
Technical Parameters list of Engine
Item Standard Value Limits
Camshaft
Camshaft base circle diameter (mm) 36
Diameter of camshaft journal (mm) 32.033-32.082
Cylinder head and valve
Planeness of cylinder gasket surface (mm) 0.03 0.1
Total height of cylinder head (mm) 112.9-113.1
Intake valve 1.35 0.85
Thickness of valve edge (mm)
Exhaust valve 1.85 1.35
Diameter of valve stem (mm) 5
Intake valve 0.020-0.036 0.10 Clearance between valve stem and
valve guide (mm)
Exhaust valve 0.030-0.045 0.15
Conical angle of valve 45-45.5
Intake valve 89.61 89.51
Total length of valve (mm)
Exhaust valve 90.91 90.41
Free height of valve spring (mm) 43.1
152/33.4
Load / mounting height of valve spring (N)/(mm)
310/25.2
Perpendicularity of valve spring 2 4
Contact width of valve seat (mm) 0.9-1.3
Inner diameter of valve guide (mm) 5.5
Protrusion of valve guide (mm) 23.0
Extended by
0.05mm
10.605-10.615
Extended by
0.25mm
10.805-10.815
Diameter of size-extended valve guide on
cylinder head (mm)
Extended by
0.50mm
11.055-11.065
Extended by
0.3mm
28.425-28.445
Intake
Extended by
0.6mm
28.725-28.745
Extended by
0.3mm
26.725-26.745
Diameter of size-extended valve seat
ring hole (mm)
Exhaust
Extended by
0.6mm
26.725-26.745


89
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
(mm)

75.0
1
st
piston ring 0.03-0.07 0.1
Side clearance of piston ring mm)
2
nd
1
st
2
nd
piston ring 0.30-0.50 0.8 Gap of piston ring opening (mm)
Oil ring 0.20-0.50 1.0
Outer diameter of piston pin (mm) 18.0
Pressing load on piston pin (under room temperature) (N) 4900-14700
Oil gap of crankshaft pin (clearance of connecting rod journal)
(mm)
0.02-0.04 0.1
Side clearance of big end of connecting rod (mm) 0.10-0.25 0.4
Crankshaft and cylinder body
Axial clearance of crankshaft (mm) 0.09-0.27 0.25
Diameter of main journal of crankshaft (mm) 48.0
Diameter of connecting rod journal (mm) 42.0
Clearance of main journal of crankshaft (mm) 0.02-0.04 0.1
Plainness of surface of cylinder body gasket (mm) <0.03 0.1
Total height of cylinder body (mm) 256
Cylindricality of cylinder body (mm) 0.01
Reference cylinder bore (mm) 75.0
Clearance between piston and cylinder (mm) 0.02-0.04


90
2. Tightening Torques
List of fastener tightening torque
Name Specification Qty. Tightening Torques (Nm)
High strength bolt
Main bearing cap bolt M91.2574.5 8 352Nm +60-64
(Synchronous fastening machine) 5Nm 13Nm
+90 - 94
Connecting rod bolts tightening
torque
M60.7533 6
(Manual) 5Nm 10Nm 13Nm +45 +45
alternate tightening
Camshaft bearing cap bolt M6135 12 111
Front camshaft bearing cap bolt M81.2530 3 201
Cylinder head bolt M91.25143.5 8 24.52Nm +180-184
Crankshaft pulley bolt M141.554 1 50Nm2Nm+602 or 165 Nm5 Nm
Flywheel bolt M111.2525 6 1005
Exhaust camshaft sprocket bolt M1230 1 8810
E-type bolt
Crankshaft rear oil seal bolt M610 E8 6 7.60.6
Rear lug blot M820 E10 2 18.41.4
Intake manifold bolt M840 E10 4 181.0
Oil pan bolt M612 E8 14 7.60.6
Sprocket cover bolt I M1090 E14 2 39.53.0
Sprocket cover bolt II M1050 E14 2 39.53.0
Sprocket cover bolt III M630 E10 2 8.40.6
Bolt M620 E10 M620 E10 8 8.40.6
Bolt M612 E10 M612 E10 11 8.40.6
Bolt M645 E10 M645 E10 6 8.40.6
Bolt M625 E10 M625 E10 11 8.40.6
Bolt M612 E8 M612 E8 22 8.40.6
Cylinder head cover bolt M627 E10 10 91.0
Oil filter bracket bolt M830 E12 3 201
Heater water returning pipe bolt M620 E8 2 7.60.6
Hydraulic oil rail bolt M835 E12 2 18.41.4
Bolts of exhaust manifold bracket M820 E12 2 201
Plug
Main oil passage plug I Inner hex M20 2 605
Main oil passage plug II Inner hex M12 1 355
Water drainage plug Inner hex M12 1 255
Oil passage plug Inner hex M10 1 202
Oil drainage plug M141.514 1 395


91

Other bolts
Bolts of balance shaft gear M8151.25 1 23.54.5
Bolts of balance shaft chain wheel M8181.25 1 455
Set track bolts M6112 2 102
Dynamic track bolts M81.2515 1 23.54.5
Starter bolt M855 2 243
Oil pressure switch R 1/8 1 102
Spark plug M14 3 27.52.5
Exhaust manifold stud M8112 6 122
Catalytic gas shroud nut M61 3 101
Q2580614 (crank signal wheel
bolt)
M6
3
12.52.5
Water temperature sensor 1 204
Hall sensor bolt Inner hex M6116 2 8.40.6
Knock sensor bolt Inner hex M81.2530 1 204
Exhaust manifold nut M8 5 352
Throttle bolts 4 60.5
Absolute pressure sensor
self-tapping screw

60.5
Square head bolt M101.2590 1 475
Idle wheel bolt M101.2538 1 499
Oxygen sensor 2 355
Oil filter
1
After contact mounting surface, turn by 3 / 4 laps
or 11 1Nm
Bolts of heat shield 1 101
Standard parts and threaded connections not mentioned in table above
M6 9-11
M8 20-25
M10 30-50
M12 60-80


92
Section II Engine Lubrication System
I. Precautions
Application Steps of Sealant:
1. Remove any old sealant on the seal gasket by using scraper.

Attention:
Thoroughly remove old sealant from grooves, fixed bolts and bolt holes on sealant application
surface.
2. Wipe sealant surface and matching surface clean with special cleaner, remove water drops, grease
and foreign substances.
3. Set the sealant with specified type completely on appointed position.
1) Install the matching parts in a certain period of time after sealant applied.
2) If there is any dirt on sealant, remove immediately.
3) Do not retighten the bolt and nut after installation.
4) Fill oil and coolant 30min after installation.
Fig. 1.2.001
Scraper


93
II. Preparation
1. Repair Tools
List of repair tools
No. Tool Outline Drawing Explanation
1 Oil pressure gauge

Measure oil pressure
2 Hose

Connect oil pressure
gauge to cylinder
body
3
Oil pressure switch
socket

Dismount and mount
oil pressure switch


94
III. Engine Oil
1. Check
1) 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.
Pull out the oil gauge and clean it .
Insert the gauge; confirm that the oil level in
engine is between the two marks as shown.
Please adjust the oil level if it is out of range.
2) Appearance of engine oil
Check the engine oil for any white turbidity
and/or severe pollution.

If the oil is turbid or polluted, it may be caused by engine coolant. Please repair or replace the
damaged parts.
3) Leakage of engine oil
Check the following areas for oil leakage.
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
4) Inspect oil pressure
Attention:
As the temperature of engine oil is high, please prevent yourself from being hurt.
Check oil pressure after vehicle parked.
Fig. 1.2.002


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Check oil level. Please refer to Engine oil
level.
Lift the vehicle, disconnect harness connector
at oil pressure switch and remove the oil
pressure switch.

Install oil pressure gauge and hose.

Start engine and warm up to normal working temperature.
Inspect oil pressure when engine operates with no load.
Note: The engine pressure will increase when the temperature of engine oil is low.
If there is obvious difference, please inspect oil circuit and oil pump for leakage.
Install the pressure switch in accordance with the following steps after inspection:
a. Remove any used sealant attached on pressure switch and engine.
b. Apply sealant as specified and tighten the pressure switch.
Please use the specified sealant: LT5699 or equivalent.
c. 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.
Avoid direct contact of your skin with waste oil for a long time. If contact has taken place, wash
thoroughly with soap or detergent as soon as possible.
Warmup the engine to check engine compartment for oil leakage. Please refer to Leakage of
engine oil.
Stop the engine and wait for 10min.
Fig. 1.2.004
Fig. 1.2.003


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Loosen engine oil filler cap and remove the oil drain bolt.
Discharge the engine oil.
Install the oil drain bolt with new washer.
Attention:
Be sure to clean oil drain bolt and install with new gasket.
Tightening torque of oil drain bolt: 34-44Nm
Fill new oil.
Please refer to Maintenance for specification and viscosity of oil.
Oil volume: 3.8L
Attention:
Do not pull out oil gauge when filling oil.
The oil filling volume varies with oil temperature and oil drainage time, thus the above data
are only for reference.
Always use oil gauge to check oil filling volume.
Warm up engine and check the oil drain bolt and oil filter for oil leakage.
Stop engine and wait for 10min.
Check the oil level. Please refer to Engine Oil Level.
IV. Oil Filter
1) 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.
Do not make the engine oil stick on drive belt.
Thoroughly wipe and dry the engine oil splashed on the engine and vehicle.
Fig. 1.2.005


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2) Installation
Remove any foreign substances attached on
mounting surface of oil filter.
Apply a film of engine oil on oil seal surface
of new oil filter.
Tighten the oil filter until the O-ring seating
on the installation surface; tighten the oil filter
by more 0.75 lap or get the tightening torque
to 11 1N m.

Attention:
The oil filter must be tightened with filter spanner.
If the filter is tightened by hand, oil leakage may occur due to inadequate tightening torque.
1) Check oil level. Please refer to Engine Oil.
2) Start engine to check whether there is oil leakage.
3) Stop engine and wait for 10min.
4) Check oil level and fill as required. Please refer to Engine Oil.
Fig. 1.2.006


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V. Oil Pan and Engine Oil Pump
1. 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 O-ring 5 Engine oil collector filter gasket 6 Engine oil collector filter 7. Oil drainage bolt
washer 8. Oil drainage bolt 9 Engine oil filter 10 Oil sump assembly
2. Dismantlement
Caution:
Do not discharge engine oil when engine is hot so as to avoid being hurt.
1) Remove external mounted generator, power steering pump, cylinder head cover and other parts to
the oil pump assembly.
2) Discharge engine oil. Please refer to Change Engine oil.


99
3) Dismount oil pan.
a. First, use loosening agent for sealants in order
to prevent oil pan sealing surface from
deformation.
b. Loosen the fixed bolts according to following
sequence: center-both sides.
Tightening torque:7.60.6 Nm

c. Knock the special tool into the space between
oil pan and cylinder body as shown in Fig.
1.2.008.
d. Slightly knock the side of special tool, in
order to make the tool move along the sealing
surface of oil pan/cylinder body, and then
dismount the oil pan.
Attention:
Do not damage the matching surface.

4) Dismount oil pump housing assembly.
5) Dismount oil pickup.
Attention:
Tightening torque: 8.40.65 Nm

3. Check after Dismantlement
1) Oil pickup
Remove any attached foreign bodies of oil pickup.
2) Oil pump housing assembly
Check the oil hole of oil pump casing assembly for blockage, and clean it if necessary.
Check the oil pump casing assembly for crack or other damage. If there is any, please replace.
3. Installation
1) Install oil filter set.
2) Install pump housing assembly.
3) Install external generator, power steering pump, cylinder head cover and other parts on the oil pump
Fig. 1.2.007
Fig. 1.2.008
Fig. 1.2.009


100
assembly.
4) 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 1N m.
Attention:
The oil filter must be tightened with filter spanner. If the filter is tightened by hand, oil leakage
may occur due to inadequate tightening torque.
5) Install oil pan.
Clean cylinder block and oil pan mating surface to ensure that there are no oil and other impurities.
Apply sealant as shown in diagram below.

Specified sealant: LT5699 or equivalent.
Oil pan
Apply sealant
as shown in
figure.
Fig. 1.2.010


101
7) Install oil drainage bolt on oil pan
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.
Attention:
After the installation of oil pan, wait at least
30min before filling engine oil.

1) Check the oil level and fill as required. Please refer to Engine Oil.
2) Start engine and make sure there is no oil leakage.
3) Stop engine and wait for 10min.
4) Recheck the oil level. Please refer to Engine Oil.
Fig. 1.2.011


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Section III Cooling System of Engine
I. Cooling Circuit
1. Cooling Circuit Diagram

Cooling circuit diagram
2. Principle Diagram of Cooling

Basic diagram of cooling
Radiator
Expansion
tank
Thermostat
Thermostat
casing
Water pump
Cylinder
body
Cylinder
cover
Thermostat off
Thermostat on
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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
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II. Engine Coolant
1. Check
1) Level check
After the engine cooled, check whether coolant level in reservoir is between MIN and Max marks.
Adjust level if necessary.

2) Leakage check
Apply pressure to cooling system with leak
detector of radiator cap to detect any leakage.

3) Test pressure
Caution:
Please do not dismount radiator cap when engine is very hot, otherwise the high-pressure engine
coolant overflowing from radiator will cause severe burns.
Attention:
Test pressure over specified value may cause radiator damaged.
When it is detected that the engine coolant is insufficient, fill engine coolant into radiator. If any
parts are damaged, please repair or replace.
2. Change Coolant
Caution:
To avoid being burned, please do not change coolant when engine is hot.
Wrap up the radiator cap with thick cloth, and turn to open it carefully. Release the pressure in
radiator first, and then fully remove cap.
Fig. 1.3.001
Fig. 1.3.002


104
Be careful not to splash engine coolant onto the drive belt.
1) Discharge engine coolant
Dismount the deflector on right side of engine.
Open the water drain plug at the bottom of radiator, and then open the radiator cover.
If necessary, remove coolant reservoir to discharge coolant and clean the reservoir before
reinstallation.
Check the discharged engine coolant for rust or other impurities or discoloration.
If it is polluted, please wash the engine cooling system. Refer to Wash Cooling System.
2) Refill coolant
Install removed coolant reservoir and water drain plug of radiator.
Attention:
Be sure to clean the water drain plug and install with new O-ring.
Make sure all the hose clamps have been tightened firmly.
Dismount the air filter upper cover and air intake hose. Please refer to Air Filter Assembly.
Disconect the outlet pipe of warm water pipe. Please lift the hose as high as possible.
Fill coolant into radiator and reservior until specified level is achieved. The coolant should be filled
slowly allowing air in system can be bleed gradually.
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.
Install air filter upper cover and air intake hose. Please refer to Air Filter Assembly.
Install radiator cap.
Warm up engine until the thermostat is turned on.
Touch the lower water pipe of radiator to detect whether there is any warm water flows out, so as to
verify that the thermostat has been turned on.
Attention:
Check the engine water temperature indicator to avoid overheating of engine.
Stop engine to lower the engine temperature.
Cooling time can be reduced by using fan.
Fill coolant in radiator through the filler if necessary.


105
Fill engine coolant in reservoir to the MAX position.
Install the radiator cap and repeat steps - more than twice until the engine coolant level does
not lower any more.
Run the engine to check the cooling system for leakage.
3) Wash cooling system
Install the dismounted radiator water drainage plug and reservoir.
Attention:
Be sure to clean the water drainage plug and mount the new O-ring.
Dismount air filter upper cover and air intake hose. Please refer to Air Filter Assembly.
Remove outlet pipe of warm water pipe. Please lift the hose as high as possible.
Fill engine coolant into radiator and coolant reservoir, and install radiator cap.
Remove connection when engine coolant overflows from warm water pipe, and then reconnect and
continue to fill engine coolant.
Install the air filter upper cover and air intake hose. Please refer to Air Filter Assembly.
Run engine to warm it up to normal working temperature.
Increase engine speed for several times with no load applied to the engine.
Stop engine and wait for it to cool.
Discharge the water in system. Please refer to Discharge engine coolant.
Repeat steps - until the radiator begins to discharge the cleared water.
III. Radiator
Caution:
Please do not dismount radiator cover when engine is very hot, otherwise the high-pressure
engine coolant will cause severe burns. Wrap up the radiator cover with thick cloth and slowly
turn it to discharge the air pressure inside. Turn and open the radiator cover and take it off
carefully after the pressure is fully released.
1) Dismantlement
Dismount engine deflector. Please refer to Deflector.
Discharge engine coolant in radiator. Please refer to Replace Engine Coolant.
Attention:
Operate after engine is cooled.
Please do not make the engine coolant splash onto the drive belt.
Dismount air intake pipe and take it off.
Disconnect the harness connector of radiator fan motor and move it aside.


106
Dismount the inlet and outlet hoses of radiator and returning hose of coolant reservoir.
Dismount bracket of radiator and take off the radiator and fan subassembly.
Attention:
Please do not damage or scratch the radiator core during dismantlement.
Disassemble cooling fan sub-assembly from radiator.
2) Installation
Install in the reverse order with dismantlement.
3) Check after Installation
Check if there is any engine coolant leakage with leak detector for radiator cover. Please refer to
Leakage Check.
Start and warm up the engine. Visually inspect whether there is any coolant leakage.
2. Inspect Radiator Cap
1) Pull out the negative pressure valve and open it. Check if it can be fully closed after pressure
release.
Make sure there is no dirt on or damage to negative pressure valve seat of radiator cover.
Make sure the opening and closing operations
of negative pressure valve are normal.

2) Inspect relief pressure of radiator cap.
Standard value: 78-98KPa
Limit: 59KPa
Connect the radiator cap to the leak detector for
radiator and apply engine coolant to sealing face
of the cover.
Replace radiator cap if operation of negative
pressure valve is abnormal or the relief pressure
decreases below limit.

3. Inspect Radiator
Check the radiator for slurry or blockage. If necessary, wash the radiator surface with following
methods.
Be careful not to bend or damage the radiating fin.
Fig. 1.3.003
Fig. 1.3.004


107
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.
1) Wash back of radiator core from top to bottom with the water hose pointing to the radiator
vertically.
2) Wash each surface of radiator core every 1min.
3) If no dirt is washed off radiator, washing must be stopped.
4) Vertically blow the back radiator downwards with compressed air. Apply the compressed air with
pressure lower than 490KPa and keep the distance above 30cm.
5) Blow each surface of radiator core with compressed air every 1min until no water is blown out.
IV. Radiator Cooling Fan
1) Dismantlement
Dismount the air intake pipe and take it off.
Disconnect the harness connector of radiator fan motor and move it aside.
Dismount the radiator cooling fan sub-assembly.
Attention:
Do not damage or scratch radiator core during dismantlement.
2) Installation
1) Disassembly
Dismount the cooling fan from fan motor.
Dismount the fan motor from wind collection cover.
2) Check after disassembly
Cooling fan
Check the cooling fan for cracks or abnormal bend. If any, replace the cooling fan.
Fan motor
Check the motor for sticking.
3) Assembly
Assemble in the reverse order with disassembly.
V. Water Pump


108
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.
After the installation of water pump, connect the hose, fix it with clamping band, and then check
if there is any leakage with leak detector for radiator cover.
1) Dismantlement
Discharge the engine coolant in radiator.
Please refer to Replace Engine Coolant.
Loosen the fixed bolt for belt pulley of water
pump.

Dismount the drive belt. Please refer to
Drive Belt.
Dismount the fixed bolt for water pump.
Attention:
Tightening torque: 8.40.65Nm

Check the water pump body assembly for severe corrosion, leakage of water-seal and erosion.
Check the water pump bearing for jamming or other damages. Replace the bearing if necessary.
3) Installation
Clean water pump installation seat.
Installation of pumps and replacement of the pump seals.
Attention:
Do not let the seal ring drop during installation.
Alternately and evenly tighten fixing bolts of water pump.
Fig. 1.3.005
Fig. 1.3.006


109
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.
Check if there is any coolant leakage with leak detector for radiator cap. Please refer to Leakage
Check.
Start and warm up the engine. Visually inspect if there is any engine coolant leakage.
VI. Thermostat Sub-assembly
1) Dismantlement
Discharge the engine coolant through water drain
plug of radiator. See Replace Engine Coolant.
Attention:
Operate after the engine has cooled.
Please do not splash the engine coolant onto
the drive belt.

Disassemble water inlet pipe and heater returning
pipe of radiator at thermostat side.
Disconnect the harness connectors of coolant
temperature sensor and water temperature alarm
switch and fixed bolts for support racks of harness
connectors of front and rear oxygen sensors, and
then remove them.

Unscrew water pump inlet bolt, remove the
thermostat.

Fig. 1.3.008
Fig. 1.3.009
Fig. 1.3.007


110
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.
Water pump inlet and thermostat housing
Check them for cracks and other damages.
3) Installation
Be careful not to splash engine coolant onto the engine and wipe and dry the engine coolant with
cleaning cloth.
Replace the thermostat seal ring.
Attention:
Do not apply engine oil or other oil substances to the seal ring.
Water pipes on thermostat housing must be installed solidly.
When mounting thermostat, its poppet valve
must be set at the highest position.

If the water temperature alarm switch needs
to be reused, apply specified sealant to its
thread.

Fig. 1.3.010
Fig. 1.3.011
Fig. 1.3.012
Highest


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If the engine coolant temperature sensor
needs to be reused, apply specified sealant to
its thread.
Check for any coolant leakage with leak
detector of radiator cap. Please refer to
Leakage Check.

Start and warm up the engine. Visually inspect if there is any engine coolant leakage.
VII. Water Piping Sub-assembly
1. Dismantlement
Discharge the engine coolant through water drainage plug at the bottom of radiator. Please refer to
Replace Engine Coolant.
Attention:
Operate after the engine has cooled.
Dismount the air filter assembly. Please refer to Air Filter Assembly.
Dismount the upper and lower water hoses of radiator.
Dismount the warm water hose and minor cycle water piping.
Unscrew water inlet pipe bolt before disassembling the water inlet pipe from back of water pump.
Attention:
Please dismount the negative terminal of battery before dismantlement.
2. Installation
Be aware of following precautions and install with steps contrary to dismantlement.
1) Firmly insert each hose. Mount the clamp properly so that it will not clamp the raised position of
water piping.
2) Replace the steel water returning pipe gasket of heater.
Attention:
Do not apply engine oil or other oil substances to the seal ring.
Water pipes on thermostat housing must be installed solidly.
1) Check if there is any engine coolant leakage with leak detector for radiator cap. Please refer to
Leakage Check.
2) Start and warm up the engine. Visually inspect if there is any engine coolant.
Fig. 1.3.013


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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
paper scraps
Radiator is damaged
Mechanical damage
Improper heat radiation
The radiator cooling is
blocked
Excessive foreign
substances (corrosion,
pollutants, sand, etc.)

The cooling fan fails to
work
The resistance for fan
rotation is too large
Insufficient air flow
The fan blade is
damaged
Fan assembly
Damaged wind collection
cover

Incorrect blend ratio of
coolant

Poor quality of engine
coolant
Viscous engine coolant
Loose clamp
Coolant hose
Broken hose
Water pump Improper sealing
Looseness
Poor sealing
Broken radiator coolant
reservoir
Radiator cap
Broken radiator core
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Insufficient engine coolant Engine coolant leaks
Coolant reservoir
Breakage of stock solution
tank
Excessively high engine
speed in the case of no-load
Long-term traveling
The engine is overloaded Abnormal driving
Driving at ultra high-speed
Drive train failure

Wheel and tyre with
incorrect specifications
mounted
Braking drag

Incorrect ignition timing

The vent of bumper is
blocked

Cover mounted
The radiator grill is
blocked
Blockage of slurry or paper
scraps
The radiator is blocked
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The condenser is
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Poor ventilation


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IX. Parameters for Maintenance
Technical specification for cooling system
Temperature of thermostat opening 82 (Initiall y open) 95 (Fully open)
Maximum lift of thermostat valve stem >8mm


114
Section IV Fuel Supply System of Engine
I. General Precautions
Caution:
The following rules should be complied with during the replacement of parts of fuel pipeline.
Set the mark Attention: combustive in workshop.
Be sure to operate in the well-ventilated area, and prepare C02 fire extinguisher in the operation
workshop.
Do not smoke during the fuel system servicing. No fire in working area.
Hold the discharged fuel in the container and cover it. Put the container in safe area.
When disassembling the fuel pipe components, note the following:
Disconnect negative pole of battery.
Replace with new clips all the time.
Do not distort the fuel pipe during installation.
Please operate on level ground.
Connect the fuel pipe joint and make sure the joint has been fixed. Make sure the joint and resin
pipe dont contact any adjacent parts.
Do not excessively tighten the hose clips to prevent damage of hose.
Check each connection for fuel leakage according to following steps after installation of fuel pipe.
- Set the ignition switch at ON position to apply fuel pressure on fuel pipeline (do not start the
engine). Then check each connection for fuel leakage.
- 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.


115
II. Preparation
The special tools are listed in the table below:
List of Special Tools
S.N. Tool Outline Diagram No. Explanation
1
Fuel pressure
gauge

JACT1F018 Measure fuel pressure
III. Fuel System
1. Check Fuel Pipe
Check the fuel pipeline, fuel filler cap and fuel tank for proper installation, leakage, crack, damage,
loose connection, worn and aging.
2. Inspect Fuel Pressure
Attention:
Always keep the joints of fuel hose sealed with O-ring.
Do not operate electrical system during inspection.
Prepare a container under the fuel pipe to be disconnect to avoid fuel splash.
1) Fully release fuel pressure. Please refer to Release Fuel Pressure.
2) Dismount the nut for fuel pressure inspection door on fuel injector guide rail.
3) Connect fuel pressure gauge.
4) Set ignition switch at ON position and check for fuel leakage.
5) Start engine and check if there is fuel leakage.
6) Obtain the reading shown in fuel pressure gauge.
Fuel pressure: 350KPa
Attention:
Do not check fuel pressure during system operation.
During the Inspection of fuel pressure, please always check the fuel piping for leakage.
7) If the check result is not good, turn to the next step.


116
8) 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
1. Dismantlement
Caution:
Do read the General Precautions before dealing with fuel system. Please refer to General
Precautions.
1) Disconnect the PCV hose joint at intake
manifold side.

2) Disconnect the injector wiring harness
connector

3) Disconnect the joint of fuel hose on fuel
guide rail.

Fig. 1.4.001

Fig. 1.4.002

Fig. 1.4.003


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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.
Do not expose the parts to the electrolyte of battery or other fluid.
Keep the connection clean and prevent damage and foreign substance, and properly cover the
connection with plastic bag or equivalent.
4) Dismount the fixing bolt for fuel guide rail.

5) Take off the fuel guide rail with injector from intake manifold.
Attention:
Avoid interference with fuel injector during removal.
Absorb the fuel leaked from fuel pipe with cleaning cloth.
6) Dismount the fuel injector from fuel guide rail with following steps:
a. Pry and dismount the snap-in.
b. Straightly pull out the fuel injector from fuel pipe.
Attention:
Pay attention to the leakage of residual fuel in fuel pipe.
Do not damage the nozzle of fuel injector.
Do not make it fall off or knock it.
Do not disassemble it.
1) Fuel Injector
Check the upper and lower seal rings of fuel injector for crack, aging and breakage. If any, please
replace.
Fig. 1.4.004


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Check the injection hole of fuel injector for blockage. If any, please wash or replace by using
special instrument.
2) 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.
3. Installation
1) Be aware of following precautions when mounting new O-ring on fuel injector.
As the upper and lower O-rings are different, do not confound them.
Fuel pipe side: thick one
Nozzle side: thin one
Please mount the O-ring by your hands.
Lubricate the O-ring with petrol.
Do not wash O-ring with solvent.
Verify that there is no foreign substance on O-ring and its matching part.
Make sure the O-ring will not be scraped by tool or fingernail, and it is not distorted or stretched
during installation.
Insert new O-ring into fuel injector straightly.
Do not deflect or distort it.
2) Mount fuel injector on fuel pipe with
following steps.
: thick one
: thin one
a. Insert the snap into the fixing groove on
fuel injector. Insert the snap slice D into
raised position F of fuel injector.

Attention:
Replace with the new snap every time.
Make sure there is no interference between the snap and O-ring.
b. Insert fuel injector into fuel pipe where snap has been mounted.
Attention:
Make sure the direction of insertion aligns with the axis.
Fig. 1.4.005


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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.
c. Make sure the fuel injector will not move or fall off. Installation is completed.
3) 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.
4) For the following steps, install with steps contrary to dismantlement.
Check for fuel leakage with following steps.
1) Set the ignition switch at ON position (when the engine stops), and then check the connection of
fuel pipe for leakage.
2) Start the engine, increase its speed and recheck the connection of fuel pipe for leakage.
V. Fuel Filter
1. Dismantlement
Caution:
Do read the General Precautions before dealing with fuel system. Please refer to General
Precautions.
Attention:
The fuel filter should be periodically replaced in accordance with the maintenance instruction
specified in Users Manual.
1) Open the fuel filler cap.
2) Release the pressure in fuel tank.
3) Dismount the rear seat cushion. Please refer
to Rear Seat.
4) Dismount the service lid for fuel tank.
Directly prize it up with flat end screwdriver.

Fig. 1.4.006


120
5) Disconnect the fuel pipe joint 1 (at fuel pump
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.
Disconnect joint with following methods:

Hold the side edge of joint and press the
raised position of joint to pull out the fuel
pipe.
If the joint attaches to the resin pipe, push and
pull the joint for several times until it moves,
and then pull out the joint.
Attention:
The joint can not be disconnected when the
raised position is fully pressed down. Do not
excessively distort the joint.

Do not disconnect the joint with any tool.
Prevent the resin pipe from being heated. Special attention must be paid when welding around
the resin pipe.
Prevent the resin pipe from contacting acidic fluid such as electrolyte of battery.
Do not bend or distort the resin pipe during installation and dismantlement.
To keep the connection clean and prevent from damage and foreign substance, please fully cover
them with plastic bag or equivalent.
6) Take off the fuel filter and fuel pipe.

2. Installation
3
2
Fig. 1.4.008
1
Fig. 1.4.007
Fig. 1.4.009


121
1) Fuel filter
Be aware of correct installation direction of
fuel filter.
towards fuel inlet pipe side

2) Connector
Connect the connector of fuel supply hose according to following methods:
Check the connection for foreign substance or damage.
Make the connector align with the resin pipe and insert the connector straightly until click is
heard.
Check whether the connector is connected properly with following methods after connection.
Visually inspect that 2 raised positions have been connected to the connectors.
Stretch the resin pipe and its connector hard
to verify that they have been firmly
connected.

Check whether there is fuel leakage with following steps.
1) Set ignition switch at ON position (when engine stopped), and then check the connection of fuel
pipe for leakage.
2) Start engine, increase its speed and recheck the connection of fuel pipe for leakage.
Fig. 1.4.010
Fig. 1.4.011


122
VI. Fuel Pump Assembly

Figure of fuel pump assembly
1. Dismantlement
Caution:
Do read the General Precautions before dealing with fuel system. See General
Precautions.
1) 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.
Attention:
If fuel level exceeds mounting surface of fuel level sensor, the fuel may overflow during the
dismantlement of fuel level sensor.
2) Open the fuel filler cap.
3) Release the pressure in fuel tank.
4) Dismount the rear seat cushion. Please refer to
Rear Seat.
5) Dismount the service lid for fuel tank.
Directly prize it up with flat end screwdriver.

Fig. 1.4.012


123
6) Disconnect the harness connector of fuel
pump and fuel pipe joint.
Fuel pipe joint of fuel pump
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.
If the joint sticks on the resin pipe, push and pull the joint for several times until it moves, and then
pull out the joint.
Attention:
The joint can not be disconnected until the raised position is fully pressed down. Do not
excessively distort the joint.
Do not disconnect the joint with any tool.
Prevent the resin pipe from being heated. Special attention must be paid when welding around
the resin pipe.
Prevent the resin pipe from contacting with acidic fluid such as electrolyte of battery.
Do not bend or distort the resin pipe during installation and dismantlement.
To keep the connection clean and prevent damage and foreign substance, please fully cover them
with plastic bag or equivalent.
7) Loose and take off the locknut with special
tool.

Fig. 1.4.014
1
2
Fig. 1.4.013


124
8) 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
straightly.

9) Take off the fuel pump.

1) Fuel pump
Visual Inspection
Check for broken or fuel impurity. If any, please replace or wash it.
Inspect Fuel Pump Operation
Actuate the fuel pump with 12V regulated power supply directly and check if the operation is
normal.
Attention:
Do not make the fuel pump operation for a long time, so as to avoid damage of pump plunger.
2) Y-ring
Check it for material loss and broken.
3) Locknut
Check for deformation, crack, material loss, broken, and damage at mounting thread.
4) Fuel Level Sensor
Check the fuel float for interference and oxidation of its surface.
3. Installation
1) Fuel pump assembly
Fig. 1.4.016
Fig. 1.4.015


125
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.
Pre-tighten the locknut during its installation, and then tighten it horizontally.
2) Connector
Insert the connector of fuel supply hose with following methods:
Check the connection for any foreign substance and damage.
Make the connector align with the resin pipe and insert the connector straightly until click is
heard.
Check whether the connector is properly connected with following methods after connected.
Visually check whether the 2 raised positions have been connected to the connectors.
Stretch the resin pipe and its connector hard and make sure they have been firmly connected.
Check for fuel leakage with following steps.
1) Set ignition switch at ON position (when engine stops), and then check the connection of fuel
pipe for leakage.
2) Start the engine, increase its speed and recheck the connection of fuel pipe for leakage.


126
VII. Fuel Tank Assembly

Breakdown diagram of fuel tank assembly
1-Filler cap 2-Filler tube 3-Fuel tank 4-Fastening band of fuel tank 5-Service lid 6-Locknut
7-Y-ring 8-Fuel pump 9-Fuel filter 10-Thermal baffle
1 Dismantlement
Caution:
Do read the General Precautions before dealing with fuel system. See General Precautions.
Discharge fuel tank if necessary. Please refer to Fuel Pump.
Please operate on level ground.
Carry out the dismantlement steps 1-6 of fuel pump. Please refer to Fuel Pump.
Disconnect fuel supply hose and vent hose.
Disconnect EVAP hose.
Support the fuel tank with special jack.
Attention:
The fastening band of fuel tank should not be blocked in supporting position.
Dismount the clamping bands of filler tube and fuel tank, and then disconnect the filler tube and
fuel tank.
Dismount fastening band of fuel tank.


127
Manually support the tank and carefully
lower the jack to dismount fuel tank.
Attention:
Make sure all connections have been
disconnected.
Make sure there is no interference with
vehicle.
2) Check after dismantlement
Fuel tank

Check for impurity of fuel. If any, clean it with hot water.
Capacity of fuel tank: 45L
EVAP hose and clips
Check the hose for blockage, corrugation, deformation and breakage.
Check the clips for damage or breakage.
Reinforced plate and its backing plate
Check the surface of reinforced plate for scratch and deformation.
Check the backing plate for crack, material loss, deformation and breakage.
3) Installation
Firmly hold fuel supply hose to insert it.
Do not set the hose clamp in expansion area of fuel pipe.
Please refer to Fuel Pipe Joint for precautions of fuel pipe joint connection.
Check for leakage with following steps.
Set ignition switch at ON position (when engine stops), and then check the connection of fuel
pipeline for leakage.
Start the engine, increase its speed and recheck the connection between piping and fuel pipe of fuel
system for leakage.
Fig. 1.4.017


128
Section V Emission Control System of Engine
I. Fuel Evaporation Control System
1. Description

Schematic diagram of fuel evaporation system
The fuel evaporation system is used to reduce hydrocarbon compositions emitted into ambient air from
fuel system. Reduction of hydrocarbon is achieved by using active carbon in EVAP carbon canister.
When the engine is stopped or fuel is filled, the fuel evaporation from sealed fuel tank will be
introduced into EVAP carbon canister with active carbon and stored there. During operation of engine,
the fuel evaporation in EVAP carbon canister will be introduced into intake manifold through clean
passage. EVAP carbon canister is controlled by ECM. With engine running, evaporation flow controlled
by EVAP canister solenoid is adjusted with direct proportion of increased air flow. During deceleration
and idling, the evaporation passage may be cut off by EVAP carbon canister solenoid.
Air cleaner
Intake manifold
EVAP carbon canister
solenoid valve
Fuel tank
EVAP carbon
canister
Fuel evaporation
Air


129
2. 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:
Do not use soap water or any other detergent when
installing vacuum pipe or cleaning pipeline.
3. Inspection of parts
1) EVAP carbon canister
Check EVAP carbon canister with following
methods:
a. Plug port 1, blow at port 3, make sure the air
flows out from port 2 freely.
b. Plug port 3, blow at port 1, make sure the air
flows out from port 2 freely.
Dismount the vacuum hose

Loose the clamps between carbon canister and fuel tank and carbon canister solenoid valve with
slip-joint pliers, pull out the vacuum hose.
1
2
3
Fig. 1.5.001
1
2
3
4
5
6


130
Dismount the carbon canister
Lift the carbon canister and dismount it from the
bracket on inner lining of left fender.

2) 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. The solenoid valve will repeat the operations of ON and OFF with signal from ECM
to actuate the variation of valve opening, so as to optimize engine control. The optimum value
memorized in ECM lies on the state of engine. When the engine operates, flow rate of fuel evaporation
from EVAP carbon canister is adjusted along with the variation of air flow.
Instruction of parts
Flow rate of fuel evaporation from EVAP carbon canister is controlled by duty cycle of ON/OFF of the
solenoid valve. The solenoid valve is actuated by ON/OFF duty cycle signal from ECM. The wider the
pulse width in ON condition is, the more fuel evaporation will flow through the valve.
Dismantlement
a. Disconnect the vacuum hose of EVAP carbon
canister solenoid valve.

Fig. 1.5.003
Fig. 1.5.002
Left front frame


131

b. Disconnect the harness connector of EVAP
carbon canister solenoid valve.

c. Remove the EVAP carbon canister
electromagnetic valve.

3) 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.
When the pressure in fuel tank is low (negative pressure), the vacuum relief valve will be opened, so as
to enable the outside air to get into fuel tank.
Fig. 1.5.004
Fig. 1.5.005


132
II. Forced Ventilating System of Crankcase
1. 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. With throttle partially opening, the intake manifold sucks blow-by gas of crankcase
through PCV valve. In normal conditions, the ventilation volume of PCV valve is sufficient to suck all
blow-by gas of crankcase and a little air. The vent air is brought into crankshaft through air intake pipe.
Ventilation hose inhales fresh air from the rear end of the air filter to the crankcase to keep the crankcase
pressure at a certain range. When the air throttle is fully open, the vacuum degree is not sufficient to
open PCV valve and thus unable to suck blow-by gas of crankcase. The air flows through connecting
hose in reversed direction. In vehicles with severe blow-by gas, PCV valve can not meet the
requirements because part of air may get into the air intake pipe at any time during operation.


133
2. Inspection of Element
Check the PCV (forced ventilation of crankcase) valve as shown below:
1) Operation principle
Operation principle list of PAV valve

Valve chamber cover side

Operating state of engine Out of work Operating state of engine Idling or deceleration
PCV valve Out of work PCV valve Fully open
Variation of vacuum Limited Variation of vacuum Slight


Operating state of engine Normal operation Operating state of engine
Improper acceleration and
high speed
PCV valve Normal operation PCV valve Retardant operation
Variation of vacuum Large Variation of vacuum Extremely large
No vacuum
High vacuum
Moderate
No


134
2) Dismantlement and Installation
Dismantlement
a. Disconnect the PCV valve hose from cylinder
cover.

b. Remove the PCV valve from cylinder
cover.

PCV valve: Hissing may be produced during
normal working of valve with air flows
through. When finger touches the valve at the
entrance, you can immediately feel a strong
vacuum pressure.

Vent hose of PCV valve
a. Check the hose and joint for leakage.
b. Disconnect all hoses and clean with compressed air. If the blockage in hose can not be cleared,
replace.

Fig. 1.5.006
Fig. 1.5.007
Fig. 1.5.008
P.C.V valve

Maintenance Manual for J2 Sedan Electrical Part of Engine

135
Chapter II Electrical Part of Engine
Section I Ignition System
I. Ignition coil
1. Parts

Ignition coil
2. Dismantlement & Installation
1) Dismantlement
Attention:
Be sure that the ignition switch is in the
OFF position.
Dismount the trimming cover of engine.
Refer to Intake Manifold section.
Disconnect the wiring harness connectors of
the ignition coil from high voltage ignition
coil.

Fig. 3.1.001


136
Remove high-voltage ignition coil bolt to
remove coil.

Dismount the spark plug with special socket.
Attention:
Please do not drop or shake it.
High-voltage ignition coil
Check the primary coil resistance between both terminals.
Primary coil resistance: 0.77-0.95
Check the resistance of secondary coil
Secondary coil resistance: 7.75-10.23 K
Attention:
The ignition coil harness connector must be disconnected for secondary coil resistance
measurement.
Spark plug
Check the spark plug:
Check insulator of spark plug for damage and broken.
Check spark plug for carbon deposit. See the following table for causes of carbon deposit.
Causes of Carbon Deposit
Phenomenon Black charcoal Hard charcoal
Reason Impurity in the fuel or high fuel-air
ratio.
Impurities in the fuel; wrong
ignition timing, or untight spark
plug.
Check spark plug electrodes for damage.
Inspect clearance of spark plug.
Fig. 3.1.002


137
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.
a. Connect spark plug to high voltage circuit.
b. Keep the distance between edge of spark plug and the grounding metal at about 14 mm.
c. Start the engine for about 3s, check whether there are sparks produced between the edge of spark
plug and the grounding metal.
Attention:
During check, be careful not to get an electric shock.
If the clearance is less than 14 mm, the sparks may also be produced even though the high
voltage wire has trouble.
If there are no sparks, replace spark plug.
3) Installation
II. Diagnosis of Common Troubles
Diagnosis Common Troubles
Symptom Possible causes Solution
Trouble of ignition coil or ignition
switch
Check or replace the ignition coil or the
ignition switch
Trouble of spark plug Check or replace spark plug
The engine cant or is
difficult to start.
Disconnected high voltage wire Check the high voltage wire
Trouble of high voltage wire or spark
plug
Check the high voltage wire or check or
Replace spark plug
Unstable idle speed
Trouble of ignition coil Check or replace the ignition coil
Trouble of high voltage wire. Check the high voltage wire Engine surge or poor
acceleration Trouble of spark plug Check or replace spark plug
Poor. fuel economy Trouble of spark plug Check or replace spark plug
III. Parameters for Maintenance
Maintenance Specification of Ignition System
Primary coil resistance 0.77-0.95 High voltage
Ignition coil Secondary coil resistance 8.70.87 K
Spark plug Spark plug clearance 0.7-0.8mm


138
Section II Starting and Charging System
I. Principle Diagram of Starting and Charging System
ENG
+ -
Df
R1 R3
R2
R4
ZD
Tr2
Tr1
120A
30A
LOCK
ACC ACC
ON
O/S
START
ETACS-
20A
B
L S
E

Principle Diagram of Starting and Charging System
II. Battery
1. How to use battery
Attention:
If the engine is necessary to be started with auxiliary battery and jumper wire, 12 V auxiliary
battery should be used.
When jumper wires are connected with battery, make sure that the jumper wires are clamped
to the terminals of battery and have good contact.
2. Methods to prevent excessive discharging of battery
The following precautions should be particularly emphasized to prevent excessive discharging of
battery.
Always keep surface of battery (esp. the top) clean and dry.
The connecting part of the terminals should be clean and tightened.
ETACSlow level effective
Anti-theft relay
Ignition switch
Central electric
box
Electric
generator
30 A fuse link
B
a
t
t
e
r
y

120 A
fuse
link
Combined
device
Magnetic
field
winding
Stator winding
Starter
Rectifier
Solenoid
switch
Charging
alarmlight
One-way clutch
Electric
motor
20 A fuse link
Starting relay
Grounding


139
If the vehicle is not used for a long time, the cathode terminal of battery should be disconnected.
Check charging condition of battery.
3. Check
1) Visual inspect
Check terminals of battery for damage and electrolyte leakage. If any, replace.
2) Voltage inspection: Inspect batter for proper voltage. (The following parameters is for reference
only)
If U>13.2V, inspect the electrical system.
If 12.5V<U<12.9V, the system is normal.
If 11V<U<12.4V, inspect charging system.
If U<11V, the battery is damaged or the charging system has trouble. Please inspect charging
system and battery.
4. Dismantlement and installation
1) Dismantlement
The ignition switch should be turned to the
OFF position.
Disconnect the negative terminal.

Dismount the positive terminal of battery and
the fixed bolts of battery pressure plate, and
then take off the pressure plate.
Take off the battery.
Take off the bracket of battery.

Fig. 3.2.002
Fig.3.2.001


140
Bracket of battery
Check for erosion. If there is, clean with warm clean water.
Battery harness
Check for erosion and damage. Replace if there is any.
3) Installation
Attention:
During connection, the anode terminal of battery should be connected first.
After installation, terminals may be smeared with mineral oil.


141
III. Starting System
1. 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.

Components of Starter
1) Dismantlement
Disconnect the negative terminal of battery.
Note: Before disconnecting the cathode terminal
of battery, pull off the starter key first.

Fig. 3.2.003
Fig. 3.2.004


142

Disconnect the harness connector of starter.
Dismount the fixing bolts of starter, then take
off the starter.

2) Installation
Attention:
Be sure to tighten the nut of B port.
Fig. 3.2.005


143
3. 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
16-Fixing bolt
11
15
14
13
12
2
3
5
6
7

4
1
10
9 8
16


144
2) Check
Solenoid switch
Before check, disconnect negative terminal of battery.
Disconnect the M port of starter.
a. Test electrical connectivity between S port
and switch body.
Replace solenoid switch if opened.

b. Test electrical connectivity between S port
and M port.
Replace solenoid switch if opened.

Pinion
a. Visual inspection of the meshing gear teeth
If the teeth are worn or damaged, replace meshing gear (check teeth of fly wheel in this step).
b. Check the teeth of pinion
If the teeth are worn or damaged, replace pinion (check teeth of rotor shaft gear in this step).
c. Check whether the pinion locks in one direction while turns smoothly in the other direction.
If it is able to lock or turnable in both directions, or if there is abnormal resistance, replace.
Fig. 3.2.006
Fig. 3.2.007
Connecting from
the power
supply
M
M end
Connecting from
the power supply


145

Electric brush
Check brush wearing with a caliper. if
excessive worn, replace.

Electric brush spring
Depatch spring from the brush and use a
spring tension gauge to check tension

Electric brush retainer
a. Test insulation voltage between brush retainer
(positive) and bearings (negative) with an
ohmmeter. If broken, replace electric brush
retainer.
b. Check for electric brush smoothly moving.
If electric brush bracket is bent, replace. If the
sliding surface is dirty, clean.

Inspection of Stator
Check whether magnet is firmly fixed on the
stator; check for crack.
If the parts have any trouble, replace the
assembly.
Attention:
Please do not clamp the stator with a table
vice, nor hammer it.

Fig. 3.2.008
Vernier caliper
Electric brush
Electric brush

Electric brush
spring
Fig. 3.2.009
Fig. 3.2.010
Fig. 3.2.011 Magnet


146
Inspection of Rotor
a. Check connectivity between adjacent fillets
with ohmmeter.
If open, replace.
b. Check conductivity between each copper
plate and shaft of commutator with
ohmmeter.
If open, replace.

c. Check surface of commutator.
If it is rough, use # 500 sandpaper to lightly
sand with method shown in figure.

d. Check diameter of commutator.
Check with a caliper; if it is less than the
specified value, replace.

Fig. 3.2.012
Fig. 3.2.013
Sand paper
Vernier
caliper
Commutator
Fig. 3.2.014


147
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.
Gear clearance adjustment
Push the pinion out with the magnetic switch
energized, meanwhile check the clearance
between the pinion and the thrust piece with a
feeler.

If the clearance is out of range, adjust by
using spacer.

Fig. 3.2.015
Fig. 3.2.016
Adjusting gasket
Stop block
Gear clearance
Pinion


148
4. 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

Starter fails to stop.
Replace the solenoid switch.
The engine fails to start.
Does engine run with
revolving of crankshaft?
Does the starter run?
Does engine run normally?

Inspect ignition/fuel system.
Yes
Yes
No
Inspect following items of
battery: 1. Charging condition
2. Connection of terminal 3.
Erosion of terminal.
No
A
Abnormal
Yes
Does the gear shaft run? Check pinion clutch.
Yes
Repair the starter.
Normal
No
Check the reduction gear, armature and the gear shaft.
No
Check the fuse and the fusible
wire.

Normal
Inspect following items of
battery: 1. Charging condition
2. Connection of terminal 3.
Erosion of terminal.
Abnormal
replace.
Abnormal
1. Charge battery.
2. Repair poor connection and
eroded terminal of battery.
A
Normal
Inspect circuitry of starting
system.
Normal
Does magnet switch make
noises during running?
Yes
Check the meshing condition
of pinion and gear ring.
Abnormal
1. Adjust the displacement of
pinion. 2. Inspect motion
mechanism of pinion. 3. Check
the gear ring.
Abnormal
Repair.
Repair the starter.
No
If wired as follows with no load, does
starter run?

Replace solenoid switch.
Yes
Repair the starter.
No


149
IV. Charging System
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.
The B port supplies electricity to vehicle electric system and charging power supply to battery. The IC
adjuster checks the input voltage at port 4 (S port) and thereby controls output voltage.
After the powered and grounded, the charging alarm light will be lit. When generator provides sufficient
voltage, the grounding circuit will be opened, while the charging alarm light will be turned off. If the
charging alarm light is still on with engine running, it has troubles.
2. Charging alarm light
If the following situations presents with generator working, the warming function of IC adjuster will be
actuated, and the charging alarm light will be turned on.
No voltage is produced or the voltage is high.
1) Dismantlement
Disconnect the negative pole of battery.

Disconnect harness connectors of generator.

Loosen the adjusting supporting nut on generator. Then adjust tension with the tension adjusting
bolt.
Tightening torque: generator adjustment nut: 22.5 2.5 Nm
Generator supporting nut: 475 N.m
Fig. 3.2.017
Fig. 3.2.018


150

Dismount the belt of generator. Please refer to the Drive Belt section.
Take off the generator from the vehicle.
2) Installation
Install with reversed order of dismantlement.
Before installing the generator, please inspect tension of generator belt. Please refer to the Drive
Belt.
Attention:
Tighten the nut of B port. Tightening torque: 10-12 Nm

Fig. 3.2.019
Fig. 3.2.020


151

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
9-Rear bearing 10-Stator 11- gasket 12- commutator 13-Electric brush retainer
14-Guide sleeve of slip ring 15-Rear cover


152
1) Disassembly
Disassemble in the following order.
Belt pulley
Rear cover
Commutator assembly
Separate front and rear cover assembly.
Attention:
Be careful to avoid damage of stator assembly.
2) Check after disassembly
Inspect of rotor
a. Resistance test
Resistance: Approximately 2.0-2.5
If it is beyond the standard range, replace.

b. Insulator test
If electrically continued, replace.
c. Inspect wearing condition of slip ring.
If it is beyond the standard range, replace.
Carbon brush
a. Check carbon bush for smooth moving.
If not, inspect carbon brush support and clean
as required.

b. Check wearing condition of carbon brush.
If Limit is exceeded, replace brush.
Fig. 3.2.021
Fig. 3.2.022
Slip ring
The mark line of wearing limit of
electric brush


153
Stator
a. Inspect continuity between terminals.
If not, replace.

b. Grounding test
If electrically continued, replace the stator.

3) Assembly
Rear bearing
Attention:
The rear bearing can not be reused after being taken off. Please with new one.
Lubrication of rear bearing out race is not permitted.
Installation of rear cover
a. Mount the carbon brushes assembly, adjuster
assembly and stator.

b. Push the carbon brushes with fingers to install them on the stator.
Attention:
Be careful to avoid damage of slip ring surface.

Fig. 3.2.025
Fig. 3.2.024
Fig. 3.2.023
Lead
Lead
Stator
core


154
5. 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.
Check the fusible wire before starting up.
Use a battery fully charged.
Inspection Flow Chart of Charging System

Attention:
If the charging system has trouble but the test results suggest normal, inspect connection of
B port (Inspect tightening torque and voltage drop).
Inspect conditions of rotor coil, rotor slip ring, electric brush and stator coil. Replace failure
parts as required.
The ignition
switch is on.
The alarm
light is off.

The alarm
light is off.

The alarm light is
on.

The engine starts
with a rev of 1500
rpm.
The alarm light is
on.
The alarm light is
off.
The alarm light is
on.
Perform following
inspection: 1. rotor 2.
Slip ring of rotor 3.
Electric brush.
Change
damaged IC
regulator.

Conduct the
following check:
1. Rotor
2. Slip ring of
rotor 3. Electric
brush
The engine
runs at idle
speed.
The alarm light
is off.
The alarm light is
on.
Normal.
The engine rev is
2500 rpm.
Measure the
voltage of B port.
More than 16.0 V.
Less than 13.0 V.

Change the
damaged IC
regulator.

Conduct the following
check: 1. Rotor 2. Slip ring
of rotor 3. Electric brush 4.
Stator.
Change the
damaged IC
regulator or
diode assembly.
Normal.
Conduct following
check: 1. Bulb of
alarm light 2. Fuse of
alarm light .
Disconnect the
connector, and
ground the L-side
harness.
Alarm light: the charging alarm light in the
combined instrument.

Electronic Control System
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155
Chapter III Electronic Control System of Engine
Section I Precautions

I. Precautions of Supplemental Restraint System (SRS)
Using the SRSs including airbag and pretensioner of safety belt together with the front seat safety belt
can contribute to reduction of the risk of injury and hazard severity of driver and front passenger in case
of crash. For information of proper maintenance of the system, please refer to Airbag part of this
manual.
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.
For dismantlement methods bell spring (hair spring) and airbag controller, please refer to the airbag
section.
Besides operations described in this manual, no electrically testing equipment should be used to test
any circuit of airbag system. The air bag circuit harness can be identified by the yellow or orange
harness or harness connectors.
II. General Precautions
1. Only digital electric meter should be used to inspect the electronic control system.
2. JAC genuine components should be used during maintenance, otherwise it is impossible to
guarantee the normal operation of system.
3. Only unleaded gasoline should be used for maintenance and operation.
4. Specified maintenance and diagnosis procedure should be followed to perform maintenance.
5. The disassembly and dismantlement for the system components are prohibited during maintenance.
6. During maintenance process, the electronic elements (electronic control modules and sensors)
should be fetched and placed very carefully to avoid the falling down.
7. Keep strong awareness of environmental protection to effectively deal with waste of the
maintenance process.
III. Precautions in Maintenance
1. Temperature of electronic control module should never be higher than 80 during hot working
conditions simulation of trouble and other maintenance operations possibly resulting in the
temperature rising.
2. The electronic controlled injection system operates with high fuel pressure (approximately 350kPa).

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156
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.
3. The dismantlement of fuel pipe and the replacement of fuel filter should be carried out by the
special personnel in well-ventilated area.
4. Power supply of electric fuel pump should be turn off before pump is removed from fuel tank in
order to avoid sparks that may cause fire. The fuel injection pump should not be test with dry state
or in water, otherwise its service life may be shortened. In addition, the positive and negative poles
of the fuel injection pump must not be reversed.
5. During inspection of ignition system, the sparking should be detected only when it is necessary and
the time should be as short as possible. The air throttle must not be opened during inspection;
otherwise copious unburned full may flow into the exhaust pipe, accordingly leading to the damage
of three-way catalyst.
6. The manual adjustment is unnecessary because the idling regulation is completed solely by the
electronic controlled injection system. The throttle limiting screw of throttle body has been adjusted
by the manufacturer in factory; the initial position must not be changed by users arbitrarily.
7. Terminals of battery must not be reversed, otherwise electronic components may be damaged.
Negative grounding is used in this system.
8. Battery cable should not be disconnected with engine running. Before welding on vehicle, cable on
negative and positive poles of battery, and all electronic components should be removed.
9. Do not test input and output signal of components by puncturing the insulator of wire.

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157
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..

Description of tool: ignition timing indicator
Function: inspect ignition timing

Fig. 4.1.001
Fig. 4.1.002

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158
Description of tool: digital universal meter
Function: measure characteristic parameters such as voltage, current and resistance of electronic
injection system

Description of tool: vacuum gauge
Function: inspect air pressure of intake manifold

Fig. 4.1.003
Fig. 4.1.004

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159
Description of tool: cylinder pressure gauge
Function: inspect pressure in each cylinder

Description of tool: fuel pressure gauge
Function: inspect pressure of fuel system, determine working states of fuel pump and fuel pressure
regulator.

Fig. 4.1.005
Fig. 4.1.006

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160
V 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.
Be sure to turn the ignition switch to OFF position and disconnect the cable of battery negative
poles before any repairing or inspection. The open circuit or short circuit of related switch, sensor
and solenoid valve may make the MIL lit.
After the operation, be sure to insert connectors and lock them firmly. Loose (unlocked) connectors
may result in the open circuit, accordingly making the MIL lit. (Make sure that there is no water,
grease and filth on the joint and port is not bent).
After the operation, be sure to route and fix the harness correctly. The interference between support
and harness etc. may result in short circuit, accordingly making the MIL lit.
After the operation, be sure to connect the rubber pipe properly. The failed connection of the rubber
pipe may cause lighting of MIL because of failure of the EVAP system and fuel injection system
etc.
Be sure to clear any uneffective DTC from ECM before transferring vehicle to user (the repair is
done).
Be sure to use the 12V battery as the power supply.
Never disconnect cable of battery with engine running.
Be sure to turn ignition to OFF position and disconnect cable of battery before connecting or
disconnecting any ECM harness connectors. Otherwise the ECM may be damaged, because even if
the ignition is turned to OFF position, the ECM still has 12V voltage.
Turn the ignition switch to OFF position and disconnect the connecting wire cable of storage
battery cathode before dismounting the any components.

Dont disassemble the ECM.
If one of the battery cable is disconnected, memory of ECM will return to the initial value. And the
ECM may start to control itself with initial value. When battery is disconnected, the engine will
operate a little differently, which doesnt mean any trouble. Dont replace any components because
of a little change.
Battery
Fig 4.1.007

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161
When connecting the ECM harness connectors, push the deflector rod (1) downward mostly to lock
securely.
When Inserting the contact pin into the ECM
or pulling it out, be aware to avoid damaging
contact pin port (bent or broken). When
connecting the contact pin, make sure that the
contact pin port of ECM is not bent or
broken.
Connect the harness connectors of ECM
firmly. Poor connection may cause extremely
high (fluctuation) voltage on the coil and
capacitor, accordingly resulting in damage of
IC.

The harness of the electronic control system of engine should be remained for a length of at least
10cm from the joint in order to avoid any trouble of the electronic control system of engine caused
by receiving the exterior noise signal and decreasing the operation of IC etc.
Keep the parts and harness of the electronic control system dry.
Inspect ECM with port and reference value to assure the normal function of ECM before replacing.
Even the very little leakage in the intake system may lead to the severe trouble.
Dont swing or vibrate the camshaft position sensor (phase) or the crankshaft position sensor
(position).
Perform DTC validation procedures or the whole function inspection after conduction of trouble
diagnosis. If repair is finished, DTC should not be seen in the validation procedures. Overall
function inspection should obtain a good result after repair completed.
When measuring the ECM with the circuit tester, never make two measuring devices contacted. If
the probes touch occasionally, the short circuit may be cause and the power transistor of ECM may
be damaged.
During measurement of input/output voltages, the grounding port must not be used. Otherwise the
transistor of ECM may be damaged. Ports other than the ECM may be used for gounding.
Fuel pump must not be used without fuel in pipes.
Fig 4.1.008
Broken
Bent

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162
Tighten clamp of fuel hose to specified torque.
Dont step on accelerator pedal when starting
the vehicle.
Dont increase the speed of engine
immediately after starting the vehicle.
Dont speed up before shutting down the
engine.

Fig 4.1.009

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163
Section II Structural Principle and Inspection of Engine Control System
I. 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. The basic structure is shown in the figure below:

Basic Structure of Engine Control System
In the engine electronic control system, the sensors are functioned as input parts to measure all kinds of
physical signals (temperature, pressure, etc.) and convert to corresponding electric signals, the ECU is
functioned to receive the input signals from sensors, calculate and process as per preset programs,
generate corresponding control signals, and output to power drive circuits, and the power drive circuits
execute different actions by driving corresponding actuators and control the engine to run as per preset
control strategy. At the same time, the malfunction diagnosis system of ECU monitors various
components and control functions in the system. Once a malfunction is detected and confirmed, the
system will save the malfunction code and activate the Limp home function. Upon the detection that
the malfunction is resolved, the system will resume to normal values.
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. This is the sole method to integrate flexibly all kinds of functions
into different variants of ECU depending on the engine and vehicle models. The structural diagram of
the electronic control system is shown as below:

Engine
Actuators
Sensors
Diagnosis
Diagnosis
Product
manufactured by
UAES
Electric fuel pump ansd
brakckt assembly
Diagnosis
interface
Stepping
motor
Speed
sensor
Throttle position
sensor
Three-way
catalytic
converter
Oxygen sensor
Ignition
coil
Phase
sensor
F
u
e
l

d
i
s
t
r
i
b
u
t
o
r

p
i
p
e

a
s
s
e
m
b
l
y

Fuel
pressure
regulator
Intake
pressure/
temperature
sensor
Fuel
filter
Fuel tank
Knock
sensor
Fuel injector
Water temperatrue
sensor
Carbon canister
control valve
Carbon canister
Throttle body assembly

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164
Illustration of Engine Control System
Note: This diagram is the control diagram, if the sensor location doesnt match with
physical parts, actual conditions should prevail.
II. Multiple-point Fuel Injection System
Multiple-point fuel injection (MPI) system comprises of the sensor detecting engine operation and the
electronic control module (ECM).
The system is controlled based on signals from these sensors; actuators operate under control of the
ECM. ECM functions include fuel injection control, idle control and ignition timing control etc. and
some trouble diagnosis means for simplifying the troubleshooting in case of trouble.
2. Input/Output Signal
List of Input/Output Signal
Sensor
Input Signal of
ECM
ECM Function Actuator
Hall sensor
Engine speed
Piston position

Intake quantity
Oxygen sensor
Oxygen
concentration in
exhaust
Throttle opening sensor Throttle opening
Knock sensor Knock of engine
Air conditioner switch
Air conditioner
pressure
Wheel speed sensor Vehicle speed
Coolant temperature sensor Coolant temperature
Control fuel
injection and
mixing
Fuel injector
3. Starting Control
Special measures should be used to control the air flow, fuel injection and ignition timing during starting.
At the beginning of starting, air in the intake manifold is still and the internal pressure of the intake
manifold is ambient air pressure. Throttle closed and the electronic throttle is designated as a fixed
parameter depends on temperature. In similar process, a specific "injection timing" is designated as the
initial injection pulse. Fuel injection amount varies according to engine temperature in order to promote
fuel film formation on intake manifold and cylinder walls; thus, when the engine reaches a certain speed,
mixture should be thicker. Once the engine starts to run, the system immediately begin to reduce the
mixture concentration At end of starting cycle, the starting enrichment function will be completely

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165
cancelled. In starting work conditions, spark advance are also adjusted and vary with the engine
temperatures, intake air temperatures and engine speeds.
4. 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; this process
continues until the temperature is proper. During this stage of running, the most important factor is the
quick heating of the three-way catalyst, for fast transition to the three-way catalyst functioning can
markedly reduce the emission. Under this operation condition, the heating three-way catalyst may be
performed by postpone the ignition advance angle properly to take advantage of the exhaust gas.
5. Acceleration/Deceleration and Back-tow Fuel Cut Control
Part of the fuel injected to the intake manifold will not reach the cylinder in time to participate
follow-up combustion stroke. Instead, it forms a film on intake manifold wall. With increasing of load
and injection duration extension, fuel stored in the film will build up dramatically. When the throttle
opening increases, part injected fuel will be absorbed by the film. Therefore, corresponding amount of
fuel must be added for compensation and to prevent the mixture from thinning during acceleration.
Once load factor is reduced, the additional fuel contained in the fuel film on intake manifold wall will be
re-released, and then it is necessary to reduce the injection duration accordingly during acceleration
course. Back-tow and towing operation condition refers to conditions that the power supplied by the
engine at the fly wheel is negative value. In this case, the engine friction and pumping gas loss can be
used to make vehicles slow down. In back-tow or towing operation condition, fuel injection is cut off in
order to reduce the fuel consumption and the emission, more importantly, the three-way catalyst can be
protected correspondingly. Once engine speed decreases to the specific fuel supply recovery speed
above idling, the fuel injection system will re-supply. In fact, ECM program has a rotation speed
recovery range which depends on the changes of such parameters as engine temperature, dynamic
change of engine speed, which can also prevent the engine speed from dropping to the specified
minimum through calculation. Once the fuel injection system re-supplies fuel, the supplemental fuel
will be supplied by using the initial injection pulse and the fuel film on the intake manifold wall will be
formed. After resumption of fuel injection, torque-based control system makes the increase of engine
torque slow and steady (smooth transition).
6. Idle Control
At idle speed, the engine does not provide torque to the fly wheel. To ensure the engine running stably at
the lowest possible idle speed, the closed-loop idle speed control system should keep the balance
between the generated torque and the "power consumption" of engine. The necessary power should be
generated with idling speed to meet the load requirements of all aspects, including those come from
internal friction from the engine crankshaft and valve mechanism, as well as the auxiliary components,
such as coolant pump. The system is based on the torque-based control strategy, which determines
required output torque of engine to maintain the required idle rotation speed under any operating
conditions with a closed-loop idle speed control strategy. The output torque increases with decreasing of
engine speed and decreases with rising of engine speed. The system request greater torque to response to
the new "disturbance factors", such as the switch of the air-conditioning compressor. With low engine
temperature, it is necessary to increase the torque to compensate the greater internal friction loss and/or

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166
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.
7. Closed-loop Control
Post treatment of three-way catalyst is an effective way to decrease the concentration of hazardous
substance in the exhaust gas. The three-way catalyst can decrease the HC, CO and NO
X
by 98% or more
and transform them into H
2
O, CO
2
and N
2
. However this high efficiency can only be achieved in a very
narrow range near the excessive air factor of engine =1. The objective of the closed-loop control is to
ensure the gas mixture concentration at this range, thus, the closed-loop control system is used to get
this target. closed-loop control system functions only with oxygen sensor equipped. Oxygen sensor
can detect oxygen content of the exhaust gas at three-way catalyst side. Rarefied gas mixture (> 1)
produces a sensor voltage of about 100mV and the concentrated gas mixture ( <1) produces a sensor
voltage of about 900mV. In case of =1, the sensor voltage has a jump. closed-loop control responds
to the input signal (>1= too thin mixture, <1= too thick mixture) to revise the control variable and
produce a correction factor as a multiplier to correct the fuel injection duration.
8. Evaporation Emission Control
Due to transfer of the external radiation heat and oil return heat, the fuel in tank is heated to form vapor.
According to limit of evaporative emission regulation, it is not permitted to exhaust the vapor containing
large quantity of HC composition directly into the atmosphere. The fuel vapor in the system is collected
with an active carbon canister through the conduit and flushed into the engine at appropriate time to
participate combustion. Flushing flow is controlled by the carbon canister control valve of ECM. The
control functions only when the closed-loop control system is running under the closed-loop
condition.
9. Fuel Injection Control
The fuel injection timing and impulse width is controlled to provide the best mixing of air/fuel
corresponding to the ever-changing operation condition of engine. The fuel injector is installed at the
inlet of every cylinder. The fuel is drawn from tank by fuel pump and delivered to each fuel injector.
Normally, each cylinder has one fuel injection operation with two revolutions of crankshaft. Injection
sequence of cylinders is 1-3-4-2.
10. Ignition Timing Control
The primary current to the ignition coil is controlled by connecting and disconnecting the power
transistor of primary ignition circuit to regulate the ignition timing so that the best ignition timing can be
provided according to operating conditions of engine. Ignition timing is determined by the ECM
according to the engine speed, intake quantity, coolant temperature and atmospheric pressure.
11. Self-diagnosis Function
When abnormal situation is detected by the sensor or actuator related to the exhaust control, the alarm
lamp of engine (inspection lamp of engine) lights up to inform the driver. DTCs (diagnose trouble code)
corresponding of this abnormal situation will be set in these conditions. The RAM data inside the ECM

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167
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
1) Fuel Injection Pump
With relay connected, the fuel injection pump will be energized when the crankshaft starts to rotate or
with engine running.
2) Fan Relay Control
The speeds of the radiator fan and condenser fan is controlled with the engine coolant temperature,
vehicle speed and air conditioner switch signal (AC).

III. On-board Diagnosis System
1. Description
On-board diagnosis system (hereinafter referred to as OBD system) is the diagnosis system integrated in
the engine control system to monitor the trouble components affecting the emission as well as the main
function state of the engine. It is capable of identifying, storing and showing the trouble information
through the self-diagnosis malfunction indicator lamp (MIL).
2. Trouble Information Record
Electronic control module constantly monitors the sensor, actuator, associated circuit, malfunction
indicator lamp (MIL) and battery voltage etc. as well as even the electronic control module itself, and
carries out the credibility detection for the output signal of sensor, the drive signal of actuator and the
internal signal (such as closed-loop control, coolant temperature, idling speed control and battery
voltage control etc.). Once a trouble is found in some link or a signal value is incredible, the electronic
control module immediately sets the trouble information record in RAM memory. Trouble information
record is stored in form of DTC and shown based on the order in which the troubles present.
The troubles can be divided into steady-state trouble" and "sporadic trouble" according to their
occurrence frequencies (for example, because of short term open circuit of harness or poor contact of
connector).

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168

Schematic Diagram for Malfunction Diagnosis of Electronic Injection System
3. Control strategy of malfunction indicator lamp
1) When no malfunction is present:
The malfunction indicator lamp lights up after the ignition switch is turned on (ON) and then goes
out after 4s.
If the engine is started within 4s, the malfunction indicator lamp goes out upon detection of speed
signal.
After the K-line is grounded for more than 2.5s, the malfunction indicator lamp will flash at a
frequency of 2Hz.
2) When a malfunction is present:
The malfunction indicator lamp will be always on after the ignition switch is turned on (ON).
After the engine is started, the malfunction indicator lamp will go out upon detection of speed
signal. If the malfunction indicator lamp in question is defined as ON mode in the malfunction
category, the malfunction indicator lamp will be always on after the corresponding conditions are
met.
4. Inspection steps
1) For the vehicles with OBD function, inspection should be carried out always with steps below:
OBD Inspection Steps

1. Connect the diagnosis equipment to the
diagnosis connector to put through it.
Function
diagnosis
Electronic
control unit
Data
collection

Function
diagnosis

Control command

Actuators
Sensors

Engine

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169

2. Turn on ignition switch.

3. 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.

4. Remove the trouble.

5. Clear memory: run the vehicle properly
following the corresponding trouble diagnosis
conditions: read trouble related information
and confirm the clearing of the trouble.
2) Connection of Diagnosis apparatus:
The K line protocol and ISO9141-2 standard diagnosis joint are adopted for the system as shown in
the figure.

Standard Diagnosis Connector

This standard diagnosis joint is connected on the harness of engine steadily. The pins 4, 7 and 16 of the
standard diagnosis joint are used for engine electronic control system. The pin 4 of the standard
diagnosis joint is connected to the grounding wire: pin 7 is connected to the pin 15 of ECM, that is, the
K data line of the electronic control system of engine; pin 16 is connected to battery negative pole.

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170
5. List of Common Control System Malfunction Codes of ECU
1.0 Table of Common Malfunction Codes for UAES Control System of
3-Cylinder Engine
DTC 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 Open-circuit of downstream oxygen sensor heating control circuit
P0037 Short-circuit of downstream oxygen sensor heating control circuit to ground
P0038 Short-circuit of downstream oxygen sensor heating control circuit to power supply
P0053 Inappropriate heating internal resistance of upstream oxygen sensor
P0054 Inappropriate heating internal resistance of downstream oxygen sensor
P0105 No signal variation of air intake pressure sensor (Frozen)
P0106 Inappropriate air intake pressure sensor
P0107 Short-circuit of air intake pressure sensor to ground
P0108 Short-circuit of air intake pressure sensor to power supply
P0112 Low signal voltage of air intake pressure sensor
P0113 High signal voltage of air intake pressure sensor
P0117 Low voltage of engine coolant temperature sensor circuit
P0118 High voltage of engine coolant temperature sensor circuit
P0122 Out-of-lower-limit of throttle position sensor circuit voltage
P0123 Out-of-upper-limit of throttle position sensor circuit voltage
P0130 Inappropriate upstream oxygen sensor signal
P0131 Low upstream oxygen sensor signal circuit voltage
P0132 High upstream oxygen sensor signal circuit voltage
P0133 Aged upstream oxygen sensor
P0134 Malfunction of upstream oxygen sensor circuit signal
P0136 Inappropriate downstream oxygen sensor signal
P0137 Low downstream oxygen sensor signal circuit voltage
P0138 High downstream oxygen sensor signal circuit voltage
P0140 Malfunction of downstream oxygen sensor circuit signal
P0170 Inappropriate closed-loop control self-learning of off-line testing air-fuel ratio
P0171 Thin closed-loop control self-learning of off-line testing air-fuel ratio
P0172 Thick closed-loop control self-learning of off-line testing air-fuel ratio
P0201 Open-circuit of 1# fuel injector control circuit
P0261 Short-circuit of 1# cylinder fuel injector control circuit to ground
P0262 Short-circuit of 1# cylinder fuel injector control circuit to power supply

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P0300 Detection of misfire in various cylinders
P0301 Detection of misfire in 1# 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 Low voltage of knock sensor signal circuit
P0328 High voltage of knock sensor signal circuit
P0340 Inappropriate installation location of phase sensor
P0341 Poor contact of phase sensor
P0342 Short-circuit of phase sensor to ground
P0343 Short-circuit of phase sensor to power supply
P0420 Aged oxygen storage capacity of three-way catalytic converter (out-of-limit of emission)
P0444 Open-circuit of carbon canister control valve control circuit
P0458 Low voltage of carbon canister control valve control circuit
P0459 High voltage of carbon canister control valve control circuit
P0480 Open-circuit of cooling fan relay control circuit (low speed)
P0481 Open-circuit of cooling fan relay control circuit (high speed)
P0501 Inappropriate vehicle speed sensor signal
P0506 Lower idling control speed against target speed
P0507 Higher idling control speed against target speed
P0508 Short-circuit of stepping motor drive pin to ground
P0509 Short-circuit of stepping motor drive pin to power supply
P0511 Open-circuit of stepping motor drive pins
P0560 Inappropriate system battery voltage signal
P0562 Low system battery voltage
P0563 High system battery voltage
P0602 Programming error of electronic control unit
P0627 Open-circuit of fuel pump relay control circuit
P0628 Short-circuit of fuel pump relay control circuit to ground
P0629 Short-circuit of fuel pump relay control circuit to power supply
P0645 Open-circuit of A/C compressor relay control circuit
P0646 Short-circuit of A/C compressor relay control circuit to ground
P0647 Short-circuit of A/C compressor relay control circuit to power supply
P0650 Malfunction of malfunction indicator lamp circuit
P0691 Short-circuit of cooling fan relay control circuit to ground (low speed)
P0692 Short-circuit of cooling fan relay control circuit to power supply (low speed)
P0693 Short-circuit of cooling fan relay control circuit to ground (high speed)
P0694 Short-circuit of cooling fan relay control circuit to power supply (high speed)

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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)
P2270 Aged downstream oxygen sensor

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IV. Engine Trouble Diagnosis
1. 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:
a. Starting hardship or failure of engine
b. Unstable idle
c. Poor drivability
If any of these situations occurs, first of all, carry out the regular inspection including the basic
inspection of engine (ignition system trouble and correct adjustment of engine etc.). Then inspect the
sub-assemblies of the electronic control system with trouble diagnose apparatus.
Attention:
Before dismantling or installing any component, read the DTC at first and then disconnect
battery negative poles.
Before disconnecting battery cables, firstly turn off the ignition switch. If battery cable is
disconnected with engine rungin or ignition at ON position, ECM may be damaged.
The harness between the ECM and sensor should be shielded by the grounding wire connected to
the vehicle body in order to prevent the interference from the ignition system and radio. If fails,
the harness should be replaced.
When checking the charging state of engine, dont disconnect the negative pole of battery to
prevent damage of ECM.
When using the outside charger to charge the battery, it is necessary to disconnect battery cable
to prevent damage of ECM.

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2. 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
Check DTC and print DTC and freeze frame
data, inspect related maintenance record
3.Recognize the symptom
Attempt to diagnose the
symptom described by the user.
User described the
symptom and the
apparatus displays DTC
5. Implement the confirmation steps of DTC.
User did not
describe the
symptom, but
apparatus
displays the
DTC.
4. Recognize the symptom
Attempt to diagnose the symptom
described by the user.
User described the
symptom and
apparatus did not
show DTC
6. Implement the basic check.
10. Check the troubled component through the
diagnosis steps
9. Use the trouble
symptom table to check
troubled system
8. Check the troubled
component
7. Run the trouble diagnosis &
check mode
11. Repair or replace the troubled components
12. Final check
Confirm no symptom found
Implement the DTC confirmation steps again,
and be sure to repaire the trouble properly.
A
b
n
o
r
m
a
l

(
D
T
C

d
e
t
e
c
t
e
d
)

Normal
The check ends
No troubled
component found
Within the scope
of technical
parameters
Beyond the scope of
the technical
parameters
Inspect with trouble
diagnosis apparatus
Troubled component
found
Abnormal (symptom
still exists)
Do not use the trouble diagnosis apparatus

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3. Trouble Symptom Check Table
List of Trouble Symptom Inspection
Symptoms Check Order No.
Unable to communicate with all the systems 1 Unable to communicate with
diagnosis apparatus Unable to communicate with ECM only 2
Engine alarm lamp failed to light up immediately after the
ignition switch is turned to ON.
3 Engine alarm lamp and
corresponding components
Engine alarm lamp keeps bright 4
No initial ignition (unable to start) 5
There is initial ignition but it burns incompletely (unable to
start)
6 Start
Too long starting duration (unable to start normally) 7
Unstable idle (fluctuant idle speed and hunting) 8
High idle speed (abnormal idle speed) 9 Idle Stability (abnormal idle speed)
Low idle speed (abnormal idle speed) 10
The engine stops at the idle when it is cold. (stop with
deceleration)
11
The engine stops at the idle when it is hot. (stop with
deceleration)
12
The engine stops at the start. (stop with acceleration) 13
Idle Stability (engine stops)
The engine stops with deceleration 14
Vehicle surge, drop or instability of vehicle speed 15
Shock or vibration during acceleration 16
Shock or vibration during deceleration 17
Poor acceleration 18
Surge 19
Driving
Knock 20
Fail to stop engine 21
High concentration of CO and HC at the idle operation 22
Low voltage of alternator 23
Abnormal idling speed when starting the air conditioner 24
Abnormal operation of fan 25

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4. Symptom List
Symptom List
Items Symptoms
Failure of starting
Starter drags the engine, but there is no combustion in cylinder and the engine
does not start.
Extinguishment after
combustion
There is combustion in cylinder, but the engine extinguishes immediately.
Start
Hard to start Engine starts after the crankshaft rotates a while.
Hunting
Engine does not maintain a constant speed and the speed changes within range
of idle speed.
Fluctuation of idle
Usually, it can be determined with the swing of tachometer pointer and the
vibration transferred to the steering wheel, selector rod and body etc.
Incorrect idle Engine is running idly at the incorrect rotation speed.
Extinguishment of engine
(with deceleration)
When releasing the accelerator pedal, no matter whether the vehicle is moving,
the engine stops.
Stability
of idle
speed
Extinguishment of engine
(with acceleration)
When the accelerator pedal is depressed or being depressed, the engine stops.
Vehicle surge, drop of
speed
The phenomenon of vehicle surge refers to that the vehicle speed (rotation
speed of engine) responds slow when there is a need to accelerate and depress
down the accelerator pedal at the current vehicle speed or the temporary decline
of vehicle speed (rotation speed of engine) during acceleration.
Poor acceleration
Poor acceleration refers to that the vehicle is unable to acquire acceleration with
the opening of air throttle even with stable acceleration; or refers to the
disability to reach the maximum vehicle speed.
Instability
When firstly depressing down the accelerator pedal to speed up, engine speed
increases slowly.
Shock There is huge shock or vibration of engine with accelerating or decelerating.
Surge
There is repeatedly forward surge when traveling with constant or variable
speed.
Driving
Knock
There is a strong voice like the hammer against the cylinder wall during the
driving which is harmful to driving.
Parking
Keep running(fail to
stop)

5. General Trouble Inspection
Engine trouble inspection should begin with the basic system. In case of starting failure, unstable idle or
insufficient fuel supply, begin the following basic systems:
a. power supply: battery, fusible link and fuse wire
b. Grounding
c. Fuel supply: fuel pipe, fuel filter, fuel pump
d. Ignition system: spark plug, high tension line, ignition coil.
e. Emission control system: Leakage of vacuum system.
f. Others: ignition timing and idle.
The trouble of electronic control system of engine is generally caused by poor contact of the harness
connector. All the harness connectors should be checked to verify whether they are connected correctly.

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6. 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.
The engine coolant temperature is 80-95 .
Lamps, electronic fan and all the accessories are turned off.
Shiftlever is at neutral position.
The steering wheel is at center (equipped with power steering system).
2) Connect the diagnosis apparatus.
3) Start engine and run it at the lowest idle speed.
4) Run engine for over 5s with speed of 2000-3000 rpm and then make the engine operate for 2min at
the idle speed.
5) Read idling speed (75050r/min).
7. Fuel Pressure Test
Attention:
Before disconnecting the fuel pipeline, it is necessary to release the fuel pressure inside the fuel
pipeline to eliminate the danger.
The O-ring should always be used to keep the seal of the connecting joint of fuel hose.
Dont operate the electrical system during inspection.
Note: Prepare a container under fuel pipe to avoid the fuel spillage when pipes disconnected.
1) Dismount the nut at fuel pressure inspection port on the guide rail of fuel injector.
2) Connect fuel pressure gauge.
3) With ignition switch at ON position, check for fuel leakage.
4) With engine running with idling speed, check for the fuel leakage.
5) Take down reading of fuel pressure gauge.
Fuel pressure: 350KPa
Attention:
Dont check fuel pressure with system operating.

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During inspection of fuel pressure, always to make sure whether there is fuel leakage in fuel
pipeline.
7) If the measured fuel pressure is more than the standard value, analyze the possible reasons referring
the following table and repair as required.
Fuel System Trouble Diagnosis Table 1
Phenomenon Possible Cause Troubleshooting
Blockage of fuel filter Replace the fuel filter
Too low fuel pressure Damaged fuel pump or poor sealing of fuel pressure
regulator resulting in fuel leakage at returning side
Replace fuel pump
Cementation of fuel pressure Replace fuel pump
Too high fuel pressure
Blockage or bend of fuel return pipe
Repair or replace fuel
pipe
8) Turn off engine and check the changes of fuel pressure gauge reading for 5min. If the reading drops,
observe the reduction rate. Referring to following table to analyze and eliminate the trouble.
Fuel System Trouble Diagnosis Table 2
Phenomenon Possible Cause Troubleshooting
Fuel pressure drops slowly after engine
stopped
Leakage of fuel injector Replace injector
Fuel pressure drops completely after engine
stopped.
Trouble of fuel pump Replace pump
9) Reduce the pressure in fuel pipeline.
10) Disconnect the fuel pressure gauge and install the inspection port nut.
11) Check for fuel leakage with following steps.
Turn the ignition switch to the "ON" position (with engine stopped), and then check for leakage at
the joint of the fuel pipeline.
Start the engine and increase speed, inspect whether there is leakage at joint of fuel system.

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Section III Structural Principle and Inspection of Engine Electronic Components
I. Intake Manifold Absolute Pressure (MAP/MAT) Sensor
1. Description
1) 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. When intake pipe pressure changes,
the diaphragm will drive the core to movement and thus change output voltage of sensor .With
sensor output voltage, ECU can determine engine intake volume, with which and reference to other
signals, injection volume control is achieved. .MAP sensor is also used to measure atmospheric
pressure during starting; under certain conditions, it allows the ECM to be adjusted automatically at
different altitudes. ECM provides 5V voltage to MAP sensor and receives voltage signal by the
signal line. The sensor is grounded with a wire from its variable resistor. MAP sensor input signal
affects ECM fuel output and ignition timing control.
2) Intake temperature sensor element is a thermistor with negative temperature coefficient (NTC). Its
resistance increases with the intake air temperature decreases. Engine ECU detects intake air
temperature changes via a contrast circuit.
2. Installation Position
Installed on the back of throttle

3. Circuit Diagram
Pin 19: 5V voltage signal
Pin 59: Manifold pressure sensor signal
Pin 40: Power ground
Pin 25: Intake air temperature sensor signal
Operating voltage: 5 0.1V

Fig. 4.3.001
I
n
t
a
k
e

p
r
e
s
s
u
r
e
/

t
e
m
p
e
r
a
t
u
r
e

s
e
n
s
o
r

5V power supply 1
Sensor grounding

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4. Diagnosis
Sensor short circuit (to ground, to power supply);
Sensor circuit open;
Sensor detects the intake pressure exceeds the upper limit;
Sensor detects the Intake pressure exceeds the lower limit;
5. Trouble Solution
Mainly check the 4 connections of the sensor and connection with ECU for short circuit, open
circuit;
Check sensor detection holes for blockage.
Whether a short circuit, open circuit, grounding problem exists in sensor wiring harness
Whether sensor is highly impacted resulting in sensor failure.
Operating pressure range: 12.5kPa - 115kPa
Operating temperature range: -40 - 125
1) Dismantlement
Disconnect the wire harness connectors of intake
manifold pressure & temperature sensors.
Attention:
Make sure that the ignition switch is at Off
position.

Disassemble the fixing screws of the intake
pressure/temperature sensor with crosshead screw
driver, remove the sensor.

2) Installation
Fig.4.3.002
Fig.4.3.003

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Apply a small amount of engine oil on seal ring of sensor in order to facilitate the installation.
Make sure that adhesive of sensor and intake manifold is well, tighten the self-tapping screw
Verify reliable installation of wire harness connector.

II. Engine Coolant Temperature (ECT) Sensor
1. Instruction of Parts
The engine coolant temperature sensor measures the engine coolant temperature and sends the signal to
the ECM for control of ignition timing and fuel injection pulse width during start, idling, and normal
running. It adopts one negative temperature coefficient thermistor, of which the resistance reduces
following the increasing of the temperature. Depending on the voltage output of the sensor, the ECM
judges the temperature of coolant and sends gas mixture with best air-fuel ratio to the engine.
2. Installation Position of Element
See figure right for installation positions.

3. Wiring Diagram
Pin 40: 5V Grounding
Pin 41: Cooling water temperature signal output
Fig. 4.3.004

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4. Diagnosis
Water temperature signal higher than the limit;
Water temperature signal lower than the limit;
Water temperature sensor short circuit, open circuit.
Room temperature resistance data: 2.5 5%k

5. Trouble Solution
It mainly checks the connections between wires of sensor and ECU and between wires of sensor
and instruments for presence of short-circuit and open-circuit.
Short circuit, open circuit, grounding problems between sensor harness.
Grounding: poor grounding easily lead to excessively high engine water temperature indication;
Operating voltage: 5V;
Operating temperature range: -40 - 135
Characteristic parameters (standard)
Coolant temperature
sensor

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183
1) Dismantlement
Discharge coolant from radiator. Please refer to
"Change Engine Coolant".
Disconnect the wire harness connector of the
engine coolant temperature sensor.

Dismantle the engine coolant temperature sensor.

2) Installation
Be aware of following precaution to install with steps contrary to dismantlement.
Apply surface sealant on threaded part of sensor and tighten with specified torque. Tightening
torque :16-24N. M
Verify reliable installation of wire harness connector.
With engine idlingvisually inspect coolant leakage.
III. Throttle Position Sensor
This sensor is one angle sensor with linear output characteristic and is composed of two arc sliding
contact resistors and two sliding contact arms. The hinges of the sliding contact arms are coaxial with
the throttle shaft. A 5V supply voltage US is applied onto two sides of the sliding resistors. At the
rotation of the throttle, the sliding contact arms rotate as well to move on the sliding contact resistors
and output the potential UP of the contact as voltage output. Therefore, its actually a rotation angle
potentiometer that outputs a voltage signal in proportional to the throttle position.
Fig. 4.3.005

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184
Its installed on throttle body.

3. Wiring diagram of throttle position sensor
Pin18: 5V power supply
Pin26: Throttle position sensor signal
Pin39: 5V grounding

4. Diagnosis
Poor acceleration, etc.

5. Solutions
Mainly inspect sensor and ECU wiring harness for short circuit, open circuit, grounding problems;
Shift the multimeter to Ohm measurement scale and connect two probes of the multimeter to 1# and
2# pines of the sensor respectively to measure the resistance. The measurement at ambient
temperature shall be 2k20%. Connect two probes to the 1# and 3# pins respectively and rotate
Fig. 4.3.006
Throttle Position
Sensor

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185
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.
Operating temperature: -40 - 125 ;

6. Dismantlement and installation of throttle
position sensor
1) Dismantlement
Disconnect the wire harness connector of air
throttle position sensor.
Note: Be sure that the ignition switch is at the
Off position.

Remove the screws of throttle position sensor
and remove the sensor.

2) Installation
Be aware of following to install with steps contrary to dismantlement.
Verify that the of the wire harness connector is inserted securely.
Tighten self-tapping screw.

IV. Crankshaft Position Sensor
1. Component Description
The crankshaft position sensor is used to provide the engine speed information and crankshaft top
Fig. 4.3.07
Fig. 4.3.08

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186
dead center information in the ignition system. Its 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. The signal wheel is installed on the crankshaft and rotates along
with the crankshaft. When the tip of tooth passes through the tip of crankshaft position sensor, the
signal wheel made of ferromagnetic material cuts the magnetic force line of permanent magnet in
the speed sensor to generate induced voltage within the coil as the speed signal output.
Performance:
Operating temperature: -40150
Working gap: 0.5-1.5 mm
2. Installation position
Its installed in the vicinity of the crankshaft.

3. Wiring Diagram
Pin46: Terminal B of crankshaft position sensor
Pin 47: Terminal A of crankshaft position sensor
Fig. 4.3.009
Crankshaft Position
Sensor

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187

4. Diagnosis
ECU real-time monitoring of the sensor and circuit
Sensor open circuit;
Internal short-circuit of sensor;
Sensor unit short-circuit to ground
Sensor unit short-circuit to system reference voltage signal wire.
5. Trouble Solution
Check sensor circuit for normal function and incorrect connection of grounding
Connect the sensor and harness to check whether the connections of power supply, grounding wire,
and signal wire are normal.
6. Removal and installation
1Removal
Disconnect the harness connector of crankshaft position sensor.
Speed sensor

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188

Unscrew fixing bolts, remove the sensor.

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

V. Camshaft phase sensor
This sensor provides crankshaft phase information to the ECU, namely differentiating the
compression top dead center and the exhaust top dead center of the crankshaft.
This sensor is manufactured by means of the Hall theory in which the Hall voltage is subject to the
varying magnetic field induction strength.
Fig. 4.3.010
Fig. 4.3.011

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189

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
current, of which the voltage UH is in proportion
to the magnetic field induction B (perpendicular to
the current IS) and the current IS. The Hall voltage
is subject to the varying magnetic field induction
strength B.
Performance:
Operating temperature: -40150
Working gap: 0.5-1.5 mm
Its installed in the vicinity of the camshaft.

3. Wiring Diagram
Pin 39: Sensor grounding
Pin 42: Sensor signal
Pin 18: 5V power supply
B BB B
I
U
H

Fig. 4.3.012

Camshaft position
sensor

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190

4. Diagnosis
ECU real-time monitoring of the sensor and circuit
Sensor open circuit;
Internal short-circuit of sensor;
Sensor unit short-circuit to ground
Sensor unit short-circuit to system reference voltage signal wire.
5. Trouble Solution
Check sensor circuit for normal function and incorrect connection of grounding
Connect the sensor and harness to check whether the connections of power supply, grounding wire,
and signal wire are normal.
1Removal
Disconnect the harness connector of camshaft position sensor.

Unscrew fixing bolts, remove the sensor.
Phase sensor
Fig. 4.3.013

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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

VI. Oxygen sensor
Oxygen sensor is used to provide information for judging whether the oxygen in air inhaled to the fuel
in engine cylinder is excessive or not after combustion. ECU uses this quantitative information for
defined cycle control of the fuel cycle so that the three major toxic components can be mostly converted
and purified in the three-way catalytic converter.
The sensing component is a kind of porous ceramic tube; the wall is surrounded by the engine exhaust
while the inside is put through to the atmosphere. The oxygen sensor, based on concentration difference
inside and outside, calculates indirectly the fuel injection pulse width to be transmitted to ECU for
controlling of fuel injection. Simultaneously, it detects rear oxygen sensor output data and compares
with front sensors data within the ECU to monitor the working conditions of the three-way catalyst
converter.
Oxygen sensor operating voltage fluctuates between 0.1-0.9V; in 10 seconds it may change for 5-8 times;
if it is lower, indicates that the sensor is aged and need to be replaced. The sensor can not be repaired.
Fig. 4.3.014

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192
Front (upstream) oxygen sensor is installed on the
exhaust manifold before the three-way catalyst
converter and the rear (downstream) oxygen sensor is
installed behind the three-way catalytic converter.

3. Wiring diagram
Pin 39: Downstream oxygen sensor grounding
Pin 29: Downstream oxygen sensor signal
Pin 4: Downstream oxygen sensor heating control
1#: To main relay power
Pin 39: Upstream oxygen sensor grounding
Pin 45: Upstream oxygen sensor signal
Pin 2: Upstream oxygen sensor heating control
1#: To main relay power

4. Diagnosis
ECU detects the oxygen sensor circuit and ECU internal power amplifier circuit and testing circuit. If
one of the following conditions occurs, the oxygen sensor fault indicator will be set:
Battery voltage not reliable
Intake manifold absolute pressure signal not reliable
Engine coolant temperature signal not reliable
Downstream
oxygen
sensor
Upstream
oxygen
sensor

Main
relay

Main
relay

Fig.4.3.015

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193
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.
5. Diagnosis
Mainly check sensor wiring connection for short circuit, open circuit;
Sensor damages are generally caused by lead or phosphorus poisoning; so pay attention to the fuel
quality; meanwhile, excessive fuel consumption may also lead to sensor failure;
Changes of the oxygen sensors should be not less than a certain times in certain period of time.
1) Dismantlement
Disconnect oxygen sensor harness connector.

Remove oxygen sensor with special remover.

Attention:
Plug mounting hole of the oxygen sensor with hairless cotton yarn to keep the debris or oil &
water away from the exhaust manifold.
Visually inspect appearance of oxygen sensor.
Reddish brown: lead poisoning
Off-white: normal
Black: carbon deposition
2) Installation
Fig. 4.3.016
Fig. 4.3.017

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194
Be aware of routing of oxygen sensor wire harness.
After replacement of oxygen sensor, oxygen sensor should be coated with a layer of anti-rust oil to
prevent rust which impede removal.

VII. Fuel Injector (INJ)
Fuel coming from the fuel pump is stored and distributed via the fuel rail components and provides the
fuel system with a more stable pressure environment in which the fuel supply pressure and quantity of
each cylinder will be balanced while the engine is running smoothly. Injector injects fuel as per the
signal from the ECM signal and defines fuel injection volume depending on opening time of injector
solenoid valve.
It is installed on the fuel guide rail.

3. Wiring Diagram
Fig. 4.3.018

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195

1# cylinder fuel injector 2# cylinder fuel injector 3# cylinder fuel injector
4. Inspection
Attention:
Please clean the fuel injector and analyze with special cleaning and analysis instrument for fuel
inject at certain interval..
1) Check the resistance.
Note: check with wire harness connector disconnected.
Standard resistance: 11.4-12.6
2) Inspect operating time of the fuel injector with trouble diagnosis apparatus.
Standard operation time: 2.0-3.0ms at the idle speed and more during the acceleration.
3) Check the operating sound of fuel injector.
Note: Use a stethoscope to check the click sound of the fuel injector at the idling speed or use the
fingers to check the vibration situation of fuel injector.
If vibration can not be felt, check the wire harness connector, fuel injector or the control signal of fuel
injector by ECM.
Please refer to Fuel System.

VIII. Knock sensor
To main relay

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196
1. 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. When the knock signal is detected, ECU will
gradually reduce it until the knock disappeared; and then gradually restore to the knock threshold; the
cycle is done repeatedly.
Installed aside of cylinder.

3. Inspection
1) Wiring diagram
Pin 30: Terminal A of knock sensor
Pin 31: Terminal B of knock sensor

2) Check the resistance.
Resistance: greater than 1M
4. Diagnosis:
ECU monitors the knock sensor, power amplifier circuit and testing circuit. If one of the following
circumstances is detected, knock sensor fault indication will be set:
Knock sensor failure;
Knock control data processing circuit fault;
Fig. 4.3.019
Knock sensor

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197
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. When
the error frequency drops below the set value, the fault indication will reset.
1 Removal
Disconnect knock sensor harness connector.

Unscrew knock sensor locking nut, remove the knock sensor.
Attention:
Do not drop or damage the sensor.
2) Installation
Install with reversed steps of disassembly.
Tightening torque: 16 - 24N m

IX. Air-conditioning switch and relay
1. Description
When air conditioner is turned on, the air conditioning switch will send the battery voltage signal to the
ECM. After air conditioner turned-on signal input, ECM drives electronic throttle to increase idling
speed of engine, and correct ignition advance angle. At the same time, ECM controls air conditioning
relay to make the compressor magnetic clutch working.

2. Inspection
Fig. 4.3.020

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198
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
Off Off
Air conditioning switch
On On
Off Off (compressor clutch does not work)
Air compressor
On On (compressor clutch works)

X. Canister solenoid valve
1. Description
Control air intake from the canister to the general intake piping. The adsorption amount of canister has
certain limits, if evaporation of gasoline attached to the canister is not consumed, it may emit into
ambient air resulting in pollution and increased insecurity.
Internal of canister valve is a solenoid valve structure and its opening is controlled with the digital pulse
square wave sent from the ECU. According to different engine operating conditions, canister solenoid
valve opening is also different; at big loading of the engine and idle time, canister solenoid valve is not
working in order to ensure the engine's output power.

3. Wiring diagram
A: Main relay output end
Pin 35: Canister solenoid valve control signal

4. Diagnosis
Fig. 4.3.021
Canister solenoid valve
Main relay

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199
Short circuit of sensor with ground
Short circuit of sensor with power line
Open circuit of sensor
5. Trouble Solution
Check sensor signal for short circuit, open circuit;
Check wiring harness for channeling;
Check sensor circuit for short circuit with power line;
Check canister magnet valve for blockage and normal ventilation;
Operating Temperature: -40 - 120 ;
Coil resistance: 19 - 22;
Working voltage: 8 - 16V;
1 Removal
Disconnect hose at canister solenoid valve
side.

Disconnect the canister solenoid valve wiring
harness connector.

Take off the canister solenoid from the cage.

2 Installation
Be aware of following precautions to install with steps contrary to removal.
When installing, air flow direction must meet requirement, meanwhile checking the canister
solenoid valve for wearing and cracks.
During the disassembly process, avoid water, oil and other liquid entering into the valve.
XI. Ignition coil
Fig. 4.3.022
Fig. 4.3.023

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200
1. 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.
This engine adopts independent ignition technology and utilizes the theory of high energy utilization by
the mutual inductance of electromagnetic coil to control the energization time and power-off moment of
the secondary coil and utilize the high voltage generated in the secondary stage of the coil to puncture
the gap of spark plug, generate strong spark, and ignite the gas mixture. Due to high air ionization
degree and low resistance during engine exhaust stroke, it only needs a low voltage to puncture the gap
of spark plug. Therefore, this system adopts grouped ignition technology, which will not waste any
energy and will save a great amount of cost.

Ignition coil operating voltage range: 6 - 16V
Secondary ignition coil resistance: 8.7 0.87 K
Primary charge time: 2.15ms
Minimum ignition duration: 1.0ms
Minimum ignition energy: 35mJ.
Installed at top of the cylinder head cover.

Fig. 4.3.025
Fig. 4.3.024

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201

3. 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; under normal circumstances, the ignition coil heats up more during working, but
overheated temperature of the ignition coil causes increaseing in ignition coil resistance, resulting in
instability of engine work, automatic flameout and other failures. But the ECU can detect the control
cable of the ignition coil. When failure of an ignition coil is detected, injector of corresponding cylinder
will be turned off.
Control cable short circuit with ground;
Control cable short circuit with power line;
Control circuit open.
4. Diagnosis
Internal short circuit, open circuit of coil;
Coil leakage, cracks in the housing;
Aging coil leading to energy shortage in ignition.
For removal and installation, please see "Ignition System."

XII. Electric Fuel Pump
1. Description
It is used to deliver the fuel to the main fuel supply pipe from the fuel tank at a certain fuel pressure and
flow, and maintain the stable fuel pressure (through the fuel pressure regulator).
It is installed inside the fuel tank
3. Wiring diagram
Pins description: the electric fuel pump has two pins, and the fuel pump casings next to the two pins are
marked with "+" and "-" signs, which represent respectively the connections to the positive (fuel pump
relay) and ground.

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4. Inspection
1) Check internal resistance of fuel pump.
Internal resistance should not be zero or infinity.
2) Check the fuel pressure
Refer to Fuel System.
Refer to Fuel Pump Assembly.
Attention:
In order to prevent accidental damage of fuel pump, please do not run the fuel pump without
fuel.
In case that the fuel pump need to be replaced, please pay attention to the cleaning of fuel tank
and pipeline and replacement of fuel filter.
Fuel pump relay
Fuel pump

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XIII. Electronic Control Module (ECM) of Engine
1. 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. This is the sole method to integrate flexibly all kinds of functions
into different variants of ECU depending on the engine and vehicle models.
In the engine electronic control system, the sensors are functioned as input parts to measure all kinds of
physical signals (temperature, pressure, etc.) and convert to corresponding electric signals, the ECU is
functioned to receive the input signals from sensors, calculate and process as per preset programs,
generate corresponding control signals, and output to power drive circuits, and the power drive circuits
execute different actions by driving corresponding actuators and control the engine to run as per preset
control strategy. At the same time, the malfunction diagnosis system of ECU monitors various
components and control functions in the system. Once a malfunction is detected and confirmed, the
system will save the malfunction code and activate the Limp home function. Upon the detection that
the malfunction is resolved, the system will resume to normal values.
1 Functions
Torque-based system structure
Determine cylinder load quantity based on intake pressure sensor
Improve control function of gas mixture under static and dynamic conditions
closed-loop control
Fuel cylinder-by-cylinder sequential injection
Ignition timing (including cylinder-by-cylinder knock control)
Exhaust control function
Catalytic converter heating control
Carbon canister control
Idling control
Limp home
Anti-theft device function
Connection between torque and external system
Control over central electronic control parts
Complete a series of OBDII control functions
Used for management system of diagnosis function
etc.

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2 ECM pin definitions:
ECM pin definition list
Pin Function Pin Function
1 Reserved terminal 33 Reserved terminal
2 Heating of upstream oxygen sensor 34 Reserved terminal
3 Ignition coil 1 35 Phase terminal C of stepping motor
4 Heating of downstream oxygen sensor 36 Phase terminal D of stepping motor
5 5V grounding 37 Carbon canister electromagnetic valve
6 Reserved terminal 38 Reserved terminal
7 Ignition coil 2 39 Sensor grounding 1
8 Non-sustained power supply 40 Sensor grounding 2
9 Engine speed output 41 Engine coolant temperature sensor
10 A/C medium pressure switch 42 Phase sensor
11 Reserved terminal 43 Electric grounding 1
12 Headlamp switch 44 A/C switch
13 Reserved terminal 45 Upstream oxygen sensor
14 Reserved terminal 46 Terminal B of engine speed sensor
15 Diagnosis K-line 47 Terminal A of engine speed sensor
16 Sustained power supply 48 Power grounding 1
17 Ignition switch 49 Fuel injector 2 (3
rd
cylinder)
18 5V power supply 2 50 Fuel injector 1 (1
st
cylinder)
19 5V power supply 1 51 Non-sustained power supply
20 Malfunction indicator lamp 52 High speed fan relay
21 Phase terminal B of stepping motor 53 Reserved terminal
22 Phase terminal A of stepping motor 54 Reserved terminal
23 SVS lamp 55 Reserved terminal
24 Fan switch 56 Reserved terminal
25 Intake temperature sensor 57 Vehicle speed signal
26 Throttle position sensor 58 Reserved terminal
27 Reserved terminal 59 Intake pressure sensor
28 Reserved terminal 60 Oil pump relay
29 Downstream oxygen sensor 61 A/C compressor relay
30 Terminal A of knock sensor 62 Low speed fan relay
31 Terminal B of knock sensor 63 Fuel injector 4 (2
nd
cylinder)
32 Main relay 64 Reserved terminal
* Specific pin number is subject to harness schematic diagram (standby terminal defined as empty pin).

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Installation position is shown in the figure right.

4. Inspection
1) Read the engine trouble record with the data wire K.
2) Check whether the connecting wire of ECM for normal conditions and put the focus on the ECM
power supply and grounding line.
3) Check for normal conditions of external sensor and reliability of output signal normal connection of
its circuit.
4) Check whether the actuator is normal and whether its line is intact.
5) Finally, replace the ECM to carry out the test.
1) Dismantlement
Turn the ignition switch to OFF position to dismantle the negative terminal of battery.
Dismantle the lower part of the console referring to console.
Disconnect the wire harness connector of ECM port. Refer to Precautions.
Unscrew fixing bolts of ECM to remove the ECM.
2) Installation
For precautions about the installation, please refer to Precautions.
Fig. 4.3.026

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Section IV Trouble Diagnosis Procedures for Engine Control System
I. Diagnosis with DTC
1. Instruction
1) The following Repair can be carried out only after the current stable trouble has been identified,
otherwise the diagnosis will be wrong.
2) The "multi-meter" hereinafter refers to the digital multi-meter and it is not permitted to use the
analog multi-meter to check the electric control system circuits.
3) When carrying out the Repair for the vehicle with the anti-theft system, if the requirement of
replacing the ECM is included in the "Next Steps" column, it is necessary to program the ECM
after replacement.
4) If the DTC points to low voltage of a specific circuit, it indicates that the circuit is likely to have
short circuit with ground or open circuit; if the DTC points to high voltage of a specific circuit, it
indicates that the circuit is likely to have short circuit with power circuit; if the DTC points to a
circuit trouble, it indicates that the circuit is likely to have broken circuit or a variety of line
troubles.
2. Diagnosis Help
1) If the DTC can not be erased, it means the trouble is stable; in case of the sporadic trouble, it is
necessary to check whether the connector of wire harness is loosened.
2) The check has been accomplished with steps above and nothing unusual has been found.
3) Effects of the maintenance of vehicle, cylinder pressure and mechanical ignition timing etc. on the
system should not be neglected during the inspection and repairing.
4) Replace the ECM to carry out the test.
If the DTC can be cleared at this time, it means the trouble site is at ECM; if the DTC still can not
be erased at this point, then remount the original ECM and repeat the procedures again to carry out
the Repair.

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3. 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
S/N Step Check result Subsequent step
1
Connect the diagnosis device and adapter, and turn the ignition switch
to ON position.
Next step
Yes To Step 5
2
Check if the intake pressure in the data flow is about 101kpa
(depending on the air pressure then).
No Next step
Yes To Step 5
3
Unplug the connector of intake pressure sensor on the harness, and
measure if the voltage between Pins 3# and 1# of this connector is
about 5V by the multimeter.
No Next step
Yes
Repair or replace
the harness
4
Check if the circuits connecting Pins 40#, 19# and 59# of ECU
respectively to Pins 1#, 3# and 4# of sensor connector are short to
ground.
No Next step
Yes Diagnosis help
5
Start the engine and run the engine idly. Slowly depress the
accelerator pedal and almost open the throttle completely; observe the
change of the Intake pressure value on the diagnosis meter, and at
this moment, the displayed value shall not change significantly; fast
depress the accelerator pedal and almost open the throttle completely,
and at this moment, the displayed value can reach above 90kpa
instantly.
No
Replace the
sensor
Fault code: P0108 the intake pressure sensor is short to power source
1
to ON position.
Next step
Yes To Step 5
2
Check if the intake pressure in the data flow is about 101kpa
(depending on the air pressure then).
No Next step
Yes To Step 5
3
Unplug the connector of intake pressure sensor on the harness, and
measure if the voltage between Pins 3# and 1# of this connector is
No Next step
Yes
Repair or replace
the harness
4
Check if the circuits connecting Pins 40#, 19# and 59# of ECU
respectively to Pins 1#, 3# and 4# of sensor connector are open or
short to power source.
No Next step
Yes Diagnosis help
5
Start the engine and run the engine idly. Slowly depress the
accelerator pedal and almost open the throttle completely; observe the
change of the Intake pressure value on the diagnosis meter, and at
this moment, the displayed value shall not change significantly; fast
depress the accelerator pedal and almost open the throttle completely,
and at this moment, the displayed value can reach above 90kpa
instantly.
No
Replace the
sensor

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Fault code: P0112 the signal voltage of intake temperature sensor is too low
1
to ON position.
Next step
Yes To Step 5
2
Observe if the Intake temperature in the data flow is equivalent to
the temperature inside the intake pipe (depending on the engine
temperature then).
Notice: if the displayed value is always -40 , the circuit may be
open.
No Next step
Yes Next step
3
Unplug the connector of intake temperature sensor on the harness,
and check if the resistance between Pins 1# and 2# of sensor
corresponds to its temperature by the multimeter (refer to the relevant
section in this repair manual for the details).
No
Replace the
sensor
Yes To Step 5
4
and check if the voltage between Pins 1# and 2# of this connector is
about 5v by the multimeter.
No Next step
Yes
Repair or replace
the harness
5
Check if the circuits connecting Pins 40# and 25# of ECU
respectively to Pins 1# and 2# of sensor connector are open or short
to power source.
No Next step
Yes Diagnosis help
6
Start the engine and run the engine idly. Observe the change of the
Intake temperature value on the diagnosis meter, and at this
moment, the displayed value increases along with the rising of engine
intake temperature.
No
Replace the
sensor
Fault code: P0113 the signal voltage of intake temperature sensor is high
1
to ON position.
Next step
Yes To Step 5
2
Observe if the Intake temperature in the data flow is equivalent to
the temperature inside the intake pipe (depending on the engine
temperature then). Notice: if the displayed value is always -40 , the
circuit may be open.
No Next step
Yes Next step
3
No
Replace the
sensor
Yes To Step 5
4
No Next step
Yes
Repair or replace
the harness
5
respectively to Pins 1# and 2# of sensor connector are short to
ground.
No Next step
Yes Diagnosis help
6
Intake temperature value on the diagnosis meter, and at this
moment, the displayed value increases along with the rising of engine
intake temperature.
No
Replace the
sensor

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Fault code: P0117 the circuit voltage of engine coolant temperature sensor is too low
1
to ON position.
Next step
Yes To Step 6
2
Observe if the Coolant temperature in the data flow is equivalent to
the engine temperature (depending on the engine temperature then).
open.
No Next step
Yes Next step
3
Unplug the connector of coolant temperature sensor on the harness,
No
Replace the
sensor
Yes To Step 6
4
No Next step
Yes
Repair or replace
the harness
5
respectively to Pins 1# and 2# of sensor connector are open or short
to power source.
No Next step
Yes Diagnosis help
6
Coolant temperature value on the diagnosis meter, and at this
moment the displayed value shall increase with the rising of engine
coolant.
No
Replace the
sensor
Fault code: P0118 the circuit voltage of engine coolant temperature sensor is too high
1
to ON position.
Next step
Yes To Step 6
2
Observe if the Coolant temperature in the data flow is equivalent to
the engine temperature (depending on the engine temperature then).
open.
No Next step
Yes Next step
3
No
Replace the
sensor
Yes To Step 6
4
No Next step
Yes
Repair or replace
the harness
5
respectively to Pins 1# and 2# of sensor connector are short to
ground.
No Next step
Yes Diagnosis help
6
Coolant temperature value on the diagnosis meter, and at this
moment the displayed value shall increase with the rising of engine
coolant.
No
Replace the
sensor

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Fault code: P0122 the circuit voltage of throttle position sensor is at the extremely low limit
1
to ON position.
Next step
Yes Next step
2
Observe if the value of Throttle opening is between 4% and 10%
(depending on the bus model).
No To Step 5
Yes Next step
3
Slowly depress the accelerator pedal to fully open the throttle, and
observe if the value of Throttle opening in the data flow increases
to 85-95% along with the increase of throttle opening (depending on
the bus model).
No To Step 5
Yes
Replace the
sensor
4
Repeat Step 3 and observe if the value of Throttle opening in the
data flow springs during change.
No Next step
Yes
Repair or replace
the harness
5
Unplug the connector of throttle position sensor on the harness, and
check if the circuits connecting Pins 39#, 18# and 26# of ECU
respectively to Pins 1#, 2# and 3# of sensor connector are short to
ground. No Next step
Yes
Replace the
sensor
6
Check if the voltage between Pins 1# and 2# of this connector is
No Diagnosis help
Fault code: P0123 the circuit voltage of throttle position sensor is at the extremely high limit
1
to ON position.
Next step
Yes Next step
2
Observe if the value of Throttle opening is between 4% and 10%
(depending on the bus model).
No To Step 5
Yes Next step
3
Slowly depress the accelerator pedal to fully open the throttle, and
observe if the value of Throttle opening in the data flow increases
to 85-95% along with the increase of throttle opening (depending on
the bus model).
No To Step 5
Yes
Replace the
sensor
4
Repeat Step 3 and observe if the value of Throttle opening in the
data flow springs during change.
No Next step
Yes
Repair or replace
the harness
5
Unplug the connector of throttle position sensor on the harness, and
check if the circuits connecting Pins 39#, 18# and 26# of ECU
respectively to Pins 1#, 2# and 3# of sensor connector are open or
short to power source. No Next step
Yes
Replace the
sensor
6
Check if the voltage between Pins 1# and 2# of this connector is
No Diagnosis help

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Fault code: P0130 the signal of upstream oxygen sensor is unreasonable
1
to ON position.
Next step
Yes Diagnosis help
2
Start the engine and run the engine idly till the coolant temperature
reaches to the normal value. Observe the change of the value of
Oxygen sensor voltage on the diagnosis meter, and at this moment,
the displayed value shall change fast between 100mV and 900mV.
No Next step
Yes
Repair or replace
the harness
3
respectively to Pin 3# (relative to gray connecting wire of oxygen
sensor) and Pin 4# (relative to black connecting wire of oxygen
sensor) of sensor connector are short to ground.
No Next step
Yes
Make check and
repair according
to diagnosis
results.
4
A. Check if the intake system has serious leakage.
B. Check if the fuel injector is blocked.
C. Check if the spark plug clearance is too big.
D. Check if the resistance of live wire branch is too high.
E. Check if the intake valve guide is worn.
Etc.
No Diagnosis help
Fault code: P0131 the circuit voltage of upstream oxygen sensor signal is too low
1
to ON position.
Next step
Yes Diagnosis help
2
No Next step
Yes
Repair or replace
the harness
3
sensor) of sensor connector are short to power source.
No Diagnosis help
Fault code: P0132 the circuit voltage of upstream oxygen sensor signal is too high
1
to ON position.
Next step
Yes Diagnosis help
2
No Next step
Yes
Repair or replace
the harness
3
No Diagnosis help

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Fault code: P0134 the upstream oxygen sensor signal is in trouble
1
to ON position.
Next step
Yes Diagnosis help
2
No Next step
Yes
Repair or replace
the harness
3
sensor) of sensor connector are open.
No Diagnosis help
Fault code: P0171 the closed loop control self leaning of off-line air/fuel ratio test is too infrequent
(Note: the following diagnosis procedures are applicable to the case that the fault codes of intake
pressure sensor, canister control valve, oxygen sensor and so on do not occur together; if the relevant
fault codes exist at the same moment, please firstly solve other faults and then make check and repair
according to the following procedure.)
1
to ON position.
Next step
Yes Next step
2
reaches to the normal value.
Under all the work conditions, observe the change of the value of
check if the displayed value remains at 100mV or so for a long time
under a certain condition.
No Diagnosis help
Yes Next step
3
Connect the fuel pressure meter to the fuel system inlet pipe, and
observe if the fuel pressure remains at 350kPa or so under all the
work conditions.
No
Check and repair
the fuel system
Yes
Repair or replace
the harness
4
sensor) of sensor connector are short to ground.
No Next step
Yes
Make check and
repair according
to diagnosis
results.
5
A. Check if the intake system has serious leakage;
C. Check if the spark plug clearance is too big.
D. Check if the resistance of live wire branch is too high.
E. Check if the intake valve guide is worn.
Etc.
No Diagnosis help
Fault code: P0172 the closed loop control self leaning of off-line air/fuel ratio test is too frequent
(Note: the following diagnosis procedures are applicable to the case that the fault codes of intake
pressure sensor, canister control valve, oxygen sensor and so on do not occur together; if the relevant
fault codes exist at the same moment, please firstly solve other faults and then make check and repair
according to the following procedure.)

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1
to ON position.
Next step
Yes Next step
2
reaches to the normal value.
Under all the work conditions, observe the change of the value of
check if the displayed value remains at 900mV or so for a long time
under a certain condition.
No Diagnosis help
Yes Next step
3
Connect the fuel pressure meter to the fuel system inlet pipe, and
observe if the fuel pressure remains at 350kPa or so under all the
work conditions.
No
Check and repair
the fuel system
Yes
Repair or replace
the harness
4
No Next step
Yes
Make check and
repair according
to diagnosis
results.
5
A. Check if the fuel injector drips fuel.
B. Check if the exhaust pipe has leakage.
C. Check if the ignition timing is incorrect.
Etc.
No Diagnosis help
Fault code: P0201 the control circuit of fuel injector of Cylinder 1# is open
1
to ON position.
Next step
Yes To Step 4
2
Unplug the connector of the fuel injector of Cylinder 1# on the
harness, and check if the voltage between Pin 1# of this connector
and the negative pole of power source is about 12V by the
multimeter.
No Next step
Yes
Repair or replace
the harness
3
Check if the circuit between Pin 1# of the fuel injector connector of
Cylinder 1# and the main relay is open or short to ground.
No Next step
Yes Next step
4
Check if the resistance between Pins 1# and 2# of the fuel injector of
Cylinder 1# at 20 is between 11 and 13 by the multimeter.
No
Replace the fuel
injector
Yes Diagnosis help
5
Check if the voltage between Pin 2# of the fuel injector of Cylinder
1# and the negative pole of power source is about 3.7V by the
multimeter.
No Next step
Yes
Repair or replace
the harness
6
Cylinder 1# and Pin 50 of ECU is open or short to power source or
ground.
No Diagnosis help

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215
1
to ON position.
Next step
Yes To Step 4
2
multimeter.
No Next step
Yes
Repair or replace
the harness
3
No Next step
Yes Next step
4
Cylinder 2# at 20 is between 11 and 13 by the multimeter.
No
Replace the fuel
injector
Yes Diagnosis help
5
multimeter.
No Next step
Yes
Repair or replace
the harness
6
ground.
No Diagnosis help
1
to ON position.
Next step
Yes To Step 4
2
multimeter.
No Next step
Yes
Repair or replace
the harness
3
No Next step
Yes Next step
4
Cylinder 3# at 20 is between 11 and 13 by the mul timeter.
No
Replace the fuel
injector
Yes Diagnosis help
5
multimeter.
No Next step
Yes
Repair or replace
the harness
6
ground.
No Diagnosis help

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216
Fault code: P0327 the circuit voltage of knocking sensor signal is too low
1
to OFF position.
Next step
Yes Next step
2
Unplug the knocking sensor connector on the harness, and check if
the resistance between Pins 1# and 2# of knocking sensor is higher
than 1M by the multimeter.
No
Replace the
sensor
Yes
Repair or replace
the harness
3
Check if the circuits connecting to Pins 1# and 2# of knocking sensor
connector to Pins 30# and 31# of ECU are open or short to power
source or ground.
No Next step
Yes Diagnosis help
4
According to the specifications, replace the knocking sensor, test the
car and make engine rotation speed higher than 2200rpm. Check if
the fault code P0327 appears again.
No
Check if it is a
sporadic fault
Fault code: P0328 the circuit voltage of knocking sensor signal is too high
1
to OFF position.
Next step
Yes Next step
2
Unplug the knocking sensor connector on the harness, and check if
the resistance between Pins 1# and 2# of knocking sensor is higher
than 1M by the multimeter.
No
Replace the
sensor
Yes
Repair or replace
the harness
3
Check if the circuits connecting to Pins 1# and 2# of knocking sensor
connector to Pins 30# and 31# of ECU are open or short to power
source or ground.
No Next step
Yes Diagnosis help
4
According to the specifications, replace the knocking sensor, test the
car and make engine rotation speed higher than 2200rpm. Check if
the fault code P0328 appears again.
No
Check if it is a
sporadic fault
Fault code: P0340 the mounting position of phase sensor is incorrect
1
to ON position.
Next step
Yes To Step 4
2
Unplug the phase sensor connector on the harness, and check if the
voltage between Pins 3# and 1# of this connector is about 12V by the
multimeter.
No Next step
Yes
Repair or replace
the harness
3
Check if the circuit connecting Pin 3# of phase sensor to Pin 87# of
main relay is open or short to ground.
Check if Pin 1# of phase sensor is grounded improperly.
No Next step

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217
Yes To Step 6
4
Check if the voltage between Pin 2# of phase sensor and the negative
pole of power source is about 9.9V.
No Next step
Yes
Repair or replace
the harness
5
Check if the circuit connecting to Pin 2# of phase sensor connector to
Pin 42# of ECU is open or short to power source or ground.
No Next step
Yes Diagnosis help
6 Check if the signal panel of camshaft is good.
No
Replace the
signal panel
Fault code: P0341 the contact of phase sensor is not good
1
to ON position.
Next step
Yes To Step 4
2
multimeter.
No Next step
Yes
Repair or replace
the harness
3
No Next step
Yes To Step 6
4
No Next step
Yes
Repair or replace
the harness
5
No Next step
Yes Diagnosis help
No
Replace the
signal panel
Fault code: P0342 the phase sensor is short to ground
1
to ON position.
Next step
Yes To Step 4
2
multimeter.
No Next step
Yes
Repair or replace
the harness
3
No Next step

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218
Yes To Step 6
4
No Next step
Yes
Repair or replace
the harness
5
No Next step
Yes Diagnosis help
No
Replace the
signal panel
Fault code: P0343 the phase sensor is short to power source
1
to ON position.
Next step
Yes To Step 4
2
multimeter.
No Next step
Yes
Repair or replace
the harness
3
No Next step
Yes To Step 6
4
No Next step
Yes
Repair or replace
the harness
5
No Next step
Yes Diagnosis help
No
Replace the
signal panel
Fault code: P0444 the control circuit of canister control valve is open
1
to ON position.
Next step
Yes To Step 4
2
Unplug the connector of canister control valve on the harness, and
check if the voltage between Pin 1# of this connector and the negative
pole of power source is about 12V by the multimeter.
No Next step
Yes
Repair or replace
the harness
3
Check if the circuit of power supply side of canister control valve is
open or short to ground.
No To Step 2
4
Check if the resistance between Pins 1# and 2# of the canister control
Yes Next step

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219
valve at 20 is between 22 and 30 by the multimeter.
No
Replace the
control valve
Yes Diagnosis help
5
Check if the voltage between Pin 1# of the canister control valve
connector and the negative pole of power source is about 3.7V by the
multimeter.
No Next step
Yes
Repair or replace
the harness
6
Check if the circuit connecting Pin 2# of canister control valve
connector to Pin 37# of ECU is open.
No Diagnosis help
Fault code: P0458 the voltage of control circuit of canister control valve is too low
1
to ON position.
Next step
Yes To Step 4
2
No Next step
Yes
Repair or replace
the harness
3
No To Step 2
Yes Next step
4
No
Replace the
control valve
Yes Diagnosis help
5
multimeter.
No Next step
Yes
Repair or replace
the harness
6
connector to Pin 37# of ECU is short to ground.
No Diagnosis help
Fault code: P0459 the voltage of control circuit of canister control valve is too high
1
to ON position.
Next step
Yes To Step 4
2
No Next step
Yes
Repair or replace
the harness
3
No To Step 2
Yes Next step
4
No
Replace the
control valve
Yes Diagnosis help
5
multimeter.
No Next step

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220
Yes
Repair or replace
the harness
6
connector to Pin 37# of ECU is short to power source.
No Diagnosis help
Fault code: P0480 the control circuit of cooling fan relay is open (low speed)
1
to OFF position.
Next step
Yes To Step 4
2
Unplug the A/C condenser cooling fan relay, turn the ignition key to
ON position, and check if the voltage between the relay power
supply side (namely Pins 30# and 87# of relay) and the negative pole
of power source is about 12V.
No Next step
Yes
Repair or replace
the harness
3
Check if the circuit of power supply side of A/C condenser cooling
fan relay is open or short to ground.
No To Step 2
Yes Replace the relay
4
Check if the voltage between the control side of A/C condenser
cooling fan relay (namely Pin 86# of relay) and the negative pole of
power source is about 3.7V by the multimeter.
No Next step
Yes
Repair or replace
the harness
5
Check if the circuit connecting to Pin 86# of relay control side to Pin
62# of ECU is open or short to power source or ground.
No Diagnosis help
Fault code: P0481 the control circuit of cooling fan relay is open (high speed)
1
to OFF position.
Next step
Yes To Step 4
2
Unplug the A/C condenser cooling fan relay, turn the ignition key to
ON position, and check if the voltage between the relay power
supply side (namely Pins 30# and 87# of relay) and the negative pole
of power source is about 12V.
No Next step
Yes
Repair or replace
the harness
3
Check if the circuit of power supply side of A/C condenser cooling
fan relay is open or short to ground.
No To Step 2
4
Check if the voltage between the control side of A/C condenser
cooling fan relay (namely Pin 86# of relay) and the negative pole of
power source is about 3.7V.
No Next step
Yes
Repair or replace
the harness
5
Check if the circuit connecting to Pin 86# of relay control side to Pin
52# of ECU is open or short to power source or ground.
No Diagnosis help

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221
Fault code: P0501 the vehicle speed signal is unreasonable
1
to OFF position.
Next step
Yes
Check and repair
ABS system
2
For the car with ABS system, please check if the ABS system has any
fault code.
No Next step
Yes Next step
3 Check if the finger of speedometer operates normally.
No
Check and repair
the instrument
circuit
Yes Next step
4 Check if the vehicle speed sensor operates normally.
No
Replace the
vehicle speed
sensor
Yes
Repair or replace
the harness
4
Check if the circuit connecting to vehicle speed sensor signal wire to
No Diagnosis help
Fault code: P0506 the idle speed is the lower than the target idle speed
1
to OFF position.
Next step
Yes Next step
2 Check if the adjusting screw, cable and condition of throttle are good.
No
Do the necessary
repair and
maintenance
Yes Next step
3 Check if the working condition of idle regulator is good.
No
Do the necessary
repair and
maintenance
Yes
Do the necessary
check and repair
4
A. Check if the pressure of fuel supply system is too low.
C. Check if the system exhaust line is blocked. No Diagnosis help
Fault code: P0507 the idle speed is the higher than the target idle speed
1
to OFF position.
Next step
Yes Next step
2 Check if the adjusting screw, cable and condition of throttle are good.
No
Do the necessary
repair and
maintenance

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222
Yes Next step
3 Check if the working condition of idle regulator is good.
No
Do the necessary
repair and
maintenance
Yes
Do the necessary
check and repair
4
A. Check if the system leaks air
B. Check if the fuel injector drips fuel.
C. Check if the pressure of fuel supply system is too high. No Diagnosis help
Fault code: P0508 the drive pin of stepping motor is short to ground
1
to ON position.
Next step
Yes Next step
2
Unplug the idle regulator connector, and check if the resistances
between Pins A and D and Pins B and C of stepping motor at 20
are 535.3.
No
Replace the
stepping motor
Yes
Repair or replace
the harness
3
Check if the circuits connecting Pins A, B, C and D of stepping motor
connector respectively to Pins 22#, 21#, 35# and 36# of ECU are
short to ground.
No Diagnosis help
Fault code: P0509 the drive pin of stepping motor is short to power source
1
to ON position.
Next step
Yes Next step
2
Unplug the idle regulator connector, and check if the resistances
between Pins A and D and Pins B and C of stepping motor at 20
are 535.3 by the multimeter.
No
Replace the
stepping motor
Yes
Repair or replace
the harness
3
short to power source.
No Diagnosis help
Fault code: P0511 the drive pin of stepping motor is in open circuit
1
to ON position.
Next step
Yes Next step
2
Unplug the stepping motor connector, and check if the resistances
between Pins A and D and Pins B and C of idle regulator at 20 are
535.3 by the multimeter.
No
Replace the
stepping motor
Yes
Repair or replace
the harness
3
open.
No Diagnosis help

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Fault code: P0560 the voltage signal of system battery is unreasonable
1
to OFF position.
Next step
Yes Next step
2 Check if the battery voltage is about 12V by the multimeter.
No
Replace the
battery
Yes
Repair or replace
the harness
3
Check if the circuits connecting Pin 8# and 51# of ECU respectively
to Pin 87# of main relay are open or short to ground.
No Next step
Yes Next step
4
Start the engine, and check if the charging voltage of generator is
always between 9V and 16V within different rotation speed ranges.
No
Replace the
generator
Yes Diagnosis help
5 Check if the grounding point of engine harness is good.
No
Repair or replace
the harness
Fault code: P0562 the voltage of system battery is too low
1
to OFF position.
Next step
Yes Next step
No
Replace the
battery
Yes
Repair or replace
the harness
3
Check if the resistances of circuits connecting Pins 8# and 51# of
ECU to Pin 87# of main relay are too high.
No Next step
Yes Next step
4
No
Replace the
generator
Yes Diagnosis help
No
Repair or replace
the harness
Fault code: P0563 the voltage of system battery is too high
1
to OFF position.
Next step
Yes Next step
No
Replace the
battery
3
Yes Next step

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224
No
Replace the
generator
Yes Diagnosis help
No
Repair or replace
the harness
Fault code: P0602 the programming of electronic control unit is in trouble
1
to ON position.
Next step
Yes Next step
2 Eliminate the fault code and reconfirm if this fault is a steady fault.
No
The system is
normal.
3 Replace ECU. End
Fault code: P0645 the control circuit of A/C compressor relay is open
1
to OFF position.
Next step
Yes To Step 4
2
Unplug the A/C compressor relay, turn the ignition key to ON
position, and check if the voltage between the relay power supply
side (namely Pins 87# and 85# of relay) and the negative pole of
power source is about 12V.
No Next step
Yes
Repair or replace
the harness
3
Check if the circuit of relay power supply side is open or short to
ground.
No To Step 2
4
Check if the voltage between the control side of A/C compressor
relay (namely Pin 86# of relay) and the negative pole of power source
is about 3.7V.
No Next step
Yes
Repair or replace
the harness
5
Check if the circuit connecting control side of A/C compressor relay
(namely Pin 86# of relay) to Pin 61# of ECU is open.
No Diagnosis help
Fault code: P0646 the control circuit of A/C compressor relay is short to ground
1
to OFF position.
Next step
Yes To Step 4
2
No Next step
3
ground.
Yes
Repair or replace
the harness

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225
No To Step 2
4
is about 3.7V by multimeter by the multimeter.
No Next step
Yes
Repair or replace
the harness
5
(namely Pin 86# of relay) to Pin 61# of ECU is short to ground.
No Next step
Yes Diagnosis help
6
Check if the electromagnetic clutch of A/C compressor operates
normally.
No
Repair or replace
the
electromagnetic
clutch
Fault code: P0647 the control circuit of A/C compressor relay is short to power source
1
to OFF position.
Next step
Yes To Step 4
2
No Next step
Yes
Repair or replace
the harness
3
ground.
No To Step 2
4
is about 3.7V by multimeter.
No Next step
Yes
Repair or replace
the harness
5
(namely Pin 86# of relay) to Pin 61# of ECU is short to power source.
No Next step
Yes Diagnosis help
6
Check if the electromagnetic clutch of A/C compressor operates
normally.
No
Repair or replace
the
electromagnetic
clutch
Fault code: P1651 the control circuit of engine malfunction lamp (SVS) is in trouble
1
to ON position.
Next step
Yes Next step
2
Test the action of engine malfunction lamp by the Actuator action
test of diagnosis device, and observe if it is always off or on.
No
The system is
normal.

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226
Yes
Repair or replace
the harness
3
Check if the circuit of power supply side of engine malfunction lamp
is open or short to ground.
No Next step
Yes
Repair or replace
the harness
4
Check if the circuit connecting pin of engine malfunction lamp
control side to Pin 23# of ECU is open or short to power source or
ground.
No Next step
Yes Diagnosis help
5 Check if the bulb of engine malfunction lamp operates normally.
No Replace the bulb
II. Diagnosis by Trouble Phenomena
1. Instruction
Before carrying out the trouble diagnosis steps with the engine trouble phenomenon, it is necessary to
firstly conduct the preliminary check:
1) Confirm that the malfunction indicator lamp of engine operates normally.
2) Check with trouble diagnoses apparatus to confirm that there is no trouble information record.
3) Confirm existence of the trouble complain from owner and the conditions about the occurrence of
the trouble.
And then check the appearance:
1) Check fuel pipes for leakage.
2) Check vacuum pipes for breakage or kink and proper connection.
3) Check intake pipes for blockage, leakage, flatness or damage.
4) Check high-voltage wire of ignition system for broken, aging, verify correct ignition sequence.
5) Check grounding position of wire harness for clean and firm.
6) Check the connector of each sensor and actuator for the looseness or poor contact.
Attention: If any of above-mentioned phenomena exists, firstly conduct maintenance operation
against it; otherwise the following trouble diagnosis and maintenance will be affected.
2. Diagnosis Help
1) Confirm that there is no trouble record related to engine.
2) Confirm the existence of the trouble complained by the owner.
3) The check has been done with steps above, and there is nothing unusual found.
4) It is not permitted to neglect the effects of the maintenance of vehicle, cylinder pressure,
mechanical ignition timing and fuel etc. on the system during the Repair process.
5) Replace the ECM to test.
If the trouble phenomenon can be cleared at this time, it means the trouble site is at ECM; if the trouble

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227
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:
1. Battery; 2. Starter; 3.Wire harness or ignition switch; 4.Mechanical part of engine
General diagnosis procedure:
No. Operating Steps Detection Results Subsequent Steps
Yes Next step
1
Check the voltage between the two terminals of battery with
multi-meter to see whether it is about 8-12V during starting
of engine.
No Replace battery
Yes Next step
2
With ignition switch at the starting position, check voltage of
starter negative terminal to verify that it is above 8V.
No
Repair or replace
wire harness
Yes
Repair or replace the
starter
3
Dismantle the starter to check its operating state. Mainly
check for sticking due to open circuit or poor lubrication.
No Next step
Yes
Change with
lubricating oil of
proper grade
4
If the trouble only present in winter, then check whether too
large resistance of starter is caused by improper selection of
the lubricating oil for engine or the gearbox oil.
No Next step
Yes
Remove large
internal resistance of
engine
5
Check engine for too large internal mechanical resistance; if
it is a case, the failure of rotation or the slow rotation of
starter may occur.
No Repeat above steps

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228
Trouble phenomenon 2: Engine start to run but can not be started successfully during the
start-up
1. No fuel in the fuel tank; 2. Fuel injection pump; 3.Crankshaft position sensor; 4.Ignition coil;
5.Mechanical part of engine
No. Operating Steps
Detection
Results
Subsequent Steps
Yes Next step
1
Connect the fuel pressure gauge (the access point is at the front
end of the induction manifold of the fuel distribution pipe
assembly) to the engine, and start the engine to determine
whether the readings of fuel pressure gauge when idling is at
about 260kPa; disconnect vacuum hose of pressure regulator
and observe whether fuel pressure is about 300kPa.
No
Repair the fuel supply
system
Yes Next step
2
Connect the electric control system diagnosis apparatus to the
engine to observe the data of "rotating speed of engine" and
start the engine to observe whether there is speed signal output.
No
Repair crankshaft
position sensor circuit
Yes Next step
3
Pull out the high-voltage wire of one of the cylinders and
connect the spark plug to make the spark plug electrodes
around 5mm away from the engine body, and start the engine to
check whether there is blue and white high-voltage spark.
No Repaire ignition system
Yes
Eliminate mechanical
trouble of engine
4
Check the pressure of all the cylinders and observe whether the
pressure of engine cylinders is insufficient.
No Next step
Yes Diagnosis help
5
Turn on the ignition switch and check whether the power
supply and earthing are normal.
No Repair related circuit

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Trouble phenomenon 3: Difficulty in warm start
1. Poor quality of fuel; 2.Fuel injection pump; 3.Coolant temperature sensor; 4.Ignition coil
No. Operating Steps
Detection
Results
Subsequent Steps
Yes Next step
1
Connect the fuel pressure gauge (the access point is at the front end
of the induction manifold of the fuel distribution pipe assembly) to
the engine and start the engine to check whether the reading of fuel
pressure gauge at idle condition is at about 260kPa. Disconnect
vacuum hose on pressure regulator and observe whether fuel
pressure is about 300kPa.
No
Repair fuel supply
system
Yes Next step
2
Pull out the high-voltage wire of one of the cylinders and connect
the spark plug to make the spark plug electrodes about 5mm away
from the engine body, and start the engine to check whether there is
the blue and white high-voltage spark.
No Repair ignition system
Yes
Repair circuit or
replace the sensor
3
Pull out connector of coolant temperature sensor and start the
engine to observe whether the engine is successfully started at this
time. (Alternatively, connect a 300 ohm resistance in series at the
connector of coolant temperature sensor to observe whether the
engine is successfully started at this time.)
No Next step
Yes Repair or replace
4
Check the vacuum pipe of fuel pressure regulator for the shedding
or air leakage.
No Next step
Yes Change fuel
5
Check fuel conditions and observe whether the trouble phenomenon
occurs just after adding fuel.
No Next step
Yes Diagnosis help
6
Turn on the ignition switch and check whether the power supply
and earthing are normal.

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Trouble phenomenon 4: Difficulty in cold start
1. 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
Yes Next step
1
Connect the fuel pressure gauge (the access point is at the
front end of the induction manifold of the fuel distribution
pipe assembly) to the engine and start the engine to check
whether the reading of fuel pressure gauge at idle condition
is at about 260kPa. Disconnect vacuum hose on pressure
regulator and observe whether fuel pressure is about 300kPa.
No
Repair fuel supply
system
Yes Next step
2
connect the spark plug to make the spark plug electrodes
about 5mm away from the engine body, and start the engine
to check whether there is the blue and white high-voltage
spark.
No
Repair the ignition
system
Yes
Repair circuit or
replace the sensor
3
Pull out the connector of coolant temperature sensor and
start the engine to observe whether the engine is successfully
started at this time. (Alternatively, connect a 2500 ohm
resistance in series at the connector of coolant temperature
sensor to observe whether the engine is successfully started
at this time.)
No Next step
Yes
Wash the air throttle
and idle air passage
4
Gently step down the accelerator pedal to observe whether it
is easy to start.
No Next step
Yes
Failure of
Replacement
5
Dismantle the fuel injector and check whether there is
leakage or blockage in the fuel injector with the cleaning
analyzer special for fuel injector.
No Next step
Yes Change fuel
6
Check the fuel conditions and observe whether the trouble
phenomenon occurs just after adding the fuel.
No Next step
Yes
Eliminate the
mechanical trouble of
engine
7
Check the pressure states of all the cylinders of engine and
observe whether the pressure of engine cylinder is
insufficient.
No Next step
Yes Diagnosis help
8

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Trouble phenomenon 5: Engine speed is normal, but it is difficult to start all the time
1. Poor quality of fuel; 2. Fuel injection pump; 3.Coolant temperature sensor; 4.Fuel injector;
5.Ignition coil; 6.Throttle body and idle bypass air passage; 7.Intake passage; 8.Ignition timing;
9.Spark plug; 10.Mechanical part of engine
Yes
Repair air intake
system
1 Check air filter for blockage and intake passage for leakage.
No Next step
Yes Next step
2
Connect the fuel pressure gauge (the access point is at the front
end of the induction manifold of the fuel distribution pipe
assembly) to the engine and start the engine to check whether the
reading of fuel pressure gauge at idle condition is at about
260kPa. Disconnect vacuum hose on pressure regulator and
observe whether fuel pressure is about 300kPa.
No
Repair fuel supply
system
Yes Next step
3
Pull out the high-voltage wire of one of the cylinders and connect
the spark plug to keep the spark plug electrodes about 5mm away
from the engine body, then start the engine to check whether there
is the blue and white high-voltage spark.
No
Repair the ignition
system
Yes Next step
4
Check the spark plug of each cylinder to observe whether model
and gap are in compliance with the specification.
No Adjust or replace
Yes
Repair the lien or
replace the sensor
5
Pull out the connector of coolant temperature sensor and start the
engine to observe whether the engine is successfully started at this
time.
No Next step
Yes
Wash throttle and
idling air passage
6 Gently step down the throttle to observe whether it is easy to start.
No Next step
Yes
Failure of
Replacement
7
Dismantle the fuel injector and check whether there is leakage or
blockage in the fuel injector with cleaning analyzer special for
fuel injector.
No Next step
Yes Change fuel
8
Check fuel condition and observe whether the trouble
No Next step
Yes
Eliminate the
engine
9
Check pressure of all the cylinders and observe whether the
pressure of engine cylinder is insufficient.
No Next step
Yes Next step
10
Check whether the ignition sequence of engine and ignition
timing is in line with the specification.
No
Repair the ignition
timing
Yes Diagnosis help
11

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Trouble phenomenon 6: Normal start-up but unstable idling at any time
1. Poor quality of fuel; 2.Fuel injector ; 3.Spark plug; 4.Throttle body and idle bypass air passage;
5.Intake passage; 6.Idle adjustor (step motor ); 7.Ignition timing; 8.Spark plug; 9.Mechanical part
of engine.
No. Operating Steps
Detection
Results
Subsequent Steps
Yes
Repair the intake
system
1 Check air filter for blockage and intake passage for leakage.
No Next step
Yes Wash or replace
2 Check idle adjustor for sticking.
No Next step
Yes Next step
3
Check the spark plug of each cylinder to observe whether its model
Yes Wash
4
Check air throttle body and idle bypass air passage for carbon
deposit.
No Next step
Yes
Failure of
Replacement
5
Dismantle the fuel injector and use the cleaning analyzer special for
fuel injector to check whether there is leakage, blockage or too poor
flow in the fuel injector.
No Next step
Yes Change fuel
6
Check fuel condition and observe whether the trouble phenomenon
occurs just after adding the fuel.
No Next step
Yes
Eliminate the
engine
7
pressure difference of each engine cylinders is large.
No Next step
Yes Next step
8
Check whether the ignition sequence of engine and ignition timing
is in compliance with specification.
No Repair ignition timing
Yes Diagnosis help
9

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Trouble phenomenon 7: Normal start-up but unstable idling during the warming-up
1. Poor quality of fuel; 2. Coolant temperature sensor; 3.Spark plug; 4.Throttle body and idle bypass
air passage; 5.Intake passage; 6.Idle adjustor; 7.Mechanical part of engine.
No. Operating Steps
Detection
Results
Subsequent Steps
Yes
Repair air intake
system
1 Check air filter for blockage and air intake passage for leakage.
No Next step
Yes Next step
2
Check the spark plug of each cylinder to observe whether its model
Yes
Wash related
components
3
Dismantle the idle adjustor to check whether there is carbon deposit
in the air throttle body, idle adjustor or idle bypass air passage.
No Next step
Yes
Repair circuit or
replace sensor
4
engine to observe whether the idle speed of engine is unstable
during warming-up.
No Next step
Yes
Failure of
Replacement
5
Dismantle the fuel injector and check whether there is leakage,
blockage or too poor flow in the fuel injector with cleaning analyzer
special for fuel injector.
No Next step
Yes Change fuel
6
Check fuel condition and observe whether the trouble phenomenon
occurs just after adding the fuel.
No Next step
Yes
Eliminate the
engine
7
pressure difference of each engine cylinders is large.
No Next step
Yes Diagnosis help
8

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Trouble phenomenon 8: Normal start-up but unstable idle speed after warmed-up
1. Poor quality of fuel; 2. Coolant temperature sensor; 3.Spark plug; 4.Air throttle body and idle
bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Mechanical part of engine.
No. Operating Steps
Detection
Results
Subsequent Steps
Yes Repair the intake system
1
Check air filter for blockage and air intake passage for
leakage.
No Next step
Yes Next step
2
Check spark plug of each cylinder to observe whether
its model and gap are in compliance with the
specification.
Yes Wash related components
3
Dismantle the idle adjustor to check whether there is
carbon deposit in the air throttle body, idle adjustor and
idle bypass air passage.
No Next step
Yes
Repair circuit or replace
sensor(s)
4
Pull out the connector of coolant temperature sensor
and start the engine to observe whether the idle speed of
engine is unstable during warm-up process.
No Next step
Yes Failure of replacement
5
leakage, blockage or too poor flow in the fuel injector
with cleaning analyzer special for fuel injector.
No Next step
Yes Change fuel
6
No Next step
Yes
Eliminate mechanical trouble
of engine
7
Check pressure of all the cylinders and observe whether
the pressure difference of each engine cylinders is large.
No Next step
Yes Diagnosis help
8
Turn on the ignition switch and check whether the
power supply and earthing are normal.

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235
Trouble phenomenon 9: Normal start-up but unstable idling speed or flameout with partially load
(for example, when the air conditioner is on)
1. Air conditioning system; 2. Idle adjustor; 3.Fuel injector
No. Operating Steps
Detection
Results
Subsequent Steps
Yes
Wash related
components
1
in the air throttle body, idle adjustor and idle bypass air passage.
No Next step
Yes To step 4
2
Observe whether power output of engine is increased air
conditioner operation, namely, use the electric control system
diagnosis apparatus to observe the changes of ignition advance
angle, fuel injector pulse width and intake volume.
No Next step
Yes Next step
3
Connect the adapter of electric control system and disconnect the
connecting wire of the pin #75 of electronic control module to
check whether there is high level signal at the wire harness end with
AC turned on.
No
Repair air
conditioning system
Yes Next step
4
Inspect pressure of air conditioning system, electromagnetic clutch
of compressor and the compressor pump of air conditioner.
No Repair AC system
5
Dismantle the fuel injector and check whether there is leakage,
blockage or too poor flow in the fuel injector with cleaning analyzer
special for fuel injector.
No Next step
Yes Diagnosis help
6

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236
Trouble phenomenon 10: Normal start-up but too high idling speed
1. Throttle body and idle bypass air passage; 2.Vacuum pipe; 3.Idle adjustor; 4.Coolant temperature
sensor; 5.Ignition timing
No. Operating Steps
Detection
Results
Subsequent Steps
Yes Adjust
1 Check throttle cable for catching or overtension..
No Next step
Yes Repair intake system
2 Check air intake system and vacuum pipeline or leakage.
No Next step
Yes
Wash related
components
3
in the air throttle body, idle adjustor and idle bypass air passage.
No Next step
Yes
Repair circuit or
replace sensor
4
engine to observe whether the idle speed of engine is too high at
this time.
No Next step
Yes Next step
5
Check whether the ignition timing of engine is in compliance with
the specification.
Yes Diagnosis help
6

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237
Trouble phenomenon 11: Engine speed fails to increase or flameout occurs during acceleration
1. 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;
8.Ignition timing; 9.Exhaust pipe.
Yes Repair intake system
1 Check air filter for blockage.
No Next step
Yes Next step
2
whether the reading of fuel pressure gauge when idling is at
about 260kPa; disconnect vacuum hose from pressure
regulator to see whether fuel pressure is about 200kPa.
No
Repair fuel supply
system
Yes Next step
3
Check spark plug of each cylinder to observe whether its
model and gap are in compliance with the specification.
Yes
Wash related
components
4
Dismantle the idle adjustor to check whether there is carbon
deposit in the air throttle body, idle adjustor and idle bypass
air passage.
No Next step
Yes Next step
5
Check whether the intake pressure sensor, air throttle
position sensor and their circuits are normal.
No
Repair circuit or
replace sensor(s)
6
leakage or blockage in the fuel injector with cleaning
No Next step
Yes Change fuel
7
No Next step
Yes Next step
8
timing is in compliance with specification.
Yes Next step
9 Check whether the operation of the exhaust pipe is smooth.
No
exhaust pipe
Yes Diagnosis help
10

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Trouble phenomenon 12: Slow response of acceleration
1. 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;
8.Ignition timing; 9. Exhaust pipe
Yes
Repair air intake
system
No Next step
Yes Next step
2
about 260kPa. disconnect vacuum hose from pressure
No
Repair fuel supply
system
Yes Next step
3
Check the spark plug of each cylinder to observe whether its
model and gap are in compliance with the specification.
Yes
Wash related
components
4
air passage.
No Next step
Yes Next step
5
Check whether the intake pressure sensor, air throttle position
sensor and its circuit are normal.
No
Repair circuit or
replace sensor
6
leakage or blockage in the fuel injector with cleaning
No Next step
Yes Change fuel
7
No Next step
Yes Next step
8
9 Check whether the operation of the exhaust pipe is smooth. No
exhaust pipe
Yes Diagnosis help
10

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Trouble phenomenon 13: Powerlessness and poor performance during acceleration
1. 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;
8.Fuel injector; 9.Ignition timing ; 10.Exhaust pipe.
Yes Repair
1
Check whether there are such troubles as the clutch slipping,
low tire pressure, braking drag, wrong size of tire and
incorrect alignment of four wheels etc.
No Next step
Yes Repair air intake system
No Next step
Yes Next step
3
about 260kPa. Disconnect vacuum hose from pressure
No Repair fuel supply system
Yes Next step
4
connect the spark plug to keep the spark plug electrodes about
5mm away from the engine body, and start the engine to
check whether the strength of high-voltage spark.
No

Repair ignition system

Yes Next step
5
Check the spark plug of each cylinder to observe whether its
model and gap is in compliance with the specification.
Yes
Wash the related
components
6
air passage.
No Next step
Yes Next step
7
Check whether the intake pressure sensor, air throttle position
sensor and its line are normal.
No
Repair circuit or replace
sensor
8
Dismantle the fuel injector and check whether there is leakage
or blockage in the fuel injector with cleaning analyzer special
for fuel injector.
No Next step
Yes Change fuel
9
No Next step
Yes Next step
10
11 Check whether the operation of the exhaust pipe is smooth. No
Repair or replace exhaust
pipe
Yes Diagnosis help
12

1.0 Table of Common Malfunction Codes for UAES Control
System of 3-Cylinder Engine
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 Open-circuit of downstream oxygen sensor heating control circuit
P0037 Short-circuit of downstream oxygen sensor heating control circuit to ground
P0038 Short-circuit of downstream oxygen sensor heating control circuit to power supply
P0053 Inappropriate heating internal resistance of upstream oxygen sensor
P0054 Inappropriate heating internal resistance of downstream oxygen sensor
P0105 No signal variation of air intake pressure sensor (Frozen)
P0106 Inappropriate air intake pressure sensor
P0107 Short-circuit of air intake pressure sensor to ground
P0108 Short-circuit of air intake pressure sensor to power supply
P0112 Low signal voltage of air intake pressure sensor
P0113 High signal voltage of air intake pressure sensor
P0117 Low voltage of engine coolant temperature sensor circuit
P0118 High voltage of engine coolant temperature sensor circuit
P0122 Out-of-lower-limit of throttle position sensor circuit voltage
P0123 Out-of-upper-limit of throttle position sensor circuit voltage
P0130 Inappropriate upstream oxygen sensor signal
P0131 Low upstream oxygen sensor signal circuit voltage
P0132 High upstream oxygen sensor signal circuit voltage
P0134 Malfunction of upstream oxygen sensor circuit signal
P0136 Inappropriate downstream oxygen sensor signal
P0137 Low downstream oxygen sensor signal circuit voltage
P0138 High downstream oxygen sensor signal circuit voltage
P0140 Malfunction of downstream oxygen sensor circuit signal
P0170 Inappropriate closed-loop control self-learning of off-line testing air-fuel ratio
P0171 Thin closed-loop control self-learning of off-line testing air-fuel ratio
P0172 Thick closed-loop control self-learning of off-line testing air-fuel ratio
P0300 Detection of misfire in various cylinders
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 Low voltage of knock sensor signal circuit
P0328 High voltage of knock sensor signal circuit
P0340 Inappropriate installation location of phase sensor
P0341 Poor contact of phase sensor
P0342 Short-circuit of phase sensor to ground
P0343 Short-circuit of phase sensor to power supply
P0420 Aged oxygen storage capacity of three-way catalytic converter (out-of-limit of emission)
P0444 Open-circuit of carbon canister control valve control circuit
P0458 Low voltage of carbon canister control valve control circuit
P0459 High voltage of carbon canister control valve control circuit
P0480 Open-circuit of cooling fan relay control circuit (low speed)
P0481 Open-circuit of cooling fan relay control circuit (high speed)
P0501 Inappropriate vehicle speed sensor signal
P0506 Lower idling control speed against target speed
P0507 Higher idling control speed against target speed
P0508 Short-circuit of stepping motor drive pin to ground
P0509 Short-circuit of stepping motor drive pin to power supply
P0511 Open-circuit of stepping motor drive pins
P0560 Inappropriate system battery voltage signal
P0562 Low system battery voltage
P0563 High system battery voltage
P0602 Programming error of electronic control unit
P0627 Open-circuit of fuel pump relay control circuit
P0628 Short-circuit of fuel pump relay control circuit to ground
P0629 Short-circuit of fuel pump relay control circuit to power supply
P0645 Open-circuit of A/C compressor relay control circuit
P0646 Short-circuit of A/C compressor relay control circuit to ground
P0647 Short-circuit of A/C compressor relay control circuit to power supply
P0650 Malfunction of malfunction indicator lamp circuit
P0691 Short-circuit of cooling fan relay control circuit to ground (low speed)
P0692 Short-circuit of cooling fan relay control circuit to power supply (low speed)
P0693 Short-circuit of cooling fan relay control circuit to ground (high speed)
P0694 Short-circuit of cooling fan relay control circuit to power supply (high speed)
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)

Manual Servicio Jac j2

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Manual Servicio Jac j2

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Maintenance Manual for J2 Sedan Foreword

Maintenance Manual for J2 Sedan

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