Maintenance Manual for J2 Sedan Foreword Maintenance Manual for J2 Sedan Foreword 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. Master Table of Contents General Description Maintenance & Chapter I General Description Chapter II Maintenance Engine Chapter I Engine mechanical system Chapter II Engine electrical system Chapter III engine electronic control system Chassis Chapter I Clutch & Manual Transmission Chapter II Traveling system Chapter III Braking system Body Electrical & Structure Chapter I Body Electrical Chapter II Body Structure Circuit Troubleshooting Maintenance Manual for J2 Sedan 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 Maintenance Manual for J2 Sedan Overview Chapter I Overview Section I General Instructio 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. 1 Maintenance Manual for J2 Sedan Section II Vehicle Information I. Identification Information Position 1 2 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 Made by China Anhui Jianghuai Automobile Co., Ltd. Brand: Jianghuai Model Engine Model Max. gross weight Ex-factory no. Engine displacement Rated power Fixed number Ex-factory date Example of Nameplate 2 5 persons Jan. 2010 Overview Maintenance Manual for J2 Sedan Overview III. Vehicle Identification Number (VIN) 1) VIN position: on the nameplate or at the left bottom of windshield. 2) Illustration of VIN Digitals Geographical region Order number Country Assembled in Vehicle Description Code Check Character Manufacturer Representative letter or number Model year Representative number 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: Digitals Inspection digit Code of engine type and rated power Truck wheelbase / passenger cars, buses and chassis length Max. gross weight Body type Vehicle type 3 Maintenance Manual for J2 Sedan Overview ① Vehicle type：2 Means passenger cars F: 3 chambers & 4 doors ② Body type G: 2 chambers & 5 doors ③ Max. Gross Weight: K: >1000-2000 ④ Truck wheelbase / passenger cars, buses and chassis length: R> 2390 - 2600 1: gasoline ≤70Kw ⑤ Code of engine type and rated power 2: gasoline >70-90Kw 3: gasoline >90-110Kw Part 3: indication of vehicle, 8 digitals Digitals Production SN Factory assembled Year 4:General Assembling Workshop of Passenger Car Manufacture Company Factory assembled 7:General Assembling Workshop of Passenger Car Manufacture Company Year 8: 2008 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). Fig. 2.1.001 4 Maintenance Manual for J2 Sedan 2. Meaning of Engine Number Fig. 2.1.002 3GB4.C – Engine model: 1.0 3-cylinder gasoline engine ☆A3408769☆: A – the year of 2010 3 - engine type (petrol, local parts) 408769– Production SN 5 Overview Maintenance Manual for J2 Sedan Overview Section III Lifting, Protection and Towing of Vehicle I. Lifting of Vehicle 1. Vehicle’s Supporting Points The positions of vehicle’s supporting points are shown in figure below. Attention: Don’t lift the vehicle by using the point other than those specified; otherwise vehicle body may be damaged. Supporting point Positions of Vehicle’s 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. 6 Maintenance Manual for J2 Sedan Overview III. Towing of Vehicle If vehicle needs to be towed, please contact the local authorized after-sales service center or a special vehicle towing service company. 1. Towing with tractor Caution: No passenger allowed in the vehicle being towed; Don’t 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. Don’t 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, ① If no other towing equipment is available, the towing hole must be used; ② Always tow the vehicle from its forehead; ③ Keep the towing rope away from the bumper; ④ 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. Don’t apply force to the towing hook from any ohter directions. Don’t start towing sharply otherwise damage may be caused. 7 Maintenance Manual for J2 Sedan Service Chapter II Service Section I Service I. Preparation 1. Maintenance Tools List of Maintenance Tools II. 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 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 Tyre Windshield Windshield wiper blade Door and engine hood Tyre exchange Inspection 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 there’s any damage, crack or excessive worn tear carefully. Clean the windshield regularly. Check whether there’s any crack or other damage of the windshield every six months or more frequently. Repair as required. If the wiper doesn’t work efficiently, check for worn or torn. 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. The tyre exchange should be conducted after each 8000 km traveling. 8 Maintenance Manual for J2 Sedan Vehicle lamps 2. Service Verify that headlamps, brake indicators, tail lamps, turning signal indicator and other lighting units work normally and have been stably fixed. Meanwhile, inspect focusing function of headlamp. Interior of Vehicle The following inspection and maintenance items should be performed regularly. List of Items to be Regularly Inspected for Interior of Vehicle Item Alarm light and buzzer Windshield wiper and washer Windshield defroster Steering wheel Seat Belt Throttle pedal Brake pedal and booster Parking brake 3. Inspection Make sure all the alarm lights and buzzers are working normally. Check whether the wiper and cleaner are working normally; check whether there is any crack in the wiper. 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. 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. 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. 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. 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. Check travel of handle. 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 Cleaning liquid for windshield Level of engine coolant Engine oil level Levels of brake fluid and clutch fluid Battery Liquid leakage Inspection Check whether there is adequate cleaning liquid in reservior. Check the coolant level when the engine is cold. Stop the vehicle on a level ground and turn off engine; check oil level. Make sure that the levels of brake fluid and clutch fluid are between the “MAX” line and “MIN” marks on reservoir. Inspect conditions of voltage and battery poles. 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. 9 Maintenance Manual for J2 Sedan Service Service operational code: I-examination; R-replacement; C-washing Service cycle (odometer readings and the number of months, whichever comes first) Item 1000km 1 10 20 30 40 50 60 70 80 90 100 Month — 6 12 18 24 30 36 42 48 54 60 R I I: every 10,000 km or 6 months 1 Driving belt 2 Check oil and gas control systems of crankcase for normal working 3 Spark plug 4 Change coolant 5 Air filter element General conditions of use C: every 5,000km R: 15,000km Harsh conditions of use C: every 3,000km R: 10,000km Oil and oil filter General conditions of use R: every 5,000 km or 6 months Harsh conditions of use R: every 3,000 km or 3 months 6 R: every 60,000 km or two years I I I R R I I I I I R I I R Ignition timing 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 12 Injector 13 Valve clearance C I C* I I C C* C* I I C* I I C C* I R 8 I I R Carbon monoxide content with engine idling C* I I 7 I I R I C C* I C* I C C* I C* 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: ① Driving in dusty areas or the vehicle is regularly exposed to salty air or sea water. ② Driving on rugged road, road with water accumulation or on mountain roads. ③ Driving in cold areas. ④ In the cold season, the engine idles a long time or used frequently in short-distance traveling. ⑤ Frequent use of brakes, regular emergency braking. . ⑥ As tractor ⑦ As taxi or leasing ⑧ At temperatures above 32 ℃, driving in urban heavy traffic for more than 50% of the total travel time. 10 Maintenance Manual for J2 Sedan Service ⑨ At a temperature below 30 ℃, driving at 120km/h or higher speed limits for more than 50% of the total travel time. ⑩ Overloaded traveling. IV. Recommended Oil and Lubricant Which listed below are the types of oil and lubricant recommended by JAC: List of Recommended Oil and Lubricant Item Capacity (L) Recommended oil / lubricant Factory filled oil: SAE10W-30 Ambient temperature for use: -25 ℃ - 35 ℃ V. Engine oil 3.8 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 0.56±0.05 DOT4 (Great Wall) AC refrigerant 600±25g R134a Wiper cleaning liquid 3 Water AC compressor lubricating oil 0.12 PAG56 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: 500±50N 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 11 Maintenance Manual for J2 Sedan Service 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. ■ Don’t 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 ① Dismount the right deflector of engine. See “Engine Deflector”. ② Open the water drain plug at the bottom of radiator, and then open the cap of radiator. ③ If necessary, please dismount coolant reservoir, drain the engine coolant, and reinstall it after cleaned. ④ Check if there’s 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 ① 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. ② Make sure that all the hose clamps have been stably tightened. ③ Dismount the upper cover of air filter and the intake hose. Please refer to “Air Filter Assembly”. ④ Disconnect outlet tube of heater pipe. Please lift the hose as high as possible. ⑤ Fill coolant into radiator and coolant reservoir to specified level; the engine coolant must be filled slowly, such as to gradually bleed air from the system. Attention: ■ Please mix the original JAC engine coolant or equivalent product with water. See “Recommended Oil and Lubricant”. 12 Maintenance Manual for J2 Sedan ■ Service If coolant overflows from the heater outlet pipe, disconnect pipe and reconnect and then continue the filling of coolant. ⑥ Install air filter upper cover and intake hose. Please refer to “Air Filter Assembly”. ⑦ Install radiator cap. ⑧ Warm up the engine until the thermostat is switched on. ■ Examine if there’s 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. ⑨ Stop the engine, allow engine temperature drops. ■ The cooling time can be reduced by using fan. ⑩ Fill engine coolant in coolant until the MAX level reached. ⑪ Install radiator cap, and repeat steps ③-⑨ for more than two times until the level of engine coolant doesn’t go down any more. ⑫ Start engine, check for any leakage in the cooling system. 3) Wash cooling system ① 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. ② Dismount air filter upper cover and the intake hose. Refer to “Air Filter Assembly”. ③ Disconnect outlet tube of heater pipe. Please lift the hose as high as possible. ④ 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. ⑤ Install air filter upper cover and intake hose. Refer to “Air Filter Assembly”. ⑥ Start the engine, warm up it to normal working temperature. ⑦ Speed up the engine for several times without load. ⑧ Stop engine, and wait till engine cooled down. ⑨ Discharge coolant inside system. Refer to “Draining Engine Coolant”. ⑩ Repeat steps ①-⑨ 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. 13 Maintenance Manual for J2 Sedan Service 1) Inspection of cooling system hose ■ Check the hose for incorrect installation, crack, damage, loose connection, worn or ageing. ■ Please repair or replace the damaged components as required. 2) Inspection of radiator cap ① 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. ② Pull out negative pressure valve to open it, and upon the pressure is released, check whether it can be completely closed. ■ Make sure there isn’t any smudge or damage on the valve seat. ■ Make sure that the valve seat can be normally opened and closed. Fig. 2.2.001 ③ Check the pressure released by radiator cap. Standard: 78-98 KPa Fig. 2.2.002 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. ① Wash back of radiator fins from the top to the bottom with water spraying normal to radiator. ② Wash each surface of the radiator every other minute. ③ In case no dirt is washed away from the radiator, the washing work should be stopped. 14 Maintenance Manual for J2 Sedan Service ④ Blow the back of radiation core with compressed air vertically from top to bottom. The pressure of compressed air should be less than 490 KPa, and a distance of more than 30 cm should be kept. ⑤ Blow radiator core surface with compressed air every other minute until no water can be blown away. 4) Check for leakage of cooling system ① Check for leakage through applying pressure to the cooling system with a leakage detector of radiator cap. ■ Test pressure: 157 KPa Caution: ■ Fig. 2.2.003 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. ② 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 Fig. 2.2.004 Engine Fuel pipeline Fuel tank Fig. 2.2.005 ① Unscrew lock bolt of air filter upper cover lift up the cover. 15 Maintenance Manual for J2 Sedan Service Fig. 2.2.006 ② 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 N·m. 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. 16 Maintenance Manual for J2 Sedan ■ Service 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 ① Use oil filter wrench to dismount the filter. Attention: ■ JAC original engine oil or equivalent product should be used. ■ Be careful not to be scalded since engine and oil are hot. ■ During dismantlement, a cloth should be prepared to wipe up the leaked or splashed oil. ■ Please keep the driving belt free from engine oil. ■ Clean any oil splashed on engine and vehicle. 2) Installation Fig. 2.2.007 ① Clear any foreign substance on mounting surface of oil filter. ② Paste a film of engine oil onto the oil seal surface of new filter. ③ Tighten. ■ Tightening torque: 10-12N·m 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 ① Inspect oil level, and fill engine oil when it is inadequate. See also “Engine Oil”. ② Start engine, check for any oil leakage. ③ Stop engine and wait for ten minutes. ④ Inspect oil level, and fill engine oil. See also “Engine Oil”. 9. Replacement of Ignition Plug 17 Maintenance Manual for J2 Sedan 1) Service Dismantlement ① Dismount the engine hood. See also “Intake manifold”. ② Disassemble the ignition coil. Please refer to “Ignition Coil”. ③ Dismount the ignition plug with plug socket. Attention: ■ 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 there’s 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 N·m. 10. Replacement of Fuel Filter 1) Dismantlement Caution: ■ Be sure to read the “General Precautions” before any handling of fuel system. See “General Precautions”. ① Open the fuel filler cap. 18 Maintenance Manual for J2 Sedan Service ② Release pressure inside fuel tank. ③ Remove the rear seat cushion. See “Rear Seat”. ④ Dismount the fuel tank service cap. ⑤ Dismount the fuel filter and fuel pipe. For detailed information, please refer to “Fuel Filter”. 2) Installation Be aware of following precautions to install with steps contrary to dismantlement. Fig. 2.2.008 ① Installation direction of fuel filter ■ Be aware of installation direction of fuel filter. Towards inlet tube. ② Installation of pipe fitting. 3) Post-installation inspection Check for any fuel leakage with following steps. ① Turn ignition switch to “ON” (with engine stopped), and then check for leakage at the joints of fuel pipeline. ② 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. 19 Maintenance Manual for J2 Sedan ■ In case any component is found damaged, repair or replace. 2. Inspection of Clutch Fluid Level and Leakage Service Fig. 2.2.009 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 ① Dismount the wheel(s) need to be adjusted. ② 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 ① Take the center hole as guide to install the wheel on balancer. Start the balancer. ② 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 20 Maintenance Manual for J2 Sedan Service weight is nearest to the calculated value, and install it to the specified outer side position, or at the specified angle relative to wheel. Attention: ■ The balance block of outer side should be installed before inner side. ■ 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. Fig. 2.2.010 Stuck weight Center of gravity Towards the groove 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. Fig. 2.2.011 Attention: ■ Never install a balance block on another one. ③ Restart the wheel balancer. Position (or angle) indicated by the wheel balancer ④ 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. ⑤ 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. 21 Maintenance Manual for J2 Sedan ■ Allowable maximum unbalance: 7. Tyre Exchange ■ Tyre exchange should be performed every 8000 km. Service Fig. 2.2.012 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. Fig. 2.2.013 Inspection for Brake Fluid Level and Leakage Highest line If fluid level is low, please check brake system for leakage. Lowest line Normal Fig. 2.2.014 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. 22 Maintenance Manual for J2 Sedan Fig. 2.2.015 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. Fig. 2.2.016 4) Loosen the release valve, press down the brake pedal slowly, and then release. Repeat this operation every other 2 or 3 s until there’s outflow of new brake fluid, and then step on the brake pedal to close the release valve. Repeat there procedures for all wheels. 5) Service 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 Brake disc 2) Type Floating caliper type / ventilated disc Brake disc diameter 241 mm Brake disc thickness 19 mm Friction block thickness 9 mm Cylinder bore 51 mm 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. 23 Maintenance Manual for J2 Sedan Service Standard Specification Table of Brake Drum Brake drum 3) Type Leading trailing shoe brake Brake drum diameter 204 mm Cylinder bore of brake slave cylinder 17.46 mm Clearance adjustment Automatically Circular runout < 0.05 mm Brake caliper Fig. 2.2.017 Check for any oil leakage. 4) Fig. 2.2.018 Rear brake slave cylinder Check for any leakage. 5) Fig. 2.1.019 Front brake shoe Check for worn or damaged conditions. ■ Standard thickness: 9 mm ■ Limit thickness: 2 mm 24 Maintenance Manual for J2 Sedan 6) Service Fig. 2.2.020 Rear brake shoe Check the brake shoe thickness and its contact state with the brake drum. If it fails to meet the requirement, replace. ■ Standard thickness of brake shoe (A): 5 mm ■ Allowable limiting thickness (A): 1 mm Fig. 2.2.021 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 steering column is loose. 2) Steering pull-rod with Check the leakage of lubricating grease Check the tightening torque the 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: ■ Fig. 2.2.022 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. 25 Maintenance Manual for J2 Sedan ■ Rock each wheel to check for proper clearance. Fig. 2.2.023 ■ Inspect operation conditions of wheel bearings. ■ Check axle, suspension nut and bolt for loosening. ■ Check shock absorber for oil leak or other damages. ■ Check the suspension ball joint for grease leakage; check ball joint dust boot for crack or other damages. Fig. 2.2.024 Fig. 2.2.025 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 26 Service Maintenance Manual for J2 Sedan Service 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 passenger’s 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, don’t repair but replace the seat belt assembly. ■ Be sure not to lubricate the lock tongue and snap ring. ■ Use original seat belt assembly of JAC. ■ Check whether the anchorage is loose. ■ 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 Nominal Diameter of Thread Pitch M5 Torque (N·m) Head mark 4 Head mark 7 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 27 Maintenance Manual for J2 Sedan Service 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%. 28 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 Maintenance Manual for J2 Sedan Contents Section IV Fuel Supply System of Engine...........................................................114 I. General Precautions ............................................................................................... 114 II. Preparation .............................................................................................................. 115 III. Fuel System ............................................................................................................. 115 IV. Fuel Injector and Guide Rail .................................................................................. 116 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 Maintenance Manual for J2 Sedan Contents Section III Structural Principle and Inspection of Engine Electronic Components ..................................................................................................................................179 I. Intake Manifold Absolute Pressure (MAP/MAT) Sensor ..................................... 179 II. Engine Coolant Temperature (ECT) Sensor......................................................... 181 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 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. 33 Maintenance Manual for J2 Sedan 6. Mechanical Part of Engine 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. Fig.1.1.001 Removal of Sealant JAC-T1F017 After dismounting fixing nuts and bolts, use the scraper to detach the matching faces and remove old sealant. Knock Slide 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 Fig.1.1.002 Scraper 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. 34 Maintenance Manual for J2 Sedan Mechanical Part of Engine 3) Position sealant with the specified size. Fig.1.1.003 ■ Put the sealant into the groove for it (if any). ■ Generally, the sealant is put inside the bolt hole; however, it is occasionally put outside the bolt hole. ■ 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. 35 Maintenance Manual for J2 Sedan Mechanical Part of Engine III. Preparation 1. Tools for Maintenance No. 1 Tool List of Special Tools Appearance Code Description Fix camshaft timing sprocket End forked clamp JAC-T1D001 2 3 Pin Used together with the end forked clamp Locating tool for piston pin Used to install and dismantle the piston pin JAC-T1F005 4 Guide sleeve 5 Flywheel chock 6 Used together with the locating tool for piston pin Valve spring compressor 36 JAC-T1F011 Used to fix the flywheel JAC-T1F012 Used to compress the valve spring Install valve cotter Maintenance Manual for J2 Sedan Mechanical Part of Engine 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 JAC-T3F003 Functioning as a guide during the installation of front oil seal of crankshaft JAC-T3F004 Used to install the front oil seal of engine crankshaft JAC-T3F005 Used to install the rear oil seal of crankshaft 11 Guide for front oil seal of crankshaft 12 Installer for front oil seal of crankshaft 13 Installer for rear oil seal of crankshaft 37 Maintenance Manual for J2 Sedan 2. Mechanical Part of Engine List of Auxiliary Materials for Assembling Engine List of Auxiliary Materials for Assembling Engine No. Name Application 1 Engine oil Used during filling and assembly 2 Silica gel 3 Sealant 4 Sealant 5 Petrol Sealant 6 3. Specification and Grade 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 Engine oil pump, water pump, oil pan and rear oil seal housing of crankshaft Oil pressure switch, draining screw plug and flywheel bolt Coolant temperature sensor and water temperature alarm switch LT5699 or equivalent LT243 or equivalent LT648 or equivalent 93# unleaded petrol or above LT271 or equivalent Stud bolt List of Auxiliary Materials for Assembling Cylinder head List of Auxiliary Materials for Assembling Cylinder head No. Name 1 Engine oil 2 Sealant Present Material and Model 5W-30 (winter) 15W-40 (summer),with SJ-class quality level and above LT271 or equivalent 3 Sealant LT962T or equivalent 38 Assembly Position Valve head, camshaft and camshaft oil seal Stud bolt Guide sleeve of spark plug, bowl patch of cylinder body/cover, connecting pipe nozzle Maintenance Manual for J2 Sedan Mechanical Part of Engine 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 ① Discharge the engine coolant from the radiator. See “Change Engine Coolant”. ② Discharge the engine oil, transmission oil and clutch oil. See "Engine Oil", “Transmission Oil” and “Clutch Pipeline”. ③ 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. ④ 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”. 39 Maintenance Manual for J2 Sedan 3. Mechanical Part of Engine Dismantlement of Related Elements in Engine Compartment ① Disconnect the following pipelines and put them aside. Attention: Use plugs to prevent leakage when disconnecting the pipelines. ■ Inlet pipe of fuel injector. See “Fuel Injector”. ■ Vacuum hose of braking vacuum booster on engine side. 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”. ② Remove the brake fluid reservoir. ③ Remove the accelerator cable. ④ 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 ① Dismount the front drive shaft. See “Front Drive Shaft”. ② Remove the front exhaust pipe. Please refer to “Exhaust System”. ③ Dismount the engine supporting beam. See “Engine Supporting Beam”. 5. Dismantlement ① Attach the lifting device hook to the hanging lug of the engine 40 Maintenance Manual for J2 Sedan Fig.1.1.004 Mechanical Part of Engine Fig.1.1.005 ② Lift the engine and fix it in place. ③ Use the manual lifting stand or equivalent to firmly support the bottom of engine and transmission assembly; adjust the lifting tension. Attention: ■ A soft pad may be placed on the supporting surface so as to ensure a totally stable state. ④ Detach left, right, front and rear suspensions of engine. See “Engine Suspension”. ⑤ 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 ① Remove A/C compressor assembly from the engine and transmission assembly. ② Dismount starter. See “Starter”. ③ 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: 41 Maintenance Manual for J2 Sedan Mechanical Part of Engine ■ Before starting engine, check oil and fluid levels (including engine oil and coolant). Refill to specified level as required.. ■ Check for fuel leakage with following steps： - 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 Engine coolant Engine oil Transmission oil, brake fluid, and clutch fluid Fuel Exhaust Level Level Level Leakage — 42 During Engine Operation Leakage Leakage Leakage Leakage Leakage After Engine Stopped Level Level Level Leakage — Maintenance Manual for J2 Sedan Mechanical Part of Engine 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: 500±50N. 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 Generator belt Method 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. 43 Maintenance Manual for J2 Sedan 3. Mechanical Part of Engine Generator Belt 1) Loosen the generator adjusting nuts and supporting nuts. Then adjust the tension by using the adjusting bolt. Fig. 1.1.007 Fig. 1.1.006 2) Tighten generator adjusting and supporting nuts. ■ Tightening torque: Generator adjusting nuts: 22.5 ± 2.5 Nm Generator supporting nuts: 47±5 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”. 44 Maintenance Manual for J2 Sedan VI. Air Filter and Air Duct 1. Parts Diagram of Positions 2. Intake Pipe Fig. 1.1.008 1) Dismantlement ① Remove the fastening bolts and clamps of front intake pipe and remove the front intake pipe assembly. ■ Tightening torque: 17-19 N·m Fig. 1.1.009 ② Loosen the lock clips from the air cleaner upper cover. 45 Mechanical Part of Engine Maintenance Manual for J2 Sedan Mechanical Part of Engine ③ Disconnect the locking clamp of intake hose, and then take off upper cover and intake hose. ■ Tightening torque: 6-9 N·m Fig. 1.1.010 Fig. 1.1.011 ④ Dismount the fixing bolt of air filter base, and then take down the base. ■ Fig. 1.1.012 Tightening torque: 8-12 N·m 2) Check after Dismantlement Check whether there is any crack or wearing on the air duct assembly. If any, replace. 3) Installation Install with steps contrary to dismantlement. Attention: ■ Properly mount every joint and tighten the clamp. 3. Replacement of Air Filter element 1) Dismantlement Fig. 1.1.013 ① Loosen the lock clips of air cleaner upper cover and lift the upper cover. 46 Maintenance Manual for J2 Sedan ② Dismount air filter element. Mechanical Part of Engine Fig. 1.1.014 2) Check after Dismantlement ■ Periodically clean or replace the filter element with recommended period. See “Periodical Maintenance”. ■ Blow the filter element from its back side with compressed air, till nothing is blown off. 3) Installation ■ Install with steps contrary to dismantlement. 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. 47 Maintenance Manual for J2 Sedan ① Discharge the engine coolant. See “Engine Coolant”. ② Dismount the engine trimming cover. ■ Tightening torque: 8-12 N·m ③ Dismount the air filter assembly. See “Air filter Assembly”. ④ Disconnect the wire harness connectors of the following parts: ■ Absolute intake pressure sensor ■ Fuel injector ■ Throttle position sensor ■ Carbon canister control solenoid ■ Accelerator cable ⑤ 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 ⑥ Remove the fastening bolts of throttle body and remove the throttle body assembly. Fig. 1.1.015 ⑦ Dismount the fuel injector assembly. See “Fuel Injector”. Fig. 1.1.016 ■ Tightening torque: 18.4±1.4 N·m 48 Mechanical Part of Engine Maintenance Manual for J2 Sedan ⑧ Dismount the supporting bracket of intake manifold and engine cylinder body. ■ Tightening torque: 10-20 N·m ⑨ Dismount the fixing bolt and nut of intake manifold. ■ Mechanical Part of Engine Fig. 1.1.017 Fig. 1.1.018 Tightening torque: 18±1.0 N·m ⑩ Take off the intake manifold. 2) Check after Dismantlement Check whether there is any crack or other damage on intake manifold and whether the matching face is distorted. If this is the case, repair or replace the intake manifold. Check for any abnormal condition of rubber rings. 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 49 Maintenance Manual for J2 Sedan Mechanical Part of Engine Caution: ■ Perform this operation after the exhaust system has completely cooled down. ① Disconnect the wire harness connectors of front oxygen sensor. Special tools should be used if necessary. ■ Tightening torque: 30-40 N·m Fig. 1.1.019 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. ② Unscrew the fixing bolt for heat shield of exhaust manifold, and then take off heat shield. ■ Tightening torque: 9-11N·m ④ Unscrew bracket bolt to remove the exhaust manifold bracket. ■ Tightening torque: 20-25 N·m ⑤ Unscrew fixing bolt to remove the exhaust manifold. ■ Tightening torque: M8 35±2 N·m 50 Fig. 1.1.020 Fig. 1.1.021 Fig. 1.1.022 Maintenance Manual for J2 Sedan Mechanical Part of Engine 2) Check after Dismantlement Check whether the matching face of exhaust manifold is distorted. 3) Installation Install with steps contrary to the dismantlement. Attention: ■ Do not reuse the non-reusable parts. ■ Do not excessively tighten oxygen sensor, otherwise it may be damaged. VIII. 1. Exhaust System Parts 2 4 7 5 1 3 6 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. 51 Maintenance Manual for J2 Sedan Mechanical Part of Engine 2) Installation ■ Install with steps contrary to dismantlement. ■ Tightening torque: 38-52 N·m ■ Replace the exhaust pipe gasket when reassembling the exhaust system each time. ■ 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. 52 Maintenance Manual for J2 Sedan Mechanical Part of Engine IX. Timing sprocket mechanism 1. Parts Balance shaft gear Timing sprocket mechanism diagram 1 – Timing chain 2 – Movable rail bolt subassembly 4. Movable rail subassembly 5 – Automatic tensioner bolt 5 – 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 Fig. 1.1.023 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 53 Maintenance Manual for J2 Sedan Mechanical Part of Engine 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 N·m Fig. 1.1.024 d) Dismantle damping wheel ■ Tightening torque: 160-170 N·m e) Remove the alternator bracket. f) Dismantle oil pan and cylinder head cover Fig. 1.1.025 Fig. 1.1.026 Fig. 1.1.027 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. Tightening sequence for bolts of cylinder head shield 54 Maintenance Manual for J2 Sedan g) Dismantle oil pump assembly Mechanical Part of Engine Fig. 1.1.028 h) Check timing Check the timing point shown in the diagram for compliance. Timing mark of primary chain Timing mark for camshaft chain wheel Timing mark of secondary chain Timing mark of primary chain Timing mark for balance shaft chain wheel Timing mark of secondary chain Timing mark for crankshaft chain wheel 55 Maintenance Manual for J2 Sedan i) Dismantle tensioner and set/dynamic tracks of the automatic timing chain. Check for any abnormalities. ■ Tightening torque: Automatic tensioner: 9 11 N • m Fig. 1.1.029 Set track: 10-12 N·m Dynamic track: 19-28 N·m j) Dismantle exhaust camshaft sprocket bolt ■ Tightening torque: 88±10 N·m Fig. 1.1.030 k) Remove t he bolts of intake cam chain wheel ■ Tightening torque: 88±10 N·m 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: 7.6±0.6 N·m Fig. 1.1.031 56 Mechanical Part of Engine Maintenance Manual for J2 Sedan m) Remove the bolts of secondary chain tensioner and remove the secondary chain tensioner. ■ Fig.1.1.033 Tightening torque: 10±2 N·m n) Remove the bolts of balance shaft chain wheel and remove the balance shaft chain wheel. ■ Mechanical Part of Engine Fig.1.1.034 Tightening torque: 45±5 N·m 2） Installation Reverse the above steps for installation. Be aware of timing and tightening torque during installation. 57 Maintenance Manual for J2 Sedan Mechanical Part of Engine X. Camshaft and balance shaft assembly 1. Parts Breakdown diagram for camshaft and balance shaft 1 – Intake camshaft subassembly 2 – Intake camshaft chain wheel 3 – Chain wheel bolts 4 – 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 ① Remove cylinder cover. See "Intake Manifold." ② Remove high-voltage ignition coil. See "Ignition Coil." ③ Disconnect PCV hose and air hose of respirator. ④ Remove the cylinder head cover from the cylinder head. ⑤ Remove camshaft timing sprocket. Seethe "timing sprocket body." ⑥ Remove camshaft position sensor from rear end of the cylinder head. Tightening torque: 9 - 11 N • m 58 Maintenance Manual for J2 Sedan Attention: ■ Handle with care to avoid collision or damage. ⑦ Remove the camshaft from cylinder head. 2） Disassembly of balance shaft Fig.1.1.035 On the basis of above-mentioned disassembly procedure of camshaft, proceed as below: Remove the bolts of balance shaft front end cap and remove the balance shaft front end cap. ①■ Tightening torque for balance shaft front end cap: 7.6±0.5N.m ② 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: 23.5±4.5N.m ③ Remove the bolts of exhaust bracket II and balance shaft side cover and remove the balance shaft. ■ Tightening torque 7.6±0.6N.m for bolts of Fig.1.1.036 Fig.1.1.037 cover: Fastening bolts for exhaust pipe bracket II: 22.5±2.5N.m 59 Mechanical Part of Engine Maintenance Manual for J2 Sedan Mechanical Part of Engine Fig.1.1.038 3） Inspection after removal ① Camshaft Measuring camshaft base circle diameter and the maximum lifting strokes of intake and exhaust. ■ Base circle diameter: 36mm Maximum lifting stroke of intake：8.7054mm Maximum lifting 8.2836mm stroke of exhaust ： If specified value is exceeded, replace the camshaft. ② Mechanical tappet ■ Fig.1.1.039 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. ① The mechanical tappet at the intake side will be grouped and assembled as per the following table to ensure the intake valve clearance. Distance between intake camshaft base circle Top end thickness of Mechanical tappet Valve clearance and valve tappet L1 mechanical tappet label (mm) 2.91＜L1≤2.93 2.70 270 0.19-0.25 2.93＜L1≤2.95 2.72 272 0.19-0.25 2.95＜L1≤2.97 2.74 274 0.19-0.25 2.97＜L1≤2.99 2.76 276 0.19-0.25 2.99＜L1≤3.01 2.78 278 0.19-0.25 3.01＜L1≤3.03 2.80 280 0.19-0.25 3.03＜L1≤3.05 2.82 282 0.19-0.25 3.05＜L1≤3.07 2.84 284 0.19-0.25 3.07＜L1≤3.09 2.86 286 0.19-0.25 3.09＜L1≤3.11 2.88 288 0.19-0.25 3.11＜L1≤3.13 2.90 290 0.19-0.25 60 Maintenance Manual for J2 Sedan Mechanical Part of Engine Distance between intake camshaft base circle Top end thickness of Mechanical tappet Valve clearance and valve tappet L1 mechanical tappet label (mm) 3.13＜L1≤3.15 2.92 292 0.19-0.25 3.15＜L1≤3.17 2.94 294 0.19-0.25 3.17＜L1≤3.19 2.96 296 0.19-0.25 3.19＜L1≤3.21 2.98 298 0.19-0.25 3.21＜L1≤3.23 3.00 300 0.19-0.25 3.23＜L1≤3.25 3.02 302 0.19-0.25 3.25＜L1≤3.27 3.04 304 0.19-0.25 3.27＜L1≤3.29 3.06 306 0.19-0.25 3.29＜L1≤3.31 3.08 308 0.19-0.25 3.31＜L1≤3.33 3.10 310 0.19-0.25 3.33＜L1≤3.35 3.12 312 0.19-0.25 3.35＜L1≤3.37 3.14 314 0.19-0.25 3.37＜L1≤3.39 3.16 316 0.19-0.25 3.39＜L1≤3.41 3.18 318 0.19-0.25 3.41＜L1≤3.43 3.20 320 0.19-0.25 3.43＜L1≤3.45 3.22 322 0.19-0.25 3.45＜L1≤3.47 3.24 324 0.19-0.25 3.47＜L1≤3.49 3.26 326 0.19-0.25 3.49＜L1≤3.51 3.28 328 0.19-0.25 3.51＜L1≤3.53 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 61 Maintenance Manual for J2 Sedan ② Mechanical Part of Engine The mechanical tappet at the exhaust side will be grouped and assembled as per the following table to ensure the intake valve clearance. Distance between exhaust camshaft base circle Top end thickness of Mechanical Valve clearance and valve tappet L2 mechanical tappet tappet label (mm) 2.99＜L2≤3.01 2.70 270 0.27-0.33 3.01＜L2≤3.03 2.72 272 0.27-0.33 3.03＜L2≤3.05 2.74 274 0.27-0.33 3.05＜L2≤3.07 2.76 276 0.27-0.33 3.07＜L2≤3.09 2.78 278 0.27-0.33 3.09＜L2≤3.11 2.80 280 0.27-0.33 3.11＜L2≤3.13 2.82 282 0.27-0.33 3.13＜L2≤3.15 2.84 284 0.27-0.33 3.15＜L2≤3.17 2.86 286 0.27-0.33 3.17＜L2≤3.19 2.88 288 0.27-0.33 3.19＜L2≤3.21 2.90 290 0.27-0.33 3.21＜L2≤3.23 2.92 292 0.27-0.33 3.23＜L2≤3.25 2.94 294 0.27-0.33 3.25＜L2≤3.27 2.96 296 0.27-0.33 3.27＜L2≤3.29 2.98 298 0.27-0.33 3.29＜L2≤3.31 3.00 300 0.27-0.33 3.31＜L2≤3.33 3.02 302 0.27-0.33 3.33＜L2≤3.35 3.04 304 0.27-0.33 3.35＜L2≤3.37 3.06 306 0.27-0.33 3.37＜L2≤3.39 3.08 308 0.27-0.33 3.39＜L2≤3.41 3.10 310 0.27-0.33 3.41＜L2≤3.43 3.12 312 0.27-0.33 3.43＜L2≤3.45 3.14 314 0.27-0.33 3.45＜L2≤3.47 3.16 316 0.27-0.33 3.47＜L2≤3.49 3.18 318 0.27-0.33 3.49＜L2≤3.51 3.20 320 0.27-0.33 3.51＜L2≤3.53 3.22 322 0.27-0.33 3.53＜L2≤3.55 3.24 324 0.27-0.33 3.55＜L2≤3.57 3.26 326 0.27-0.33 3.57＜L2≤3.59 3.28 328 0.27-0.33 3.59＜L2≤3.61 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 62 Maintenance Manual for J2 Sedan Mechanical Part of Engine Installation precautions: ■ Mechanical tappet should be applied with proper amount of oil evenly; after the cylinder head is assembled, it should turn flexibly without sticking or other abnormalities. ■ 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) ③ 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. ④ Install camshaft timing sprocket ⑤ Install the timing chain wheel of balance shaft. During installation, notice to align the timing mark of balance shaft. Fig.1.1.040 Backlash of balance shaft gear: 0.06-0.12mm Backlash of 0.08-0.14mm balance shaft idler gear: Timing mark of balance shaft gear and idler gear ⑥ Be aware of following items to install with steps contrary to dismantlement. ■ Before installing cylinder head cover, clear any sealant on cylinder head. ■ Make sure that cylinder head cover gasket is put into the installation slot. 5) Check after Dismantlement ■ 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. 63 Maintenance Manual for J2 Sedan Mechanical Part of Engine XI. Cylinder head 1. On-vehicle Maintenance 1) Inspect the cylinder pressure: ① Thoroughly warm up the engine and then stop it. ② Release the fuel pressure. See “Release of Fuel Pressure”. ③ Disconnect the fuse of fuel pump, otherwise the fuel may be sprayed out during measurement. ④ Use special ignition coil and spark plug removal tool. See "Ignition Coil" and the "Spark Plug." ⑤ Dismantle engine trimming cover. See “Intake manifold”. ⑥ Install a cylinder pressure gauge (with joint) on the spark plug hole. ⑦ 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: 1200±100 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. ⑧ After inspection, remount the dismounted parts. ⑨ Start engine, confirm that the engine runs smoothly. 64 Maintenance Manual for J2 Sedan 2. Mechanical Part of Engine Parts Diagram of Cylinder head 3. Dismantlement and Installation 1) Dismantlement ① Discharge engine coolant and oil. See “Change Engine Coolant” and “Change Engine Oil”. Attention: ■ Perform these steps after engine cooled down. ■ Do not splash engine coolant or oil onto the drive belt. ② 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." ③ Loosen the cylinder head bolts with special tool. ④ Remove the cylinder gasket. 65 Maintenance Manual for J2 Sedan Mechanical Part of Engine 2) Check after Dismantlement ① Cylinder head Bolt Measure the length of cylinder head bolt. ■ Limit: 143.5±0.7mm. Replace the cylinder head bolt if this Limit is exceeded. ② Cylinder head ■ 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. Fig. 1.1.041 Standard value: below 0.03mm Height of cylinder head (new): 113±0.1mm If the the standard value is exceeded, grind or replace the cylinder head according to the specification. Attention: ■ The total grindable margin of matching surface between cylinder head and cylinder body should not be greater than 0.2mm. 3) Installation Fig.1.1.042 ① Install new cylinder gasket. ② 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. 66 Maintenance Manual for J2 Sedan Mechanical Part of Engine 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°. Fig.1.1.043 Attention: Painting Mark ■ 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”. ③ Then, perform the installation steps which are just contrary to dismantlement. 4) Check after 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. 67 Maintenance Manual for J2 Sedan Mechanical Part of Engine 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 Fig.1.1.044 1) Disassembly ① Dismount the spark plug with the special socket. ② Dismount the valve cotter, valve spring and spring seat. ■ Compress the valve spring with the special 68 JAC-T1F001 Maintenance Manual for J2 Sedan Mechanical Part of Engine compressor. Attention: ■ Pay attention to the position of upper dead point of piston. ■ Label the dismounted valve, valve spring and other parts, and write down their corresponding cylinder numbers and positions ■ Store the parts reliably. ③ Dismount the valve oil seal. ④ See “Replacement of Valve Seat” to replace the valve seat, if required. ⑤ See “Valve Guide” to replace the valve guide, if required. Fig.1.1.045 JAC-T1F012 Fig.1.1.046 2) Assembly ① Install valve guide if it has been dismounted. See “Valve Guide”. ② Install valve seat, if it has been dismounted. See “Valve Seat”. ③ 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 Fig1.1.047 JAC-T3F001 Attention: ■ The valve oil seal should not be reused. ■ The valve oil seal must be installed with the proper special tool. ④ Install valve. ⑤ Install valve spring. 69 Maintenance Manual for J2 Sedan Mechanical Part of Engine Note: The parts with paint mark should be installed upwards. ⑥ Install retaining seat for valve spring. ⑦ Install valve cotter. ■ Use the valve spring compressor during the installation. ■ After installation, lightly knock the edge of valve stem with a rubber hammer to check the mounting condition. ⑧ Install spark plug with the spark plug socket. 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. Fig.1.1.048 Good Bad ■ Inspect thickness of valve edge. Replace the valve if the measurement is less than the specified value. Fig.1.1.049 Contact (required to be at the center of surface) For intake valve: 1.35-1.65mm， For exhaust valve: 1.85±0.15mm ■ Bad Thickness of edge 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° 70 Maintenance Manual for J2 Sedan 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. Mechanical Part of Engine Fig.1.1.050 Valve guide Valve guide Standard value: 0.020-0.036mm Outer Diameter of Valve Stem Inner Diameter of Valve Conduit 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: Fig.1.1.051 For the hole with diameter of 10.655-10.665mm, extend the size of valve guide by 0.05mm. For the hole with diameter of 10.855-10.865mm, extend the size of valve guide by 0.25mm. For the hole with diameter of 11.105-11.115mm, extend the size of valve guide by 0.50mm. c. Protrusion Height 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. 71 Maintenance Manual for J2 Sedan Standard values: 图 1.1.052 Mechanical Part of Engine End Face of Valve Stem For intake valve: 53.21mm Valve Protrusion Height For exhaust valve: 54.10mm Limits: Surface of Valve Spring Seat 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. Fig.1.1.053 Cut Away 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. Fig.1.1.054 Valve Seat Height Inner Diameter of Extended Hole Cylinder Body Assembly 72 Maintenance Manual for J2 Sedan 1. Mechanical Part of Engine Parts Disassembly Diagram of Cylinder Body Assembly 2. Disassembly and Assembly 1) Disassembly ① Dismount the engine assembly from the vehicle, and then detach the transmission from engine. See “Engine Assembly” for detailed dismantlement steps. ③ Fix whole engine. ④ Discharge engine oil. See “Change Engine Oil” ⑤ Dismount following engine accessories. See relevant chapters for detailed dismantlement steps. ■ Drive belt ■ Alternator, compressor and relevant brackets ■ Intake and exhaust manifolds 73 Maintenance Manual for J2 Sedan ■ Water pump and its components ■ Ignition coil ■ Cylinder cover, damping wheel, oil pan ■ Engine timing sprocket mechanism ⑥ ■ Mechanical Part of Engine Dismount the flywheel assembly. Fix the flywheel by the special tool to dismount the fixing bolt. Tightening torque: For flywheel: 95-105N·m Attention: ■ Fixing bolts should be loosened in the diagonal orders. ⑦ 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. ⑧ Remove crankshaft rear oil seal bracket ■ Tightening torque: 7.0-8.2N·m ■ 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. ⑨ 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: 13±1N·m + 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 74 Maintenance Manual for J2 Sedan Mechanical Part of Engine rod. ■ Maintain the connecting rod big end and the connecting rod body match sequentially and maintain the connecting rod big end serial number in consistency ⑩ Dismount bearing shell from the connecting rod and the connecting rod cover. Attention: ■ Identify their mounting positions, and properly place them to avoid confusion. ⑪ Dismount ring from the piston. Check the side clearance of piston ring before dismounting. See “Check after Disassembly” below. Attention: ■ Fig.1.1.055 Use the piston ring expander. Piston Ring Expander ⑫ 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. Fig.1.1.056 Front Mark 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. Push Rod Guide Sleeve D Base ⑬ Dismount the crankshaft bearing cap. Before loosening the crankshaft bearing cap, measure axial clearance of crankshaft. See “Check after Disassembly” below. 75 Maintenance Manual for J2 Sedan Loosen the bolts of crankshaft bearing cap in the following sequence. ■ Mechanical Part of Engine Fig.1.1.057 Tightening torque: 35±2 N·m＋60°～64° 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. Fig.1.1.058 ⑭ Dismount the crankshaft. Fig.1.1.059 2) Check after Disassembly ① Axial clearance of Crankshaft Detection methods are as shown in the figure Standard value: 0.09-0.27mm If measurement is not within the standard range, replace the thrust washer and repeat measurement. If it is still over limit, replace the crankshaft. ② Big End Clearance of Connecting Rod Measure the gap between the connecting rod and the crankshaft by using feeler gauge. Fig.1.1.060 Standard value: 0.10-0.3mm Limit: 0.4mm If the limit is exceeded, replace the connecting rod and measure again. Replace the crankshaft if measurement is still out of the limit. 76 Maintenance Manual for J2 Sedan ③ Side clearance of Piston Ring Mechanical Part of Engine Fig.1.1.061 Bad Measure the side clearance between piston ring and piston ring groove top land by the feeler gauge. Feeler Gauge Standard values: Good st For 1 piston ring, 0.03～0.07mm For 2nd piston ring, 0.04～0.06mm Feeler Gauge Piston Ring Limits: For 1st piston ring, 0.1mm For 2nd 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. ④ End Gap of Piston Ring Ensure that the inner diameter of cylinder stays within the specified range. Piston Pressed and Fixed Fig.1.1.062 Feeler Gauge Piston Ring 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. Piston Ring Measured Point Standard values: For 1st piston ring, 0.15-0.30mm For 2nd piston ring, 0.30-0.50mm Limits: For 1st piston ring, 0.8mm For 2nd 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. ⑤ Planeness of Cylinder Body Remove any gasket material and eliminate the engine oil, sediment, carbon or other contaminants on surface of cylinder body. 77 Maintenance Manual for J2 Sedan Mechanical Part of Engine Attention: ■ Be careful to prevent gasket materials from falling into the engine oil or coolant. Measure planeness of cylinder body in different directions at six positions using ruler and feeler gauge. Ruler Fig.1.1.063 Standard values: below 0.05mm Limits: below 0.1mm If the limit is exceeded, replace cylinder body. Feeler Gauge ⑥ 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 ⑦ Diameter of Piston Skirt Fig.1.1.064 Use outside micrometer to check whether the piston skirt is distorted. Standard values:74.973mm Dial Indicator ⑧ 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) Standard value: 0.02-0.04mm If the calculated value exceeds the limit, replace piston and piston ring assembly. ⑨ 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 78 Maintenance Manual for J2 Sedan Mechanical Part of Engine 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) ⑩ 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. ⑪ 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. Fig.1.1.065 Dial Indicator ⑫ 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. c. 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. Lightly put the connecting rod cover to specified place, and screw the bolt to specified torque. Fig.1.1.066 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. 79 Maintenance Manual for J2 Sedan Mechanical Part of Engine Standard value: 0.02 - 0.04mm + (0.01mm) expansion Limit:0.1mm ⑬ Roundness and Cylindricality of Crankshaft Measure sizes of each main crankshaft journal and 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. Fig.1.1.067 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. ⑭ 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. Plastic Wire Gauge Fig.1.1.068 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.1.1.069 Round-angle Rolling Area 80 Maintenance Manual for J2 Sedan Mechanical Part of Engine ⑮ Flywheel Check whether the flywheel and the signal disk are distorted or cracked. Attention: ■ Do not disassemble the flywheel. 16 Crankshaft signal wheel ○ Fig.1.1.070 Check whether the crank signal wheel has distortions, cracks and other anomalies. Check whether the bolts are loose 3) Assembly ① 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. ② 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 1 2 3 4 Hole group marking Black／Black Black／Yellow Black／Red Black／White 0 (up / down) Yellow／Black Yellow／ Yellow／Red Yellow／ 1 (up / down) Yellow White Red／Black Red／Yellow Red／Red 2(up / down) Red／White 5 Black／Purple Yellow／Purple Red／Purple 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. 81 Maintenance Manual for J2 Sedan Mechanical Part of Engine ③ Add oil to bearing surface Install crankshaft on cylinder block. When rotating the crankshaft by hand, check whether the rotation of crankshaft is smooth. ④ Install main bearing cap. Fig.1.1.071 ■ 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. ⑤ 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: 35±2N·m 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”. ⑥ Install piston onto the connecting rod with following instructions. a. Fig.1.1.072 Measure the following lengths (See right Figure). Piston B： Distance from piston flange to piston flange inside Connecting Rod Piston Pin A： Distance from piston flange to piston flange outside 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 82 Maintenance Manual for J2 Sedan Mechanical Part of Engine 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. Fig.1.1.073 Guide Sleeve B Guide Sleeve A Attention: ■ If the pressing load exceeds specified value, replace the piston pin and piston assembly and/or the connecting rod. Standard value: 108±54N·m ⑦ 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 b) Size Color Standard Colorless Extended by 0.50mm Blue Extended by 1.00mm Yellow To install the blade, install one end of blade into the groove (as shown in the diagram) before pressing the other areas to place. 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.1.1.074 Piston Ring Expander 83 Maintenance Manual for J2 Sedan b. Mechanical Part of Engine Install first and second piston rings. Install first and second piston rings with the identification marks facing upwards (on the piston top side) by using expander. Notes: Piston ring opening direction 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 ⑧ 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. ⑨ ■ 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. ■ ■ 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 ■ 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. 84 Maintenance Manual for J2 Sedan ■ 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. Mechanical Part of Engine Fig.1.1.075 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 ⑩ Install connecting rod cover. During installation, first use high pressure gas for blowing the expansion sections. Fig.1.1.076 When tightening connecting rod bolt, the order of “5Nm→10Nm→13Nm+45°+45°”alternate 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. ⑪ Install rear oil seal housing of crankshaft with rear oil seal assemble to the cylinder block. ⑫ Installation of knock sensor, Hall sensors, oil pressure switch. Attention: ■ 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. ⑬ Be aware of following to install with steps contrary to dismantlement. ■ Flywheel Alternately tighten bolts to specified torque. 85 Maintenance Manual for J2 Sedan XIV. Mechanical Part of Engine 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. 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. The bearing gap is high. Replace. 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. The heat shield for transmission is damaged. Replace The engine oil is thin (low oil pressure). Change oil. 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. 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. The water pump is leaky. Replace. Jam in radiator The coolant contains the impurities. Replace the coolant. High temperature of coolant The water tank cover is not strictly sealed. Replace. The cooling system is jammed. Rinse or replace. The thermostat is at fault. Replace. Low cylinder pressure Low oil pressure High engine oil pressure Engine quiver Noise of valve Noise from connecting rod bearing shell and the main bearing shell Poor cooling performance 86 Maintenance Manual for J2 Sedan Trouble Low temperature of coolant Ineffective fan Exhaust system leaks Abnormal noise Mechanical Part of Engine 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. The sensor or the wire harness is at fault. Repair or replace. The sensor or the starter is at fault. Repair or replace. 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 pipe gasket damaged Replace. The muffler loosened Tighten it The rubber pad cut off Replace. The exhaust pipe or muffler contacts vehicle body. Correct The exhaust pipe or the muffler is damaged. Repair or replace. 87 Maintenance Manual for J2 Sedan Mechanical Part of Engine XV. Parameters for Maintenance 1. List for Technical Parameters of Engine Technical Parameters list of Engine Item Standard Value Limits Camshaft base circle diameter (mm) 36 — Diameter of camshaft journal (mm) 32.033-32.082 — 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 Exhaust valve 1.85 1.35 Φ5 — Camshaft Cylinder head and valve Thickness of valve edge (mm) Diameter of valve stem (mm) Clearance between valve stem and Intake valve 0.020-0.036 0.10 valve guide (mm) Exhaust valve 0.030-0.045 0.15 45°-45.5° — Intake valve 89.61 89.51 Exhaust valve 90.91 90.41 43.1 — 152/33.4 — 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) φ5.5 — 23.0 — φ10.605-10.615 — φ10.805-10.815 — φ11.055-11.065 — φ28.425-28.445 — φ28.725-28.745 — φ26.725-26.745 — φ26.725-26.745 — Conical angle of valve Total length of valve (mm) Free height of valve spring (mm) Load / mounting height of valve spring (N)/(mm) Protrusion of valve guide (mm) Diameter of size-extended valve guide on cylinder head (mm) Intake Diameter of size-extended valve seat ring hole (mm) Exhaust Extended by 0.05mm Extended by 0.25mm Extended by 0.50mm Extended by 0.3mm Extended by 0.6mm Extended by 0.3mm Extended by 0.6mm 88 Maintenance Manual for J2 Sedan Item Mechanical Part of Engine Standard Value Limits 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 75.0 — Oil pump and oil pan Piston and connecting rod Reference outer diameter of piston (mm) 1st piston ring 0.03-0.07 0.1 nd 0.02-0.06 0.1 st 1 piston ring 0.15-0.30 0.8 2nd piston ring 0.30-0.50 0.8 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 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 — — — 0.02-0.04 — Side clearance of piston ring mm) 2 piston ring Gap of piston ring opening (mm) Crankshaft and cylinder body Reference cylinder bore (mm) 75.0 Clearance between piston and cylinder (mm) 89 Maintenance Manual for J2 Sedan 2. Mechanical Part of Engine Tightening Torques List of fastener tightening torque Name Specification Qty. Tightening Torques (Nm) High strength bolt Main bearing cap bolt M9×1.25×74.5 8 35±2Nm +60°-64° (Synchronous fastening machine) 5Nm → 13Nm +90 ° - 94 ° Connecting rod bolts tightening M6×0.75×33 torque 6 Camshaft bearing cap bolt M6×1×35 12 11±1 Front camshaft bearing cap bolt M8×1.25×30 3 20±1 Cylinder head bolt M9×1.25×143.5 8 24.5±2Nm +180°-184° Crankshaft pulley bolt M14×1.5×54 1 50Nm±2Nm+60°±2° or 165 Nm±5 Nm Flywheel bolt M11×1.25×25 6 100±5 Exhaust camshaft sprocket bolt M12×30 1 88±10 (Manual) 5Nm → 10Nm → 13Nm +45 ° +45 ° alternate tightening E-type bolt Crankshaft rear oil seal bolt M6×10 E8 6 7.6±0.6 Rear lug blot M8×20 E10 2 18.4±1.4 Intake manifold bolt M8×40 E10 4 18±1.0 Oil pan bolt M6×12 E8 14 7.6±0.6 Sprocket cover bolt I M10×90 E14 2 39.5±3.0 Sprocket cover bolt II M10×50 E14 2 39.5±3.0 Sprocket cover bolt III M6×30 E10 2 8.4±0.6 Bolt M6×20 E10 M6×20 E10 8 8.4±0.6 Bolt M6×12 E10 M6×12 E10 11 8.4±0.6 Bolt M6×45 E10 M6×45 E10 6 8.4±0.6 Bolt M6×25 E10 M6×25 E10 11 8.4±0.6 Bolt M6×12 E8 M6×12 E8 22 8.4±0.6 Cylinder head cover bolt M6×27 E10 10 9±1.0 Oil filter bracket bolt M8×30 E12 3 20±1 Heater water returning pipe bolt M6×20 E8 2 7.6±0.6 Hydraulic oil rail bolt M8×35 E12 2 18.4±1.4 Bolts of exhaust manifold bracket M8×20 E12 2 20±1 Plug Main oil passage plug I Inner hex M20 2 60±5 Main oil passage plug II Inner hex M12 1 35±5 Water drainage plug Inner hex M12 1 25±5 Oil passage plug Inner hex M10 1 20±2 Oil drainage plug M14×1.5×14 1 39±5 90 Maintenance Manual for J2 Sedan Mechanical Part of Engine Other bolts Bolts of balance shaft gear M8×15×1.25 1 23.5±4.5 Bolts of balance shaft chain wheel M8×18×1.25 1 45±5 Set track bolts M6×1×12 2 10±2 Dynamic track bolts M8×1.25×15 1 23.5±4.5 Starter bolt M8×55 2 24±3 Oil pressure switch R 1/8 1 10±2 Spark plug M14 3 27.5±2.5 Exhaust manifold stud M8×1×12 6 12±2 Catalytic gas shroud nut M6×1 3 10±1 Q2580614 (crank signal wheel M6 bolt) 3 12.5±2.5 Water temperature sensor 1 20±4 Hall sensor bolt Inner hex M6×1×16 2 8.4±0.6 Knock sensor bolt Inner hex M8×1.25×30 1 20±4 Exhaust manifold nut M8 5 35±2 4 6±0.5 Throttle bolts Absolute pressure self-tapping screw sensor 6±0.5 Square head bolt M10×1.25×90 1 47±5 Idle wheel bolt M10×1.25×38 1 49±9 2 35±5 1 After contact mounting surface, turn by 3 / 4 laps or 11 ± 1Nm 1 10±1 Oxygen sensor Oil filter Bolts of heat shield Standard parts and threaded connections not mentioned in table above M6 9-11 M8 20-25 M10 30-50 M12 60-80 91 Maintenance Manual for J2 Sedan Mechanical Part of Engine Section II Engine Lubrication System I. Precautions Application Steps of Sealant: 1. Remove any old sealant on the seal gasket by using scraper. Fig. 1.2.001 Scraper Attention: ■ Thoroughly remove old sealant from grooves, fixed bolts and bolt holes on sealant application surface. 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. 92 Maintenance Manual for J2 Sedan Mechanical Part of Engine II. Preparation 1. Repair Tools List of repair tools No. Tool Outline Drawing 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 93 Explanation Maintenance Manual for J2 Sedan Mechanical Part of Engine 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. ① Pull out the oil gauge and clean it . ② Fig. 1.2.002 Insert the gauge; confirm that the oil level in engine is between the two marks as shown. ③ Please adjust the oil level if it is out of range. 2) Appearance of engine oil ① Check the engine oil for any white turbidity and/or severe pollution. ② 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. 94 Maintenance Manual for J2 Sedan ① Check oil level. Please refer to “Engine oil level”. ② Lift the vehicle, disconnect harness connector at oil pressure switch and remove the oil pressure switch. Mechanical Part of Engine Fig. 1.2.003 ③ Install oil pressure gauge and hose. Fig. 1.2.004 ④ Start engine and warm up to normal working temperature. ⑤ 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. ⑥ 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. ■ Tightening torque: 8-12N·m 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. ① Warmup the engine to check engine compartment for oil leakage. Please refer to “Leakage of engine oil”. ② Stop the engine and wait for 10min. 95 Maintenance Manual for J2 Sedan Mechanical Part of Engine ③ Loosen engine oil filler cap and remove the oil drain bolt. ④ Discharge the engine oil. ⑤ 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: 34-44N·m ⑥ 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. ⑦ Warm up engine and check the oil drain bolt and oil filter for oil leakage. ⑧ Stop engine and wait for 10min. ⑨ Check the oil level. Please refer to “Engine Oil Level”. IV. Oil Filter 1. Fig. 1.2.005 Dismantlement and Installation 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. 96 Maintenance Manual for J2 Sedan Mechanical Part of Engine 2) Installation ① Remove any foreign substances attached on mounting surface of oil filter. ② Apply a film of engine oil on oil seal surface of new oil filter. Fig. 1.2.006 ③ 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. 2. Check after Installation 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”. 97 Maintenance Manual for J2 Sedan Mechanical Part of Engine 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”. 98 Maintenance Manual for J2 Sedan 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:7.6±0.6 N·m 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. Mechanical Part of Engine Fig. 1.2.007 Fig. 1.2.008 Attention: ■ Do not damage the matching surface. 4) Dismount oil pump housing assembly. Fig. 1.2.009 5) Dismount oil pickup. Attention: ■ Tightening torque: 8.4±0.65 N·m 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 99 Maintenance Manual for J2 Sedan Mechanical Part of Engine 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. Fig. 1.2.010 Oil pan Apply sealant as shown in figure. ■ Specified sealant: LT5699 or equivalent. 100 Maintenance Manual for J2 Sedan 7) Install oil drainage bolt on oil pan Fig. 1.2.011 ■ The oil drainage bolt gasket for the oil pan is a one-time product, new one should be used after removal. ■ Install the oil drainage bolt washer of oil pan shown in the figure. Attention: ■ After the installation of oil pan, wait at least 30min before filling engine oil. 5. Check after Installation 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”. 101 Mechanical Part of Engine Maintenance Manual for J2 Sedan Cooling System of Engine Heater water returning pipe bolts I Heater water returning pipe bolts II Spacer of heater water returning pipe Thermost subassembly Water pump feeder Water pump inlet bolt Throttle pre-heating outlet hose Heater water returning pipe Throttle pre-heating outlet hose Water pump assembly Cooling Circuit Diagram Bolts for water pump 1. Coolant pump puller Cooling Circuit Fixing bolts of coolant pump pulley I. Seal ring of water pump Section III Mechanical Part of Engine Cooling circuit diagram 2. Principle Diagram of Cooling Radiator Expansion tank Thermostat Thermostat casing Thermostat on Cylinder body Thermostat off Cylinder cover Basic diagram of cooling 102 Air throttle body Warm air heat exchanger Water pump Maintenance Manual for J2 Sedan Mechanical Part of Engine 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. Fig. 1.3.001 2) Leakage check Apply pressure to cooling system with leak detector of radiator cap to detect any leakage. Fig. 1.3.002 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. 103 Maintenance Manual for J2 Sedan ■ Mechanical Part of Engine Be careful not to splash engine coolant onto the drive belt. 1) Discharge engine coolant ① Dismount the deflector on right side of engine. ② Open the water drain plug at the bottom of radiator, and then open the radiator cover. ③ If necessary, remove coolant reservoir to discharge coolant and clean the reservoir before reinstallation. ④ 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 ① 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. ② Make sure all the hose clamps have been tightened firmly. ③ Dismount the air filter upper cover and air intake hose. Please refer to “Air Filter Assembly”. ④ Disconect the outlet pipe of warm water pipe. Please lift the hose as high as possible. ⑤ 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. ⑥ Install air filter upper cover and air intake hose. Please refer to “Air Filter Assembly”. ⑦ Install radiator cap. ⑧ 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. ⑨ Stop engine to lower the engine temperature. ■ Cooling time can be reduced by using fan. ■ Fill coolant in radiator through the filler if necessary. 104 Maintenance Manual for J2 Sedan Mechanical Part of Engine ⑩ Fill engine coolant in reservoir to the MAX position. ⑪ Install the radiator cap and repeat steps ③-⑨ more than twice until the engine coolant level does not lower any more. ⑫ Run the engine to check the cooling system for leakage. 3) Wash cooling system ① Install the dismounted radiator water drainage plug and reservoir. Attention: ■ Be sure to clean the water drainage plug and mount the new O-ring. ② Dismount air filter upper cover and air intake hose. Please refer to “Air Filter Assembly”. ③ Remove outlet pipe of warm water pipe. Please lift the hose as high as possible. ④ 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. ⑤ Install the air filter upper cover and air intake hose. Please refer to “Air Filter Assembly”. ⑥ Run engine to warm it up to normal working temperature. ⑦ Increase engine speed for several times with no load applied to the engine. ⑧ Stop engine and wait for it to cool. ⑨ Discharge the water in system. Please refer to “Discharge engine coolant”. ⑩ Repeat steps ①-⑨ until the radiator begins to discharge the cleared water. III. Radiator 1. Dismantlement and Installation 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 ① Dismount engine deflector. Please refer to “Deflector”. ② 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. ③ Dismount air intake pipe and take it off. ④ Disconnect the harness connector of radiator fan motor and move it aside. 105 Maintenance Manual for J2 Sedan Mechanical Part of Engine ⑤ Dismount the inlet and outlet hoses of radiator and returning hose of coolant reservoir. ⑥ Dismount bracket of radiator and take off the radiator and fan subassembly. Attention: ■ Please do not damage or scratch the radiator core during dismantlement. ⑦ 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. Fig. 1.3.003 2) Inspect relief pressure of radiator cap. Standard value: 78-98KPa Fig. 1.3.004 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. 106 Maintenance Manual for J2 Sedan ■ Mechanical Part of Engine When washing the radiator without dismantling it, please dismount all accessories such as cooling fan, wind collection cover and horn. Then wrap up the harness connectors with adhesive tape to prevent water from flowing in. 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 and Installation 1) Dismantlement ① Dismount the air intake pipe and take it off. ② Disconnect the harness connector of radiator fan motor and move it aside. ③ Dismount the radiator cooling fan sub-assembly. Attention: ■ Do not damage or scratch radiator core during dismantlement. 2) Installation Install in the reverse order with dismantlement. 2. Disassembly and Assembly 1) Disassembly ① Dismount the cooling fan from fan motor. ② Dismount the fan motor from wind collection cover. 2) Check after disassembly ① Cooling fan Check the cooling fan for cracks or abnormal bend. If any, replace the cooling fan. ② Fan motor Check the motor for sticking. 3) Assembly Assemble in the reverse order with disassembly. V. Water Pump 107 Maintenance Manual for J2 Sedan 1. Mechanical Part of Engine Dismantlement and Installation Attention: ■ Be careful not to splash the engine coolant onto the drive belt while dismantling the water pump. ■ If the water pump can not be disassembled, it should be replaced as a whole. ■ 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 Fig. 1.3.005 ① Discharge the engine coolant in radiator. Please refer to “Replace Engine Coolant”. ② Loosen the fixed bolt for belt pulley of water pump. ③ Dismount the drive belt. Please refer to “Drive Belt”. ④ Dismount the fixed bolt for water pump. Fig. 1.3.006 Attention: ■ Tightening torque: 8.4±0.65N·m 2) Check after Dismantlement ■ 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 ① Clean water pump installation seat. ② 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. 108 Maintenance Manual for J2 Sedan Mechanical Part of Engine a）. Install belt pulley of water pump. b）. Install drive belt and adjust it in accordance with specified tension. Please refer to “Drive Belt”. c）. Fill engine coolant. Please refer to “Refill engine coolant”. 2. Check after Installation ■ 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 and Installation 1) Dismantlement ① Discharge the engine coolant through water drain plug of radiator. See “Replace Engine Coolant”. Fig. 1.3.007 Attention: ■ Operate after the engine has cooled. ■ Please do not splash the engine coolant onto the drive belt. ② Disassemble water inlet pipe and heater returning pipe of radiator at thermostat side. Fig. 1.3.008 ③ 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. ④ Unscrew water pump inlet bolt, remove the thermostat. 109 Fig. 1.3.009 Maintenance Manual for J2 Sedan Mechanical Part of Engine Fig. 1.3.010 2) Check after Dismantlement ① Thermostat ■ Inspect opening of thermostat valve at normal room temperature. Temperature of thermostat (ON): 82℃ (initially open) 95℃ (fully open) Maximum lift of valve stem: ≥8mm Please replace the thermostat when the measurement exceeds the specified range. ② Water pump inlet and thermostat housing Check them for cracks and other damages. 3) Installation Be aware of following precautions to install with steps contrary to dismantlement. ① Be careful not to splash engine coolant onto the engine and wipe and dry the engine coolant with cleaning cloth. ② 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. ③ When mounting thermostat, its poppet valve must be set at the highest position. Fig. 1.3.011 Highest ④ If the water temperature alarm switch needs to be reused, apply specified sealant to its thread. ■ Specified sealant: LT648 or equivalent. 110 Fig. 1.3.012 Maintenance Manual for J2 Sedan Mechanical Part of Engine ⑤ If the engine coolant temperature sensor needs to be reused, apply specified sealant to its thread. ■ Specified sealant: LT648 or equivalent. 2. Check after Installation ■ 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. Fig. 1.3.013 VII. Water Piping Sub-assembly 1. Dismantlement ① 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. ② Dismount the air filter assembly. Please refer to “Air Filter Assembly”. ③ Dismount the upper and lower water hoses of radiator. ④ Dismount the warm water hose and minor cycle water piping. ⑤ 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. 3. Check after Installation 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. 111 Maintenance Manual for J2 Sedan VIII. Mechanical Part of Engine 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 Improper heat radiation Radiator is damaged Blockage due to dust or paper scraps — Mechanical damage The radiator cooling is blocked Failed Parts of Cooling System Insufficient air flow The cooling fan fails to work The resistance for fan rotation is too large Excessive foreign substances (corrosion, pollutants, sand, etc.) Fan assembly — — — — — — — — Viscous engine coolant The fan blade is damaged Damaged wind collection cover Incorrect blend ratio of coolant Poor quality of engine coolant Coolant hose Water pump Insufficient engine coolant Engine coolant leaks Radiator cap Coolant reservoir Loose clamp Broken hose Improper sealing Looseness Poor sealing Broken radiator coolant reservoir Broken radiator core Breakage of stock solution tank Excessively high engine speed in the case of no-load — The engine is overloaded Abnormal driving Long-term traveling Trouble of Parts of Other Systems 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 Poor ventilation The radiator grill is blocked The radiator is blocked The condenser is blocked 112 — — Cover mounted Blockage of slurry or paper scraps — Poor ventilation — Maintenance Manual for J2 Sedan IX. Mechanical Part of Engine Parameters for Maintenance Technical specification for cooling system Temperature of thermostat opening 82℃ (Initially open) 95℃ (Fully open) Maximum lift of thermostat valve stem >8mm 113 Maintenance Manual for J2 Sedan Mechanical Part of Engine 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 don’t 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. 114 Maintenance Manual for J2 Sedan Mechanical Part of Engine II. Preparation The special tools are listed in the table below: List of Special Tools S.N. Tool 1 Fuel pressure gauge Outline Diagram No. Explanation JAC－T1F018 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. 115 Maintenance Manual for J2 Sedan Mechanical Part of Engine 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. Fig. 1.4.001 2) Disconnect connector Fig. 1.4.002 3) Disconnect the joint of fuel hose on fuel guide rail. the injector wiring harness 116 Fig. 1.4.003 Maintenance Manual for J2 Sedan Mechanical Part of Engine Attention: ■ Please prepare the container and cleaning cloth in advance as fuel leakage may take place. ■ Avoid the naked flame and spark. ■ Please keep any parts away from heat source. Special attention must be paid when welding around them. ■ 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) Fig. 1.4.004 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. 2. Check after Dismantlement 1) Fuel Injector ■ Check the upper and lower seal rings of fuel injector for crack, aging and breakage. If any, please replace. 117 Maintenance Manual for J2 Sedan ■ Mechanical Part of Engine Check the injection hole of fuel injector for blockage. If any, please wash or replace by using special instrument. 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 ④ on fuel pipe ①with following steps. Fig. 1.4.005 ③ : thick one ⑤ : thin one a. Insert the snap ② 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. 118 Maintenance Manual for J2 Sedan Mechanical Part of Engine ■ Insert the snap slice C into the raised position B of fuel pipe. ■ Make sure the flange A of fuel pipe is properly mounted in the fixing groove on snap flange. 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. 4. Check after Installation 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 “User’s Manual”. 1) Open the fuel filler cap. Fig. 1.4.006 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. 119 Maintenance Manual for J2 Sedan 5) Disconnect the fuel pipe joint 1 (at fuel pump side), joint 2 (at fuel filter side) and grounding end 3 of fuel filter. Mechanical Part of Engine Fig. 1.4.007 Attention: 1 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. Fig. 1.4.008 3 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: 2 ■ 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. Fig. 1.4.009 Installation Be aware of following precautions to install with steps contrary to dismantlement. 120 Maintenance Manual for J2 Sedan Mechanical Part of Engine 1) Fuel filter ■ Be aware of correct installation direction of fuel filter. Fig. 1.4.010 towards fuel inlet pipe side 2) Connector Connect the connector of fuel supply hose according to following methods: ① Check the connection for foreign substance or damage. ② Make the connector align with the resin pipe and insert the connector straightly until “click” is heard. ③ 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. 3. Check after Installation Fig. 1.4.011 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. 121 Maintenance Manual for J2 Sedan Mechanical Part of Engine 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. 122 Fig. 1.4.012 Maintenance Manual for J2 Sedan 6) Disconnect the harness connector of fuel pump and fuel pipe joint. Mechanical Part of Engine Fig. 1.4.013 ① Fuel pipe joint of fuel pump 1 2 ② Harness connector of fuel harness Disconnect the joint with following methods: ■ Hold the side edge of joint and press the raised position of joint to pull out the pipe. ■ 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. ■ Tightening torque: 70-80N·m 123 Fig. 1.4.014 Maintenance Manual for J2 Sedan Mechanical Part of Engine Fig. 1.4.015 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. 2. Check after Dismantlement Fig. 1.4.016 1) Fuel pump ① Visual Inspection ■ Check for broken or fuel impurity. If any, please replace or wash it. ② 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 Be aware of following precautions and install with steps contrary to dismantlement. 1) Fuel pump assembly 124 Maintenance Manual for J2 Sedan Mechanical Part of Engine ■ The Y-ring must fully fit with fuel tank during installation. ■ Tilt the fuel pump to facilitate its installation and pay attention to its direction. ■ There should be no turn-up on Y-ring during the installation. ■ Pre-tighten the locknut during its installation, and then tighten it horizontally. 2) Connector Insert the connector of fuel supply hose with following methods: ① Check the connection for any foreign substance and damage. ② Make the connector align with the resin pipe and insert the connector straightly until “click” is heard. ③ 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. 4. Check after Installation 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. 125 Maintenance Manual for J2 Sedan Mechanical Part of Engine 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 and Installation 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. ① Carry out the dismantlement steps 1-6 of fuel pump. Please refer to “Fuel Pump”. ② Disconnect fuel supply hose and vent hose. ③ Disconnect EVAP hose. ④ Support the fuel tank with special jack. Attention: ■ The fastening band of fuel tank should not be blocked in supporting position. ⑤ Dismount the clamping bands of filler tube and fuel tank, and then disconnect the filler tube and fuel tank. ⑥ Dismount fastening band of fuel tank. 126 Maintenance Manual for J2 Sedan ■ Tightening torque: 30-40N·m ⑦ Manually support the tank and carefully lower the jack to dismount fuel tank. Mechanical Part of Engine Fig. 1.4.017 Attention: ■ Make sure all connections have been disconnected. ■ Make sure there is no interference with vehicle. 2) Check after dismantlement ① Fuel tank ■ Check for impurity of fuel. If any, clean it with hot water. ■ Capacity of fuel tank: 45L ② EVAP hose and clips ■ Check the hose for blockage, corrugation, deformation and breakage. ■ Check the clips for damage or breakage. ③ 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 Be aware of following precautions to install with steps contrary to dismantlement. ■ 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. 2. Check after Installation Check for leakage with following steps. ① Set ignition switch at “ON” position (when engine stops), and then check the connection of fuel pipeline for leakage. ② Start the engine, increase its speed and recheck the connection between piping and fuel pipe of fuel system for leakage. 127 Maintenance Manual for J2 Sedan Mechanical Part of Engine Section V Emission Control System of Engine I. Fuel Evaporation Control System 1. Description Intake manifold Air cleaner EVAP carbon canister solenoid valve Fuel evaporation EVAP carbon canister Fuel tank Air 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. 128 Maintenance Manual for J2 Sedan 2. Mechanical Part of Engine Diagram of Fuel Evaporative Emission Pipeline 2 4 5 1 6 3 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 Note: 6-Fuel filter Fig. 1.5.001 Do not use soap water or any other detergent when installing vacuum pipe or cleaning pipeline. 3. 5-Fuel inlet pipe of engine 2 1 3 Inspection of parts 1) EVAP carbon canister ① 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. ② 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. 129 Maintenance Manual for J2 Sedan Mechanical Part of Engine ③ Dismount the carbon canister Lift the carbon canister and dismount it from the bracket on inner lining of left fender. Fig. 1.5.002 Left front frame 左前车架 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. ① 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. ② Dismantlement a. Fig. 1.5.003 Disconnect the vacuum hose of EVAP carbon canister solenoid valve. 130 Maintenance Manual for J2 Sedan b. Disconnect the harness connector of EVAP carbon canister solenoid valve. Fig. 1.5.004 c. Remove the EVAP electromagnetic valve. Fig. 1.5.005 carbon canister Mechanical Part of Engine 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. 131 Maintenance Manual for J2 Sedan Mechanical Part of Engine 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. 132 Maintenance Manual for J2 Sedan 2. Mechanical Part of Engine Inspection of Element Check the PCV (forced ventilation of crankcase) valve as shown below: 1) Operation principle Operation principle list of PAV valve High vacuum No vacuum Valve chamber cover side Valve chamber cover side Operating state of engine Out of work Operating state of engine Idling or deceleration PCV valve Out of work PCV valve Fully open Variation of vacuum Limited Variation of vacuum Slight No Moderate Valve chamber cover side Valve chamber cover side Improper acceleration and Operating state of engine Normal operation Operating state of engine PCV valve Normal operation PCV valve Retardant operation Variation of vacuum Large Variation of vacuum Extremely large 133 high speed Maintenance Manual for J2 Sedan Mechanical Part of Engine 2) Dismantlement and Installation ① Dismantlement a. Disconnect the PCV valve hose from cylinder cover. b. Remove the PCV valve from cylinder cover. Fig. 1.5.006 Fig. 1.5.007 3) Check after Dismantlement ① 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. Fig. 1.5.008 P.C.V valve ② 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. 134 Maintenance Manual for J2 Sedan Chapter II Electrical Part of Engine Section I I. Ignition coil 1. Parts Ignition System Ignition coil 2. Dismantlement & Installation 1) Dismantlement Attention: Fig. 3.1.001 ■ Be sure that the ignition switch is in the “OFF” position. ① Dismount the trimming cover of engine. Refer to “Intake Manifold” section. ② Disconnect the wiring harness connectors of the ignition coil from high voltage ignition coil. 135 Electrical Part of Engine Maintenance Manual for J2 Sedan ③ Remove high-voltage ignition coil bolt to remove coil. ■ Tightening torque: 6-8N·m ④ Dismount the spark plug with special socket. Electrical Part of Engine Fig. 3.1.002 Tightening torque: 25-30N·m Attention: ■ Please do not drop or shake it. 2) Check after dismantlement ① High-voltage ignition coil ■ Check the primary coil resistance between both terminals. Primary coil resistance: 0.77-0.95 Ω ■ Check the resistance of secondary coil Secondary coil resistance: 7.75-10.23 KΩ Attention: ■ The ignition coil harness connector must be disconnected for secondary coil resistance measurement. ② 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 Reason Black charcoal Impurity in the fuel or high fuel-air ratio. ■ Check spark plug electrodes for damage. ■ Inspect clearance of spark plug. 136 Hard charcoal Impurities in the fuel; wrong ignition timing, or untight spark plug. Maintenance Manual for J2 Sedan Electrical Part of Engine Inspect clearance of spark plug by using feeler. Standard value: 0.7-0.8 mm If the clearance is beyond the standard value, replace. ■ Check sparking ability of spark plug. 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 Install with steps contrary to dismantlement. II. Diagnosis of Common Troubles Diagnosis Common Troubles Symptom The engine can’t or is difficult to start. Unstable idle speed Engine surge or poor acceleration Poor. fuel economy Possible causes Solution Trouble of ignition coil or ignition Check or replace the ignition coil or the switch ignition switch Trouble of spark plug Check or replace spark plug Disconnected high voltage wire Check the high voltage wire Trouble of high voltage wire or spark Check the high voltage wire or check or plug Replace spark plug Trouble of ignition coil Check or replace the ignition coil Trouble of high voltage wire. Check the high voltage wire Trouble of spark plug Check or replace spark plug Trouble of spark plug Check or replace spark plug III. Parameters for Maintenance Maintenance Specification of Ignition System High voltage Ignition coil Spark plug Primary coil resistance Secondary coil resistance Spark plug clearance 137 0.77-0.95Ω 8.7±0.87 KΩ 0.7-0.8mm Maintenance Manual for J2 Sedan Section II I. Electrical Part of Engine Starting and Charging System Principle Diagram of Starting and Charging System 120 A 中央电器盒 box 熔断片 fuse link 120A Central 熔断片 30A 30 A fuse link electric 熔断片 20A 20 A fuse link Battery 蓄电池 LOCK Ignition switch START 点火开关 ACC ON O/S Combined Charging 组合仪表 充电指示灯 alarm light device - + Anti-theft relay Starting relay 防盗继电器 起动继电器 B S L Electric generator 发电机 R2 整流器 Rectifier Magnetic field磁场绕组 winding ETACS－low level effective ETACS-低电平有效 Df R1 R3 接地 Grounding ZD 起动机 Starter 定子绕组 Stator winding ENG 电动机 单向离合器 Electric motor R4 Tr1 Tr2 Solenoid 电磁开关 switch One-way clutch 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. 138 Maintenance Manual for J2 Sedan Electrical Part of Engine ■ If the vehicle is not used for a long time, the cathode terminal of battery should be disconnected. ■ Check charging condition of battery. 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) ① If U>13.2V, inspect the electrical system. ② If 12.5V<U<12.9V, the system is normal. ③ If 11V<U<12.4V, inspect charging system. ④ 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. Fig.3.2.001 ① Disconnect the negative terminal. ② Dismount the positive terminal of battery and the fixed bolts of battery pressure plate, and then take off the pressure plate. ③ Take off the battery. ④ Take off the bracket of battery. 139 Fig. 3.2.002 Maintenance Manual for J2 Sedan Electrical Part of Engine 2) Check after dismantlement ① Bracket of battery ■ Check for erosion. If there is, clean with warm clean water. ② Battery harness ■ Check for erosion and damage. Replace if there is any. 3) Installation Install with steps contrary to dismantlement. Attention: ■ During connection, the anode terminal of battery should be connected first. ■ After installation, terminals may be smeared with mineral oil. 140 Maintenance Manual for J2 Sedan Electrical Part of Engine 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. 2. Dismantlement and installation Fig. 3.2.003 Components of Starter 1) Dismantlement ① Fig. 3.2.004 Disconnect the negative terminal of battery. Note: Before disconnecting the cathode terminal of battery, pull off the starter key first. 141 Maintenance Manual for J2 Sedan ② Disconnect the harness connector of starter. ③ Dismount the fixing bolts of starter, then take off the starter. Fig. 3.2.005 2) Installation Install with steps contrary to dismantlement. Attention: ■ Be sure to tighten the nut of “B” port. 142 Electrical Part of Engine Maintenance Manual for J2 Sedan 3. Electrical Part of Engine Disassembly and Assemblage 1) Disassembly 7 4 1 11 10 8 9 16 6 5 3 2 15 14 13 12 Exploded View of Starter 1-Screw 2-Front support 3-Stop ring 9-Planetary gear 10-Ball 4-Snap ring 5-Pinion 6-Gear ring 7-Solenoid switch 8-Plantery gear 11-Gasket 12-Stator 13-Rotor 14-Electric brush retainer 15-Rear support 16-Fixing bolt 143 Maintenance Manual for J2 Sedan Electrical Part of Engine 2) Check ① Solenoid switch ■ Before check, disconnect negative terminal of battery. ■ Disconnect the “M” port of starter. 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. Fig. 3.2.006 Connecting from the power supply “M” ■ Fig. 3.2.007 Connecting from the power supply “M” end Replace solenoid switch if opened. ② 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. 144 Maintenance Manual for J2 Sedan Electrical Part of Engine ③ Electric brush Fig. 3.2.008 ■ Check brush wearing with a caliper. if excessive worn, replace. Vernier caliper Electric brush ④ Electric brush spring ■ Depatch spring from the brush and use a spring tension gauge to check tension Fig. 3.2.009 Electric brush Electric brush spring ⑤ Electric brush retainer a. Test insulation voltage between brush retainer (positive) and bearings (negative) with an ohmmeter. If broken, replace electric brush retainer. Fig. 3.2.010 b. Check for electric brush smoothly moving. ■ If electric brush bracket is bent, replace. If the sliding surface is dirty, clean. ⑥ 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. 145 Fig. 3.2.011 Magnet Maintenance Manual for J2 Sedan ⑦ 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. Electrical Part of Engine Fig. 3.2.012 Fig. 3.2.013 Sand paper d. Check diameter of commutator. ■ Check with a caliper; if it is less than the specified value, replace. Fig. 3.2.014 Vernier caliper Commutator 146 Maintenance Manual for J2 Sedan Electrical Part of Engine 3) Assemblage When assembling the starter, the bearing, the gear and the friction surface should be lubricated by adding high temperature grease. And then conduct the following operations. ① Gear clearance adjustment Fig. 3.2.015 ■ Push the pinion out with the magnetic switch energized, meanwhile check the clearance between the pinion and the thrust piece with a feeler. Stop block Gear clearance Pinion ■ If the clearance is out of range, adjust by using spacer. 147 Fig. 3.2.016 Adjusting gasket Maintenance Manual for J2 Sedan 4. Electrical Part of Engine Diagnosis flow chart of Common Troubles (if there is any abnormity found, disconnect negative pole of battery at once.) Inspection Flow Chart of Common Troubles of Starting System Replace the solenoid switch. Starter fails to stop. The engine fails to start. Yes Does engine run with revolving of crankshaft? Yes Does engine run normally? Inspect ignition/fuel system. No No Inspect following items of Abnormal A battery: 1. Charging condition Normal 2. Connection of terminal 3. Repair the starter. Erosion of terminal. Yes Yes Does the gear shaft run? Does the starter run? No Check pinion clutch. No Check the reduction gear, armature and the gear shaft. Abnormal Check the fuse and the fusible wire. replace. Normal Inspect following items of battery: 1. Charging condition Abnormal 1. 2. Connection of terminal 3. 2. Erosion of terminal. Normal Charge battery. Repair poor connection and eroded terminal of battery. A Abnormal Inspect circuitry of starting system. Repair. Normal Does magnet switch make noises during running? No Repair the starter. Yes Check the meshing condition of pinion and gear ring. Abnormal If wired as follows with no load, does Yes Replace solenoid switch. starter run? 1. Adjust the displacement of pinion. 2. Inspect motion mechanism of pinion. 3. Check the gear ring. No Repair the starter. 148 Maintenance Manual for J2 Sedan Electrical Part of Engine IV. Charging System 1. System Description The generator is used to provide DC voltage to vehicle electric system and keep charged condition of battery. The voltage output is controlled by IC adjuster. 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. 3. Dismantlement and installation 1) Dismantlement ① Disconnect the negative pole of battery. ② Disconnect harness connectors of generator. ③ 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 Fig. 3.2.017 Fig. 3.2.018 Generator supporting nut: 47±5 N.m 149 Maintenance Manual for J2 Sedan Fig. 3.2.019 Electrical Part of Engine Fig. 3.2.020 ④ Dismount the belt of generator. Please refer to the “Drive Belt” section. ⑤ Take off the generator from the vehicle. 2) Installation ■ 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 N·m 150 Maintenance Manual for J2 Sedan 4. Electrical Part of Engine Disassembly and Assembly Exploded View of Engine 1-Lock nut 2-Belt pulley 9-Rear bearing 3-Spacer 4-Front end cover 5-Front bearing 6- Bearing cap 7-Bolt 12- commutator 10-Stator 11- gasket 14-Guide sleeve of slip ring 151 15-Rear cover 8-rotor 13-Electric brush retainer Maintenance Manual for J2 Sedan Electrical Part of Engine 1) Disassembly Disassemble in the following order. ① Belt pulley ② Rear cover ③ Commutator assembly ④ Separate front and rear cover assembly. Attention: ■ Be careful to avoid damage of stator assembly. 2) Check after disassembly ① Inspect of rotor a. Fig. 3.2.021 Resistance test Resistance: Approximately 2.0-2.5 Ω ■ If it is beyond the standard range, replace. Slip ring b. Insulator test ■ If electrically continued, replace. c. Inspect wearing condition of slip ring. ■ If it is beyond the standard range, replace. ② Carbon brush a. Check carbon bush for smooth moving. Fig. 3.2.022 ■ If not, inspect carbon brush support and clean as required. b. Check wearing condition of carbon brush. ■ If Limit is exceeded, replace brush. 152 The mark line of wearing limit of electric brush Maintenance Manual for J2 Sedan Electrical Part of Engine ③ Stator a. Inspect continuity between terminals. ■ Fig. 3.2.023 If not, replace. b. Grounding test ■ Lead Fig. 3.2.024 Lead If electrically continued, replace the stator. Stator core 3) Assembly ① 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. ② Installation of rear cover Fig. 3.2.025 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. 153 Maintenance Manual for J2 Sedan 5. Electrical Part of Engine Trouble Diagnosis for Charging System Be sure that the battery has been sufficiently charged before test of generator. A 30 V volt meter and a proper test probe should be used in test. Inspection chart is helpful for inspection of generator. ■ Check the fusible wire before starting up. ■ Use a battery fully charged. Inspection Flow Chart of Charging System The ignition switch is on. The alarm light is off. The alarm light is on. The engine starts with a rev of 1500 rpm. The alarm light is off. Disconnect the connector, and ground the L-side harness. The alarm light is on. The alarm light is on. Conduct the following check: 1. Rotor 2. Slip ring of rotor 3. Electric brush The alarm light is off. Conduct following check: 1. Bulb of alarm light 2. Fuse of alarm light . Perform following inspection: 1. rotor 2. Slip ring of rotor 3. Electric brush. The engine runs at idle speed. Change damaged IC regulator. The alarm light is off. Normal. The alarm light is on. Normal. The engine rev is 2500 rpm. Measure the voltage of B port. Alarm light: the “charging” alarm light in the combined instrument. More than 16.0 V. Change the damaged IC regulator. Less than 13.0 V. Conduct the following check: 1. Rotor 2. Slip ring of rotor 3. Electric brush 4. Stator. Change the damaged IC regulator or diode assembly. 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. 154 Maintenance Manual for J2 Sedan Chapter III Electronic Control System of Engine Section I I. Electronic Control System of Engine Precautions 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). 155 Maintenance Manual for J2 Sedan Electronic Control System of Engine Even with engine stopped, there is high pressure in fuel pipelines. Therefore, the fuel pipe should not be dismantled casually during the course of maintenance. In case that it is necessary to repair fuel system, pressure in fuel system should be released before dismantlement of fuel pipe. 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. 156 Maintenance Manual for J2 Sedan Electronic Control System of Engine IV. Common tools for diagnose ■ Description of tool: diagnose tool of electronic controlled injection system Function: reading/clearing DTC of electronic injection system, view data flow, test actions of parts, etc.. Fig. 4.1.001 ■ Description of tool: ignition timing indicator Function: inspect ignition timing Fig. 4.1.002 157 Maintenance Manual for J2 Sedan ■ Electronic Control System of Engine Description of tool: digital universal meter Function: measure characteristic parameters such as voltage, current and resistance of electronic injection system Fig. 4.1.003 ■ Description of tool: vacuum gauge Function: inspect air pressure of intake manifold Fig. 4.1.004 158 Maintenance Manual for J2 Sedan ■ Electronic Control System of Engine Description of tool: cylinder pressure gauge Function: inspect pressure in each cylinder Fig. 4.1.005 ■ Description of tool: fuel pressure gauge Function: inspect pressure of fuel system, determine working states of fuel pump and fuel pressure regulator. Fig. 4.1.006 159 Maintenance Manual for J2 Sedan V Electronic Control System of Engine Precautions for On-board diagnose (OBD) system of engine The electronic control module (ECM) has an OBD system. The malfunction indicator lamp (MIL) of OBD system will be lit to indicate the driver that there is malfunction caused by aging of the exhaust system. ■ 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. Fig 4.1.007 Battery ■ ■ Don’t 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 doesn’t mean any trouble. Don’t replace any components because of a little change. 160 Maintenance Manual for J2 Sedan Electronic Control System of Engine ■ When connecting the ECM harness connectors, push the deflector rod (1) downward mostly to lock securely. ■ When Inserting the contact pin into the ECM 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. Fig 4.1.008 Bent 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. ■ Don’t 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. 161 Maintenance Manual for J2 Sedan ■ Tighten clamp of fuel hose to specified torque. Fig 4.1.009 ■ Don’t step on accelerator pedal when starting the vehicle. ■ Don’t increase the speed of engine immediately after starting the vehicle. ■ Don’t speed up before shutting down the engine. 162 Electronic Control System of Engine Electronic Control System of Engine Maintenance Manual for J2 Sedan Section II I. Structural Principle and Inspection of Engine Control System System Description Generally, the engine management system is mainly composed of three parts, namely sensors, micro-processor (ECU), and actuators, to control the intake volume, fuel injection amount, and ignition advance angle during the running of the engine. The basic structure is shown in the figure below: Sensors Diagnosis Diagnosis Actuators Engine 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. Carbon canister control valve Carbon canister Throttle body assembly Intake pressure/ temperature sensor Fuel pressure regulator Fuel distributor pipe assembly 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: Ignition coil Phase sensor Oxygen sensor Three-way catalytic converter Fuel injector Throttle position sensor Water temperatrue sensor Knock sensor Stepping motor Fuel filter Speed sensor Diagnosis interface Product manufactured by UAES Fuel tank Electric fuel pump ansd brakckt assembly 163 Maintenance Manual for J2 Sedan Electronic Control System of Engine Illustration of Engine Control System Note: This diagram is the control diagram, if the sensor location doesn’t match with physical parts, actual conditions should prevail. II. Multiple-point Fuel Injection System 1. System Description 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 Hall sensor Engine speed Piston position ECM Function Actuator Control fuel injection and mixing Fuel injector Absolute intake pressure sensor Intake quantity 3. 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 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 164 Maintenance Manual for J2 Sedan Electronic Control System of Engine 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 165 Maintenance Manual for J2 Sedan Electronic Control System of Engine maintain higher idling speed. Sum of all these required output torque is delivered to the torque coordinator to carry out the calculation to get the corresponding intake density, gas mixture composition and ignition timing. 7. λClosed-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 NOX by 98% or more and transform them into H2O, CO2 and N2. However this high efficiency can only be achieved in a very narrow range near the excessive air factor of engine λ=1. The objective of the λ 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. λ 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 (λ> 1) produces a sensor voltage of about 100mV and the concentrated gas mixture (λ <1) produces a sensor voltage of about 900mV. In case of λ=1, the sensor voltage has a jump. λ closed-loop control responds to the input signal (λ>1= too thin mixture, λ<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 λ 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 166 Maintenance Manual for J2 Sedan Electronic Control System of Engine related to the sensor and actuator can be read with the diagnosis apparatus, and the actuator may be driven forcibly in some cases. 12. Other Control Functions 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 λ 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). 167 Electronic Control System of Engine Maintenance Manual for J2 Sedan Function diagnosis Function diagnosis Electronic control unit Data collection Control command Sensors Actuators Engine 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. 168 Maintenance Manual for J2 Sedan Electronic Control System of Engine 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. 169 Maintenance Manual for J2 Sedan 5. Electronic Control System of Engine List of Common Control System Malfunction Codes of ECU 1.0 Table of Common Malfunction Codes for UAES Control System of 3-Cylinder Engine 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 P0202 Open-circuit of 2# fuel injector control circuit P0203 Open-circuit of 3# 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 P0264 Short-circuit of 2# cylinder fuel injector control circuit to ground P0265 Short-circuit of 2# cylinder fuel injector control circuit to power supply 170 Maintenance Manual for J2 Sedan Electronic Control System of Engine DTC Information Introduction of Malfunction Codes (UAES) P0267 Short-circuit of 3# cylinder fuel injector control circuit to ground P0268 Short-circuit of 3# cylinder fuel injector control circuit to power supply P0300 Detection of misfire in various cylinders P0301 Detection of misfire in 1# cylinder P0302 Detection of misfire in 2# cylinder P0303 Detection of misfire in 3# cylinder P0321 No detection of missing tooth BM signal after certain angle rotation of crankshaft P0322 No pulse signal of speed sensor (open-circuit or short-circuit) P0327 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) 171 Maintenance Manual for J2 Sedan Electronic Control System of Engine DTC Information Introduction of Malfunction Codes (UAES) P1651 Malfunction of SVS lamp drive circuit P2177 Out-of-upper-limit of air-fuel ratio closed-loop control self-learning (Medium load zone) P2178 Out-of-lower-limit of air-fuel ratio closed-loop control self-learning (Medium load zone) P2195 Aged upstream oxygen sensor P2196 Aged upstream oxygen sensor P2270 Aged downstream oxygen sensor P2271 Aged downstream oxygen sensor 172 Maintenance Manual for J2 Sedan Electronic Control System of Engine 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, don’t 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. 173 Electronic Control System of Engine Maintenance Manual for J2 Sedan 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 User described the symptom and the User described the symptom and apparatus did not show DTC apparatus displays DTC User did not describe the 4. Recognize the symptom Attempt to diagnose the symptom described by the user. symptom, but 3.Recognize the symptom apparatus Attempt to diagnose the symptom described by the user. displays the DTC. 5. Implement the confirmation steps of DTC. 6. Implement the basic check. Do not use the trouble diagnosis apparatus Inspect with trouble diagnosis apparatus Within the scope of technical 7. Run the trouble diagnosis & parameters 9. Use the trouble symptom table to check troubled system No troubled component found 10. Check the troubled component through the diagnosis steps check mode Beyond the scope of the technical parameters 8. Check the troubled component Troubled component Abnormal (DTC detected) found 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. Normal The check ends 174 Abnormal (symptom still exists) Maintenance Manual for J2 Sedan 3. Electronic Control System of Engine Trouble Symptom Check Table List of Trouble Symptom Inspection Symptoms Check Order No. Unable to communicate with Unable to communicate with all the systems 1 diagnosis apparatus Unable to communicate with ECM only 2 Engine alarm lamp and corresponding components Engine alarm lamp failed to light up immediately after the ignition switch is turned to ON. Engine alarm lamp keeps bright 4 No initial ignition (unable to start) 5 There is initial ignition but it burns incompletely (unable to Start start) Idle Stability (abnormal idle speed) 7 Unstable idle (fluctuant idle speed and hunting) 8 High idle speed (abnormal idle speed) 9 Low idle speed (abnormal idle speed) 10 deceleration) Driving 6 Too long starting duration (unable to start normally) The engine stops at the idle when it is cold. (stop with Idle Stability (engine stops) 3 The engine stops at the idle when it is hot. (stop with deceleration) 11 12 The engine stops at the start. (stop with acceleration) 13 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 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 25 175 Maintenance Manual for J2 Sedan 4. Electronic Control System of Engine Symptom List Symptom List Items Failure of starting Start Extinguishment after combustion Hard to start Hunting Stability of idle speed Fluctuation of idle Incorrect idle Extinguishment of engine (with deceleration) Extinguishment of engine (with acceleration) Vehicle surge, drop of speed Poor acceleration Driving Instability Shock Surge Knock Parking 5. Symptoms Starter drags the engine, but there is no combustion in cylinder and the engine does not start. There is combustion in cylinder, but the engine extinguishes immediately. Engine starts after the crankshaft rotates a while. Engine does not maintain a constant speed and the speed changes within range of idle speed. Usually, it can be determined with the swing of tachometer pointer and the vibration transferred to the steering wheel, selector rod and body etc. Engine is running idly at the incorrect rotation speed. When releasing the accelerator pedal, no matter whether the vehicle is moving, the engine stops. When the accelerator pedal is depressed or being depressed, the engine stops. 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 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. When firstly depressing down the accelerator pedal to speed up, engine speed increases slowly. There is huge shock or vibration of engine with accelerating or decelerating. There is repeatedly forward surge when traveling with constant or variable speed. There is a strong voice like the hammer against the cylinder wall during the driving which is harmful to driving. Keep running(fail to stop) 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. 176 Maintenance Manual for J2 Sedan 6. Electronic Control System of Engine Inspection of Idling Speed 1) Conditions Attention: ■ Check the regular items including spark plug, fuel injector and compression pressure of the cylinder at beginning of inspection. ① The engine coolant temperature is 80-95℃. ② Lamps, electronic fan and all the accessories are turned off. ③ Shiftlever is at neutral position. ④ 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 (750±50r/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. ■ Don’t 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: ■ Don’t check fuel pressure with system operating. 177 Maintenance Manual for J2 Sedan Electronic Control System of Engine ■ 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 Too low fuel pressure Too high fuel pressure Possible Cause Troubleshooting Blockage of fuel filter Replace the fuel filter Damaged fuel pump or poor sealing of fuel pressure Replace fuel pump regulator resulting in fuel leakage at returning side Cementation of fuel pressure Replace fuel pump Repair or replace fuel Blockage or bend of fuel return pipe 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 Fuel pressure drops slowly after engine stopped Fuel pressure drops completely after engine stopped. 9) Possible Cause Troubleshooting Leakage of fuel injector Replace injector Trouble of fuel pump Replace pump 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. ① Turn the ignition switch to the "ON" position (with engine stopped), and then check for leakage at the joint of the fuel pipeline. ② Start the engine and increase speed, inspect whether there is leakage at joint of fuel system. 178 Maintenance Manual for J2 Sedan Electronic Control System of Engine 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 Fig. 4.3.001 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 Intake pressure/ temperature sensor 5V power supply 1 Sensor grounding 179 Maintenance Manual for J2 Sedan Electronic Control System of Engine 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 ℃ 6. Dismantlement and Installation 1) Dismantlement ① Disconnect the wire harness connectors of intake manifold pressure & temperature sensors. Fig.4.3.002 Attention: ■ Make sure that the ignition switch is at “Off” position. ② Disassemble the fixing screws of the intake pressure/temperature sensor with crosshead screw driver, remove the sensor. Fig.4.3.003 2) Installation Be aware of following precautions and install with steps contrary to dismantlement. 180 Maintenance Manual for J2 Sedan Electronic Control System of Engine ■ 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 Fig. 4.3.004 See figure right for installation positions. 3. Wiring Diagram Pin 40: 5V Grounding Pin 41: Cooling water temperature signal output 181 Maintenance Manual for J2 Sedan Electronic Control System of Engine Coolant temperature sensor 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%kΩ Characteristic parameters (standard) 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 ℃ 6. Dismantlement and Installation 182 Maintenance Manual for J2 Sedan Electronic Control System of Engine 1) Dismantlement ① Discharge coolant from radiator. Please refer to "Change Engine Coolant". Fig. 4.3.005 ② Disconnect the wire harness connector of the engine coolant temperature sensor. ③ 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 idling，visually inspect coolant leakage. III. Throttle Position Sensor 1. Instruction of Parts 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, it’s actually a rotation angle potentiometer that outputs a voltage signal in proportional to the throttle position. 183 Maintenance Manual for J2 Sedan 2. Installation Position Electronic Control System of Engine Fig. 4.3.006 It’s installed on throttle body. 3. Wiring diagram of throttle position sensor Pin18: 5V power supply Pin26: Throttle position sensor signal Pin39: 5V grounding Throttle Position Sensor 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 2kΩ±20%. Connect two probes to the 1# and 3# pins respectively and rotate 184 Maintenance Manual for J2 Sedan Electronic Control System of Engine the throttle. The resistance measurement shall vary linearly following the opening of the throttle. The measurement on 2# and 3# pins shall be on the contrary. Note: While observing the variation of resistance, pay attention to observe for presence of high resistance leap. Operating temperature: -40 - 125 ℃; 6. Dismantlement and installation of throttle position sensor Fig. 4.3.07 1) Dismantlement ① Disconnect the wire harness connector of air throttle position sensor. Note: Be sure that the ignition switch is at the “Off” position. ② Remove the screws of throttle position sensor and remove the sensor. Fig. 4.3.08 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 185 Maintenance Manual for J2 Sedan Electronic Control System of Engine dead center information in the ignition system. It’s composed of a permanent magnet and a coil enwinding the magnet. The crankshaft signal wheel is one toothed disc, which originally has 60 teeth, but with two missing teeth. 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: -40～150 ℃ Working gap: 0.5-1.5 mm 2. Installation position It’s installed in the vicinity of the crankshaft. Fig. 4.3.009 Crankshaft Position Sensor 3. Wiring Diagram Pin46: Terminal B of crankshaft position sensor Pin 47: Terminal A of crankshaft position sensor 186 Maintenance Manual for J2 Sedan Electronic Control System of Engine Speed sensor 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 1）Removal ① Disconnect the harness connector of crankshaft position sensor. 187 Maintenance Manual for J2 Sedan Electronic Control System of Engine Fig. 4.3.010 ② Unscrew fixing bolts, remove the sensor. Fig. 4.3.011 2） Installation Be aware of following precaution to install with steps contrarily. ■ Be aware of installation gap. Standard: 0.5 - 1.5mm ■ Tightening torque: 7.8 - 9 N • m V. Camshaft phase sensor 1. Component Description 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. 188 Maintenance Manual for J2 Sedan Electronic Control System of Engine B I 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. UH Performance: Operating temperature: -40～150 ℃ Working gap: 0.5-1.5 mm 2. Installation position It’s installed in the vicinity of the camshaft. Fig. 4.3.012 Camshaft position sensor 3. Wiring Diagram Pin 39: Sensor grounding Pin 42: Sensor signal Pin 18: 5V power supply 189 Maintenance Manual for J2 Sedan Electronic Control System of Engine Phase sensor 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 1）Removal ① Disconnect the harness connector of camshaft position sensor. Fig. 4.3.013 ② Unscrew fixing bolts, remove the sensor. 190 Maintenance Manual for J2 Sedan Electronic Control System of Engine Fig. 4.3.014 2） Installation Be aware of following precaution to install with steps contrarily. ■ Be aware of installation gap. Standard: 0.5 - 1.5mm ■ VI. 1. Tightening torque: 7.8 - 9 N • m Oxygen sensor Component Description 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. 191 Maintenance Manual for J2 Sedan 2. Installation position Electronic Control System of Engine Fig.4.3.015 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 Downstream oxygen sensor Main relay Upstream oxygen sensor 4. Main relay 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 192 Maintenance Manual for J2 Sedan Electronic Control System of Engine Injector drive-level fault Oxygen sensor fault indication is set, with the fuel cycle quantitative control cut off; use the basic fuel injection time stored in the ECU for the quantitative fuel control. 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. 6. Dismantlement and Installation 1) Dismantlement ① Disconnect oxygen sensor harness connector. Fig. 4.3.016 ② Remove oxygen sensor with special remover. Fig. 4.3.017 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 193 Maintenance Manual for J2 Sedan Electronic Control System of Engine Be aware of following items to install with steps contrary to dismantlement. ■ Be aware of routing of oxygen sensor wire harness. ■ Tightening torque: 30-40N·m ■ After replacement of oxygen sensor, oxygen sensor should be coated with a layer of anti-rust oil to prevent rust which impede removal. VII. Fuel Injector (INJ) 1. Instruction of Parts 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. 2. Installation Position Fig. 4.3.018 It is installed on the fuel guide rail. 3. Wiring Diagram 194 Maintenance Manual for J2 Sedan Electronic Control System of Engine To main relay 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: 11.4-12.6Ω 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. 5. Dismantlement and Installation Please refer to “Fuel System”. VIII. Knock sensor 195 Maintenance Manual for J2 Sedan 1. Electronic Control System of Engine Description Knock sensor is installed in the cylinder block side usually between the 2, 3-cylinder, it is helpful for engine knock balance; the ECU uses the knock sensor output vibration frequency signal to judge whether there is knock with ECU internal filtering. 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. 2. Fig. 4.3.019 Installation position Installed aside of cylinder. 3. Inspection 1) Wiring diagram Pin 30: Terminal A of knock sensor Pin 31: Terminal B of knock sensor Knock sensor 2) Check the resistance. Resistance: greater than 1MΩ 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; 196 Maintenance Manual for J2 Sedan Cylinder judging signal not reliable; Sensor circuit failure. Electronic Control System of Engine 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. 5. Removal and installation Fig. 4.3.020 1） Removal ① Disconnect knock sensor harness connector. ② 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. ■ IX. 1. Tightening torque: 16 - 24N • m Air-conditioning switch and relay 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 197 Electronic Control System of Engine Maintenance Manual for J2 Sedan 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 On On Off Off (compressor clutch does not work) On On (compressor clutch works) Air conditioning switch Air compressor 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. 2. Installation position 3. Wiring diagram Fig. 4.3.021 A: Main relay output end Pin 35: Canister solenoid valve control signal Canister solenoid valve Main relay 4. Diagnosis 198 Maintenance Manual for J2 Sedan 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 - 22Ω; Working voltage: 8 - 16V; 6. Removal and installation Electronic Control System of Engine Fig. 4.3.022 1） Removal ① Disconnect hose at canister solenoid valve side. ② Disconnect the canister solenoid valve wiring harness connector. Fig. 4.3.023 ③ 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 199 Maintenance Manual for J2 Sedan 1. Electronic Control System of Engine Description Ignition coil converts the low voltage of the primary winding into the high voltage of secondary winding and discharged at spark plug to ignite the fuel air mixture in cylinder. 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. Fig. 4.3.024 Ignition coil operating voltage range: 6 - 16V Secondary ignition coil resistance: 8.7 ± 0.87 KΩ Primary charge time: 2.15ms Minimum ignition duration: 1.0ms Minimum ignition energy: 35mJ. 2. Installation position Fig. 4.3.025 Installed at top of the cylinder head cover. 200 Maintenance Manual for J2 Sedan 3. Electronic Control System of Engine Diagnosis ECU does not function to diagnose ignition coil failures. Therefore, if there is any failure of ignition coil, no DTC is set. Only by checking the ignition coil resistance can the proper working of the ignition coil be determined; 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. 5. Removal and installation 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). 2. Installation Position 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. 201 Maintenance Manual for J2 Sedan Electronic Control System of Engine Fuel pump relay Fuel pump 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”. 5. Dismantlement and Installation 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. 202 Maintenance Manual for J2 Sedan XIII. 1. Electronic Control System of Engine Electronic Control Module (ECM) of Engine System description The greatest characteristic in the electronic control system of the M7 engine is the adoption of torque-based control strategy. The torque-based control strategy is mainly intended to link a great amount of different control objectives. 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 λ 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. 203 Maintenance Manual for J2 Sedan Electronic Control System of Engine 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 (3rd cylinder) 18 5V power supply 2 50 Fuel injector 1 (1st 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 (2nd cylinder) 32 Main relay 64 Reserved terminal * Specific pin number is subject to harness schematic diagram (standby terminal defined as empty pin). 204 Maintenance Manual for J2 Sedan 3. Installation Position Electronic Control System of Engine Fig. 4.3.026 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. 5. Dismantlement and Installation 1) Dismantlement ① Turn the ignition switch to “OFF” position to dismantle the negative terminal of battery. ② Dismantle the lower part of the console referring to “console”. ③ Disconnect the wire harness connector of ECM port. Refer to “Precautions”. ④ Unscrew fixing bolts of ECM to remove the ECM. 2) Installation ■ Install in the reverse order with dismantlement. ■ For precautions about the installation, please refer to “Precautions”. 205 Maintenance Manual for J2 Sedan Electronic Control System of Engine 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. 206 Electronic Control System of Engine Maintenance Manual for J2 Sedan 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 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 2 Check if the intake pressure in the data flow is about 101kpa (depending on the air pressure then).。 Yes To Step 5 No Next step 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. Yes To Step 5 No Next step 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. Yes Repair or replace the harness No Next step Yes Diagnosis help No Replace the sensor Check result Subsequent step 3 4 5 Check result 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. Subsequent step Next step Fault code: P0108 “the intake pressure sensor is short to power source” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 2 Check if the intake pressure in the data flow is about 101kpa (depending on the air pressure then). Yes To Step 5 No Next step 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. Yes To Step 5 No Next step 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. Yes Repair or replace the harness No Next step Yes Diagnosis help No Replace the sensor 3 4 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. 207 Next step Electronic Control System of Engine Maintenance Manual for J2 Sedan Fault code: P0112 “the signal voltage of intake temperature sensor is too low” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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. 3 4 5 6 Check result Subsequent step Next step Yes To Step 5 No Next step 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). Yes Next step No Replace the sensor Unplug the connector of intake temperature sensor on the harness, and check if the voltage between Pins 1# and 2# of this connector is about 5v by the multimeter. Yes To Step 5 No Next step 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. Yes Repair or replace the harness No Next step 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. Yes Diagnosis help No Replace the sensor Check result Subsequent step Fault code: P0113 “the signal voltage of intake temperature sensor is high” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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 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). Yes Next step No Replace the sensor Unplug the connector of intake temperature sensor on the harness, and check if the voltage between Pins 1# and 2# of this connector is about 5v by the multimeter. Yes To Step 5 No Next step Check if the circuits connecting Pins 40# and 25# of ECU respectively to Pins 1# and 2# of sensor connector are short to ground. Yes Repair or replace the harness No Next step 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. Yes Diagnosis help No Replace the sensor 3 4 5 6 208 Next step Electronic Control System of Engine Maintenance Manual for J2 Sedan Fault code: P0117 “the circuit voltage of engine coolant temperature sensor is too low” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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). Notice: if the displayed value is always -40℃, the circuit may be open. No Next step Unplug the connector of coolant 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). Yes Next step No Replace the sensor Unplug the connector of coolant temperature sensor on the harness, and check if the voltage between Pins 1# and 2# of this connector is about 5v by the multimeter. Yes To Step 6 No Next step Check if the circuits connecting Pins 40# and 41# of ECU respectively to Pins 1# and 2# of sensor connector are open or short to power source. Yes Repair or replace the harness No Next step Start the engine and run the engine idly. Observe the change of the “Coolant temperature” value on the diagnosis meter, and at this moment the displayed value shall increase with the rising of engine coolant. Yes Diagnosis help No Replace the sensor 3 4 5 6 Check result Subsequent step Next step Fault code: P0118 “the circuit voltage of engine coolant temperature sensor is too high” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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). Notice: if the displayed value is always -40℃, the circuit may be open. No Next step Unplug the connector of coolant 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). Yes Next step No Replace the sensor Unplug the connector of coolant temperature sensor on the harness, and check if the voltage between Pins 1# and 2# of this connector is about 5v by the multimeter. Yes To Step 6 No Next step Check if the circuits connecting Pins 40# and 41# of ECU respectively to Pins 1# and 2# of sensor connector are short to ground. Yes Repair or replace the harness No Next step Start the engine and run the engine idly. Observe the change of the “Coolant temperature” value on the diagnosis meter, and at this moment the displayed value shall increase with the rising of engine coolant. Yes Diagnosis help No Replace the sensor 3 4 5 6 Check result 209 Subsequent step Next step Maintenance Manual for J2 Sedan 210 Electronic Control System of Engine Electronic Control System of Engine Maintenance Manual for J2 Sedan Fault code: P0122 “the circuit voltage of throttle position sensor is at the extremely low limit” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 2 Observe if the value of “Throttle opening” is between 4% and 10% (depending on the bus model). Yes Next step No To Step 5 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). Yes Next step No To Step 5 Repeat Step 3 and observe if the value of “Throttle opening” in the data flow springs during change. Yes Replace the sensor No Next step 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. Yes Repair or replace the harness No Next step Check if the voltage between Pins 1# and 2# of this connector is about 5V by the multimeter. Yes Replace the sensor No Diagnosis help 3 4 5 6 Check result Subsequent step Next step Fault code: P0123 “the circuit voltage of throttle position sensor is at the extremely high limit” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 2 Observe if the value of “Throttle opening” is between 4% and 10% (depending on the bus model). Yes Next step No To Step 5 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). Yes Next step No To Step 5 Repeat Step 3 and observe if the value of “Throttle opening” in the data flow springs during change. Yes Replace the sensor No Next step 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. Yes Repair or replace the harness No Next step Check if the voltage between Pins 1# and 2# of this connector is about 5V by the multimeter. Yes Replace the sensor No Diagnosis help 3 4 5 6 Check result 211 Subsequent step Next step Electronic Control System of Engine Maintenance Manual for J2 Sedan Fault code: P0130 “the signal of upstream oxygen sensor is unreasonable” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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 Check if the circuits connecting Pins 39# and 45# of ECU 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. Yes Repair or replace the harness No Next step Yes Make check and repair according to diagnosis results. No Diagnosis help 3 4 Check result 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. Subsequent step Next step Fault code: P0131 “the circuit voltage of upstream oxygen sensor signal is too low” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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 Check if the circuits connecting Pins 39# and 45# of ECU 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 power source. Yes Repair or replace the harness No Diagnosis help 3 Check result Subsequent step Next step Fault code: P0132 “the circuit voltage of upstream oxygen sensor signal is too high” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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 Check if the circuits connecting Pins 39# and 45# of ECU 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 power source. Yes Repair or replace the harness No Diagnosis help 3 Check result 212 Subsequent step Next step Electronic Control System of Engine Maintenance Manual for J2 Sedan Fault code: P0134 “the upstream oxygen sensor signal is in trouble” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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 Check if the circuits connecting Pins 39# and 45# of ECU 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 open. Yes Repair or replace the harness No Diagnosis help 3 Check result Subsequent step Next step 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.) S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 2 Start the engine and run the engine idly till the coolant temperature reaches to the normal value. Under all the work conditions, observe the change of the value of “Oxygen sensor voltage” on the diagnosis meter, and at this moment, check if the displayed value remains at 100mV or so for a long time under a certain condition. 3 4 5 Check result Subsequent step Next step Yes Next step No Diagnosis help 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. Yes Next step No Check and repair the fuel system Check if the circuits connecting Pins 39# and 45# of ECU 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. Yes Repair or replace the harness No Next step Yes Make check and repair according to diagnosis results. No Diagnosis help 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. 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.) 213 Electronic Control System of Engine Maintenance Manual for J2 Sedan S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 2 Start the engine and run the engine idly till the coolant temperature reaches to the normal value. Under all the work conditions, observe the change of the value of “Oxygen sensor voltage” on the diagnosis meter, and at this moment, check if the displayed value remains at 900mV or so for a long time under a certain condition. 3 4 5 Check result Subsequent step Next step Yes Next step No Diagnosis help 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. Yes Next step No Check and repair the fuel system Check if the circuits connecting Pins 39# and 45# of ECU 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 power source. Yes Repair or replace the harness No Next step Yes Make check and repair according to diagnosis results. No Diagnosis help Check result Subsequent step 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. Fault code: P0201 “the control circuit of fuel injector of Cylinder 1# is open” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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 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. Yes Repair or replace the harness No Next step Yes Next step No Replace the fuel injector 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. Yes Diagnosis help No Next step Check if the circuit between Pin 2# of the fuel injector connector of Cylinder 1# and Pin 50 of ECU is open or short to power source or ground. Yes Repair or replace the harness No Diagnosis help 3 4 5 6 Check if the resistance between Pins 1# and 2# of the fuel injector of Cylinder 1# at 20℃ is between 11Ω and 13Ω by the multimeter. 214 Next step Electronic Control System of Engine Maintenance Manual for J2 Sedan Fault code: P0202 “the control circuit of fuel injector of Cylinder 2# is open” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. Yes To Step 4 2 Unplug the connector of the fuel injector of Cylinder 2# 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 Check if the circuit between Pin 1# of the fuel injector connector of Cylinder 2# and the main relay is open or short to ground. Yes Repair or replace the harness No Next step Yes Next step No Replace the fuel injector Check if the voltage between Pin 2# of the fuel injector of Cylinder 2# and the negative pole of power source is about 3.7V by the multimeter. Yes Diagnosis help No Next step Check if the circuit between Pin 2# of the fuel injector connector of Cylinder 2# and Pin 63 of ECU is open or short to power source or ground. Yes Repair or replace the harness No Diagnosis help Check result Subsequent step 3 4 5 6 Check result Subsequent step Next step Check if the resistance between Pins 1# and 2# of the fuel injector of Cylinder 2# at 20℃ is between 11Ω and 13Ω by the multimeter. Fault code: P0203 “the control circuit of fuel injector of Cylinder 3# is open” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. Yes To Step 4 2 Unplug the connector of the fuel injector of Cylinder 3# 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 Check if the circuit between Pin 1# of the fuel injector connector of Cylinder 3# and the main relay is open or short to ground. Yes Repair or replace the harness No Next step Yes Next step No Replace the fuel injector Check if the voltage between Pin 2# of the fuel injector of Cylinder 3# and the negative pole of power source is about 3.7V by the multimeter. Yes Diagnosis help No Next step Check if the circuit between Pin 2# of the fuel injector connector of Cylinder 3# and Pin 49 of ECU is open or short to power source or ground. Yes Repair or replace the harness No Diagnosis help 3 4 5 6 Check if the resistance between Pins 1# and 2# of the fuel injector of Cylinder 3# at 20℃ is between 11Ω and 13Ω by the multimeter. 215 Next step Electronic Control System of Engine Maintenance Manual for J2 Sedan Fault code: P0327 “the circuit voltage of knocking sensor signal is too low” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to OFF position. 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 1MΩ by the multimeter. No Replace the sensor 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. Yes Repair or replace the harness No Next step 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. Yes Diagnosis help No Check if it is a sporadic fault Check result Subsequent step 3 4 Check result Subsequent step Next step Fault code: P0328 “the circuit voltage of knocking sensor signal is too high” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to OFF position. 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 1MΩ by the multimeter. No Replace the sensor 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. Yes Repair or replace the harness No Next step 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. Yes Diagnosis help No Check if it is a sporadic fault Check result Subsequent step 3 4 Next step Fault code: P0340 “the mounting position of phase sensor is incorrect” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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 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. Yes Repair or replace the harness No Next step 3 216 Next step Electronic Control System of Engine Maintenance Manual for J2 Sedan S/N Step Check result Subsequent step 4 Check if the voltage between Pin 2# of phase sensor and the negative pole of power source is about 9.9V. Yes To Step 6 No Next step 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. Yes Repair or replace the harness No Next step Yes Diagnosis help No Replace the signal panel Check result Subsequent step 5 6 Check if the signal panel of camshaft is good. Fault code: P0341 “the contact of phase sensor is not good” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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. Yes To Step 4 2 No Next step 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. Yes Repair or replace the harness No Next step Check if the voltage between Pin 2# of phase sensor and the negative pole of power source is about 9.9V. Yes To Step 6 No Next step 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. Yes Repair or replace the harness No Next step Yes Diagnosis help No Replace the signal panel Check result Subsequent step 3 4 5 6 Next step Check if the signal panel of camshaft is good. Fault code: P0342 “the phase sensor is short to ground” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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 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. Yes Repair or replace the harness No Next step 3 217 Next step Electronic Control System of Engine Maintenance Manual for J2 Sedan S/N Step Check result Subsequent step 4 Check if the voltage between Pin 2# of phase sensor and the negative pole of power source is about 9.9V. Yes To Step 6 No Next step 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. Yes Repair or replace the harness No Next step Yes Diagnosis help No Replace the signal panel Check result Subsequent step 5 6 Check if the signal panel of camshaft is good. Fault code: P0343 “the phase sensor is short to power source” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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. Yes To Step 4 2 No Next step 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. Yes Repair or replace the harness No Next step Check if the voltage between Pin 2# of phase sensor and the negative pole of power source is about 9.9V. Yes To Step 6 No Next step 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. Yes Repair or replace the harness No Next step Yes Diagnosis help No Replace the signal panel Check result Subsequent step 3 4 5 6 Next step Check if the signal panel of camshaft is good. Fault code: P0444 “the control circuit of canister control valve is open” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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. Yes To Step 4 2 No Next step Check if the circuit of power supply side of canister control valve is open or short to ground. Yes Repair or replace the harness No To Step 2 Yes Next step 3 4 Check if the resistance between Pins 1# and 2# of the canister control 218 Next step Electronic Control System of Engine Maintenance Manual for J2 Sedan S/N Step Check result Subsequent step No Replace the control valve 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. Yes Diagnosis help No Next step Check if the circuit connecting Pin 2# of canister control valve connector to Pin 37# of ECU is open. Yes Repair or replace the harness No Diagnosis help valve at 20℃ is between 22Ω and 30Ω by the multimeter. 5 6 Fault code: P0458 “the voltage of control circuit of canister control valve is too low” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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. Yes To Step 4 2 No Next step Check if the circuit of power supply side of canister control valve is open or short to ground. Yes Repair or replace the harness No To Step 2 Yes Next step No Replace the control valve 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. Yes Diagnosis help No Next step Check if the circuit connecting Pin 2# of canister control valve connector to Pin 37# of ECU is short to ground. Yes Repair or replace the harness No Diagnosis help 3 4 5 6 Check result Check if the resistance between Pins 1# and 2# of the canister control valve at 20℃ is between 22Ω and 30Ω by the multimeter. Subsequent step Next step Fault code: P0459 “the voltage of control circuit of canister control valve is too high” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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. Yes To Step 4 2 No Next step Check if the circuit of power supply side of canister control valve is open or short to ground. Yes Repair or replace the harness No To Step 2 Yes Next step No Replace the control valve Yes Diagnosis help No Next step 3 4 5 Check result Check if the resistance between Pins 1# and 2# of the canister control valve at 20℃ is between 22Ω and 30Ω by the multimeter. 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. 219 Subsequent step Next step Electronic Control System of Engine Maintenance Manual for J2 Sedan S/N Step Check result Subsequent step 6 Check if the circuit connecting Pin 2# of canister control valve connector to Pin 37# of ECU is short to power source. Yes Repair or replace the harness No Diagnosis help Check result Subsequent step Fault code: P0480 “the control circuit of cooling fan relay is open (low speed)” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to OFF position. 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 Check if the circuit of power supply side of A/C condenser cooling fan relay is open or short to ground. Yes Repair or replace the harness No To Step 2 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. Yes Replace the relay No Next step 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. Yes Repair or replace the harness No Diagnosis help 3 4 5 Next step Fault code: P0481 “the control circuit of cooling fan relay is open (high speed)” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to OFF position. 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 Check if the circuit of power supply side of A/C condenser cooling fan relay is open or short to ground. Yes Repair or replace the harness No To Step 2 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. Yes Replace the relay No Next step 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. Yes Repair or replace the harness No Diagnosis help 3 4 5 Check result 220 Subsequent step Next step Electronic Control System of Engine Maintenance Manual for J2 Sedan Fault code: P0501 “the vehicle speed signal is unreasonable” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to OFF position. 2 For the car with ABS system, please check if the ABS system has any fault code. 3 4 4 Check result Next step Yes Check and repair ABS system No Next step Yes Next step No Check and repair the instrument circuit Yes Next step No Replace the vehicle speed sensor Yes Repair or replace the harness No Diagnosis help Check result Subsequent step Check if the finger of speedometer operates normally. Check if the vehicle speed sensor operates normally. Check if the circuit connecting to vehicle speed sensor signal wire to Pin 57# of ECU is open or short to power source or ground. Subsequent step Fault code: P0506 “the idle speed is the lower than the target idle speed” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to OFF position. 2 3 4 Next step Yes Next step No Do the necessary repair and maintenance Yes Next step No Do the necessary repair and maintenance Yes Do the necessary check and repair No Diagnosis help Check result Subsequent step Check if the adjusting screw, cable and condition of throttle are good. Check if the working condition of idle regulator is good. A. Check if the pressure of fuel supply system is too low. B. Check if the fuel injector is blocked. C. Check if the system exhaust line is blocked. Fault code: P0507 “the idle speed is the higher than the target idle speed” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to OFF position. 2 Next step Yes Next step No Do the necessary repair and maintenance Check if the adjusting screw, cable and condition of throttle are good. 221 Electronic Control System of Engine Maintenance Manual for J2 Sedan 3 4 Yes Next step No Do the necessary repair and maintenance Yes Do the necessary check and repair No Diagnosis help Check result Subsequent step Check if the working condition of idle regulator is good. 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. Fault code: P0508 “the drive pin of stepping motor is short to ground” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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 53±5.3Ω. No Replace the stepping motor 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. Yes Repair or replace the harness No Diagnosis help Check result Subsequent step 3 Next step Fault code: P0509 “the drive pin of stepping motor is short to power source” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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 53±5.3Ω by the multimeter. No Replace the stepping motor 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 power source. Yes Repair or replace the harness No Diagnosis help Check result Subsequent step 3 Next step Fault code: P0511 “the drive pin of stepping motor is in open circuit” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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 53±5.3Ω by the multimeter. 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 open. 222 Next step Yes Next step No Replace the stepping motor Yes Repair or replace the harness No Diagnosis help Electronic Control System of Engine Maintenance Manual for J2 Sedan Fault code: P0560 “the voltage signal of system battery is unreasonable” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to OFF position. 2 3 4 5 Check result Next step Yes Next step No Replace the battery Yes Repair or replace the harness No Next step Yes Next step No Replace the generator Yes Diagnosis help No Repair or replace the harness Check result Subsequent step Check if the battery voltage is about 12V by the multimeter. Check if the circuits connecting Pin 8# and 51# of ECU respectively to Pin 87# of main relay are open or short to ground. Start the engine, and check if the charging voltage of generator is always between 9V and 16V within different rotation speed ranges. Subsequent step Check if the grounding point of engine harness is good. Fault code: P0562 “the voltage of system battery is too low” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to OFF position. 2 Check if the battery voltage is about 12V by the multimeter. 3 4 5 Check if the resistances of circuits connecting Pins 8# and 51# of ECU to Pin 87# of main relay are too high. Start the engine, and check if the charging voltage of generator is always between 9V and 16V within different rotation speed ranges. Next step Yes Next step No Replace the battery Yes Repair or replace the harness No Next step Yes Next step No Replace the generator Yes Diagnosis help No Repair or replace the harness Check result Subsequent step Check if the grounding point of engine harness is good. Fault code: P0563 “the voltage of system battery is too high” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to OFF position. 2 Check if the battery voltage is about 12V by the multimeter. 3 Start the engine, and check if the charging voltage of generator is 223 Next step Yes Next step No Replace the battery Yes Next step Electronic Control System of Engine Maintenance Manual for J2 Sedan S/N Step Check result Subsequent step No Replace the generator Yes Diagnosis help No Repair or replace the harness Check result Subsequent step always between 9V and 16V within different rotation speed ranges. 4 Check if the grounding point of engine harness is good. Fault code: P0602 “the programming of electronic control unit is in trouble” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 2 3 Next step Yes Next step No The system is normal. Eliminate the fault code and reconfirm if this fault is a steady fault. Replace ECU. End Fault code: P0645 “the control circuit of A/C compressor relay is open” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to OFF position. 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 Check if the circuit of relay power supply side is open or short to ground. Yes Repair or replace the harness No To Step 2 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. Yes Replace the relay No Next step Check if the circuit connecting control side of A/C compressor relay (namely Pin 86# of relay) to Pin 61# of ECU is open. Yes Repair or replace the harness No Diagnosis help 3 4 5 Check result Subsequent step Next step Fault code: P0646 “the control circuit of A/C compressor relay is short to ground” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to OFF position. 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. 3 Check result Check if the circuit of relay power supply side is open or short to ground. 224 Subsequent step Next step Yes To Step 4 No Next step Yes Repair or replace the harness Electronic Control System of Engine Maintenance Manual for J2 Sedan S/N 4 5 6 Step Check result Subsequent step No To Step 2 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 by multimeter by the multimeter. Yes Replace the relay No Next step Check if the circuit connecting control side of A/C compressor relay (namely Pin 86# of relay) to Pin 61# of ECU is short to ground. Yes Repair or replace the harness No Next step Yes Diagnosis help No Repair or replace the electromagnetic clutch Check if the electromagnetic clutch of A/C compressor operates normally. Fault code: P0647 “the control circuit of A/C compressor relay is short to power source” S/N Step 1 Connect the diagnosis device and adapter, and turn the ignition switch to OFF position. 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 Check if the circuit of relay power supply side is open or short to ground. Yes Repair or replace the harness No To Step 2 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 by multimeter. Yes Replace the relay No Next step Check if the circuit connecting control side of A/C compressor relay (namely Pin 86# of relay) to Pin 61# of ECU is short to power source. Yes Repair or replace the harness No Next step Yes Diagnosis help No Repair or replace the electromagnetic clutch 3 4 5 6 Check result Check if the electromagnetic clutch of A/C compressor operates normally. Subsequent step Next step Fault code: P1651 “the control circuit of engine malfunction lamp (SVS) is in trouble” S/N Step Check result 1 Connect the diagnosis device and adapter, and turn the ignition switch to ON position. 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. 225 Subsequent step Next step Yes Next step No The system is normal. Electronic Control System of Engine Maintenance Manual for J2 Sedan S/N Step Check result Subsequent step 3 Check if the circuit of power supply side of engine malfunction lamp is open or short to ground. Yes Repair or replace the harness No Next step Yes Repair or replace the harness No Next step Yes Diagnosis help No Replace the bulb 4 5 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. Check if the bulb of engine malfunction lamp operates normally. 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 226 Electronic Control System of Engine Maintenance Manual for J2 Sedan 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. 1 Operating Steps Detection Results Check the voltage between the two terminals of battery with Yes Next step No Replace battery Yes Next step multi-meter to see whether it is about 8-12V during starting of engine. 2 3 Subsequent Steps With ignition switch at the starting position, check voltage of starter negative terminal to verify that it is above 8V. Dismantle the starter to check its operating state. Mainly No Yes Repair or replace wire harness Repair or replace the starter check for sticking due to open circuit or poor lubrication. No Next step Change with If the trouble only present in winter, then check whether too 4 Yes large resistance of starter is caused by improper selection of lubricating oil of proper grade the lubricating oil for engine or the gearbox oil. No Next step Remove large Check engine for too large internal mechanical resistance; if 5 Yes it is a case, the failure of rotation or the slow rotation of internal resistance of engine starter may occur. No 227 Repeat above steps Electronic Control System of Engine Maintenance Manual for J2 Sedan Trouble phenomenon 2: Engine start to run but can not be started successfully during the start-up General trouble position: 1. No fuel in the fuel tank; 2. Fuel injection pump; 3.Crankshaft position sensor; 4.Ignition coil; 5.Mechanical part of engine General diagnosis procedure: No. Detection Operating Steps Results Connect the fuel pressure gauge (the access point is at the front Yes Subsequent Steps Next step end of the induction manifold of the fuel distribution pipe 1 assembly) to the engine, and start the engine to determine whether the readings of fuel pressure gauge when idling is at No about 260kPa; disconnect vacuum hose of pressure regulator Repair the fuel supply system and observe whether fuel pressure is about 300kPa. Connect the electric control system diagnosis apparatus to the 2 3 Yes engine to observe the data of "rotating speed of engine" and Next step Repair crankshaft start the engine to observe whether there is speed signal output. No Pull out the high-voltage wire of one of the cylinders and Yes Next step No Repaire ignition system position sensor circuit 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. 4 5 Check the pressure of all the cylinders and observe whether the Yes Eliminate mechanical trouble of engine pressure of engine cylinders is insufficient. Turn on the ignition switch and check whether the power supply and earthing are normal. 228 No Next step Yes Diagnosis help No Repair related circuit Electronic Control System of Engine Maintenance Manual for J2 Sedan Trouble phenomenon 3: Difficulty in warm start General trouble position: 1. Poor quality of fuel; 2.Fuel injection pump; 3.Coolant temperature sensor; 4.Ignition coil General diagnosis procedure: No. Detection Operating Steps Results Connect the fuel pressure gauge (the access point is at the front end Yes Subsequent Steps Next step of the induction manifold of the fuel distribution pipe assembly) to 1 the engine and start the engine to check whether the reading of fuel pressure gauge at idle condition is at about 260kPa. Disconnect No vacuum hose on pressure regulator and observe whether fuel Repair fuel supply system pressure is about 300kPa. Pull out the high-voltage wire of one of the cylinders and connect 2 Yes Next step No Repair ignition system 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. Pull out connector of coolant temperature sensor and start the engine to observe whether the engine is successfully started at this 3 Yes Repair circuit or replace the sensor time. (Alternatively, connect a 300 ohm resistance in series at the connector of coolant temperature sensor to observe whether the No Next step Yes Repair or replace No Next step Yes Change fuel No Next step Yes Diagnosis help No Repair related circuit engine is successfully started at this time.) 4 5 6 Check the vacuum pipe of fuel pressure regulator for the shedding or air leakage. Check fuel conditions and observe whether the trouble phenomenon occurs just after adding fuel. Turn on the ignition switch and check whether the power supply and earthing are normal. 229 Electronic Control System of Engine Maintenance Manual for J2 Sedan Trouble phenomenon 4: Difficulty in cold start General trouble position: 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 General diagnosis procedure: No. Operating Steps Detection Results 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 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. Yes Next step No Repair the ignition system Yes Repair circuit or replace the sensor No Next step Yes Wash the air throttle and idle air passage No Next step Dismantle the fuel injector and check whether there is leakage or blockage in the fuel injector with the cleaning analyzer special for fuel injector. Yes Failure of Replacement No Next step Check the fuel conditions and observe whether the trouble phenomenon occurs just after adding the fuel. Yes Change fuel No Next step Check the pressure states of all the cylinders of engine and observe whether the pressure of engine cylinder is insufficient. Yes Eliminate the mechanical trouble of engine No Next step Yes Diagnosis help No Repair related circuit 2 3 4 5 6 7 8 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.) Gently step down the accelerator pedal to observe whether it is easy to start. Turn on the ignition switch and check whether the power supply and earthing are normal. 230 Subsequent Steps Electronic Control System of Engine Maintenance Manual for J2 Sedan Trouble phenomenon 5: Engine speed is normal, but it is difficult to start all the time General trouble position: 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 General diagnosis procedure: No. 1 2 3 4 5 6 7 8 9 10 11 Operating Steps Detection Results Subsequent Steps Yes Repair air intake system No Next step 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. Yes Next step No Repair fuel supply system 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. Yes Next step No Repair the ignition system Check the spark plug of each cylinder to observe whether model and gap are in compliance with the specification. Yes Next step No Adjust or replace Pull out the connector of coolant temperature sensor and start the engine to observe whether the engine is successfully started at this time. Yes Repair the lien or replace the sensor No Next step Yes Wash throttle and idling air passage No Next step Dismantle the fuel injector and check whether there is leakage or blockage in the fuel injector with cleaning analyzer special for fuel injector. Yes Failure of Replacement No Next step Check fuel condition and observe whether the trouble phenomenon occurs just after adding the fuel. Yes Change fuel No Next step Check pressure of all the cylinders and observe whether the pressure of engine cylinder is insufficient. Yes Eliminate the mechanical trouble of engine No Next step Yes Next step No Repair the ignition timing Yes Diagnosis help No Repair related circuit Check air filter for blockage and intake passage for leakage. Gently step down the throttle to observe whether it is easy to start. Check whether the ignition sequence of engine and ignition timing is in line with the specification. Turn on the ignition switch and check whether the power supply and earthing are normal. 231 Electronic Control System of Engine Maintenance Manual for J2 Sedan Trouble phenomenon 6: Normal start-up but unstable idling at any time General trouble position: 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. General diagnosis procedure: No. Detection Operating Steps Results Yes 1 2 3 4 Check air filter for blockage and intake passage for leakage. Check the spark plug of each cylinder to observe whether its model and gap are in compliance with the specification. Check air throttle body and idle bypass air passage for carbon deposit. system No Next step Yes Wash or replace No Next step Yes Next step No Adjust or replace Yes Wash No Next step Yes fuel injector to check whether there is leakage, blockage or too poor flow in the fuel injector. 6 Repair the intake Check idle adjustor for sticking. Dismantle the fuel injector and use the cleaning analyzer special for 5 Subsequent Steps Check fuel condition and observe whether the trouble phenomenon occurs just after adding the fuel. Failure of Replacement No Next step Yes Change fuel No Next step Eliminate the 7 8 9 Check pressure of all the cylinders and observe whether the Yes engine pressure difference of each engine cylinders is large. Check whether the ignition sequence of engine and ignition timing is in compliance with specification. Turn on the ignition switch and check whether the power supply and earthing are normal. 232 mechanical trouble of No Next step Yes Next step No Repair ignition timing Yes Diagnosis help No Repair related circuit Electronic Control System of Engine Maintenance Manual for J2 Sedan Trouble phenomenon 7: Normal start-up but unstable idling during the warming-up General trouble position: 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. General diagnosis procedure: No. Detection Operating Steps Results Yes 1 2 3 Check air filter for blockage and air intake passage for leakage. Check the spark plug of each cylinder to observe whether its model and gap are in compliance with the specification. Dismantle the idle adjustor to check whether there is carbon deposit Next step Yes Next step No Adjust or replace Yes Yes engine to observe whether the idle speed of engine is unstable during warming-up. No Dismantle the fuel injector and check whether there is leakage, Yes blockage or too poor flow in the fuel injector with cleaning analyzer special for fuel injector. 6 system Wash related components in the air throttle body, idle adjustor or idle bypass air passage. Pull out the connector of coolant temperature sensor and start the 5 Repair air intake No No 4 Subsequent Steps Check fuel condition and observe whether the trouble phenomenon occurs just after adding the fuel. Next step Repair circuit or replace sensor Next step Failure of Replacement No Next step Yes Change fuel No Next step Eliminate the 7 8 Check pressure of all the cylinders and observe whether the Yes engine pressure difference of each engine cylinders is large. Turn on the ignition switch and check whether the power supply and earthing are normal. 233 mechanical trouble of No Next step Yes Diagnosis help No Repair related circuit Maintenance Manual for J2 Sedan Electronic Control System of Engine Trouble phenomenon 8: Normal start-up but unstable idle speed after warmed-up General trouble position: 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. General diagnosis procedure: No. 1 Detection Operating Steps Results Yes Repair the intake system No Next step Yes Next step specification. No Adjust or replace Dismantle the idle adjustor to check whether there is Yes Wash related components No Next step Check air filter for blockage and air intake passage for leakage. Check spark plug of each cylinder to observe whether 2 3 its model and gap are in compliance with the carbon deposit in the air throttle body, idle adjustor and idle bypass air passage. Pull out the connector of coolant temperature sensor 4 7 8 Repair circuit or replace sensor(s) No Next step Yes Failure of replacement with cleaning analyzer special for fuel injector. No Next step Check fuel condition and observe whether the trouble Yes Change fuel No Next step Dismantle the fuel injector and check whether there is 6 Yes and start the engine to observe whether the idle speed of engine is unstable during warm-up process. 5 Subsequent Steps leakage, blockage or too poor flow in the fuel injector phenomenon occurs just after adding the fuel. Check pressure of all the cylinders and observe whether Yes Eliminate mechanical trouble of engine the pressure difference of each engine cylinders is large. Turn on the ignition switch and check whether the power supply and earthing are normal. 234 No Next step Yes Diagnosis help No Repair related circuit Electronic Control System of Engine Maintenance Manual for J2 Sedan Trouble phenomenon 9: Normal start-up but unstable idling speed or flameout with partially load (for example, when the air conditioner is on) General trouble position: 1. Air conditioning system; 2. Idle adjustor; 3.Fuel injector General diagnosis procedure: No. 1 Detection Operating Steps Results Dismantle the idle adjustor to check whether there is carbon deposit Wash related components in the air throttle body, idle adjustor and idle bypass air passage. Observe whether power output of engine is increased air 2 Yes Subsequent Steps No Next step Yes To step 4 No Next step Yes Next step 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. Connect the adapter of electric control system and disconnect the 3 connecting wire of the pin #75 of electronic control module to check whether there is high level signal at the wire harness end with No AC turned on. 4 6 conditioning system Yes Next step No Repair AC system Yes Failure of replacement special for fuel injector. No Next step Turn on the ignition switch and check whether the power supply Yes Diagnosis help No Repair related circuit Inspect pressure of air conditioning system, electromagnetic clutch of compressor and the compressor pump of air conditioner. Dismantle the fuel injector and check whether there is leakage, 5 Repair air blockage or too poor flow in the fuel injector with cleaning analyzer and earthing are normal. 235 Electronic Control System of Engine Maintenance Manual for J2 Sedan Trouble phenomenon 10: Normal start-up but too high idling speed General trouble position: 1. Throttle body and idle bypass air passage; 2.Vacuum pipe; 3.Idle adjustor; 4.Coolant temperature sensor; 5.Ignition timing General diagnosis procedure: No. 1 2 Detection Operating Steps Results Yes Adjust No Next step Yes Repair intake system No Next step Check throttle cable for catching or overtension.. Check air intake system and vacuum pipeline or leakage. Yes 3 Dismantle the idle adjustor to check whether there is carbon deposit Pull out the connector of coolant temperature sensor and start the 6 components Yes Next step Repair circuit or replace sensor engine to observe whether the idle speed of engine is too high at this time. 5 Wash related in the air throttle body, idle adjustor and idle bypass air passage. No 4 Subsequent Steps No Next step Yes Next step No Repair ignition timing Yes Diagnosis help No Repair related circuit Check whether the ignition timing of engine is in compliance with the specification. Turn on the ignition switch and check whether the power supply and earthing are normal. 236 Electronic Control System of Engine Maintenance Manual for J2 Sedan Trouble phenomenon 11: Engine speed fails to increase or flameout occurs during acceleration General trouble position: 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. General diagnosis procedure: No. 1 2 3 4 5 6 7 8 9 10 Operating Steps Detection Results Subsequent Steps Yes Repair intake system No Next step 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 when idling is at about 260kPa; disconnect vacuum hose from pressure regulator to see whether fuel pressure is about 200kPa. Yes Next step No Repair fuel supply system Check spark plug of each cylinder to observe whether its model and gap are in compliance with the specification. Yes Next step No Adjust or replace Dismantle the idle adjustor to check whether there is carbon deposit in the air throttle body, idle adjustor and idle bypass air passage. Yes Wash related components No Next step Yes Next step No Repair circuit or replace sensor(s) Dismantle the fuel injector and check whether there is leakage or blockage in the fuel injector with cleaning analyzer special for fuel injector. Yes Failure of replacement No Next step Check fuel condition and observe whether the trouble phenomenon occurs just after adding the fuel. Yes Change fuel No Next step Check whether the ignition sequence of engine and ignition timing is in compliance with specification. Yes Next step No Repair ignition timing Yes Next step No Repair or replace the exhaust pipe Yes Diagnosis help No Repair related circuit Check air filter for blockage. Check whether the intake pressure sensor, air throttle position sensor and their circuits are normal. Check whether the operation of the exhaust pipe is smooth. Turn on the ignition switch and check whether the power supply and earthing are normal. 237 Electronic Control System of Engine Maintenance Manual for J2 Sedan Trouble phenomenon 12: Slow response of acceleration General trouble position: 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 General diagnosis procedure: No. Operating Steps Detection Results Subsequent Steps Yes Repair air intake system No Next step 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 when idling is at about 260kPa. disconnect vacuum hose from pressure regulator to see whether fuel pressure is about 300kPa. Yes Next step No Repair fuel supply system Check the spark plug of each cylinder to observe whether its model and gap are in compliance with the specification. Yes Next step No Adjust or replace Yes Wash related components No Next step Yes Next step No Repair circuit or replace sensor Dismantle the fuel injector and check whether there is leakage or blockage in the fuel injector with cleaning analyzer special for fuel injector. Yes Failure of replacement No Next step Check fuel condition and observe whether the trouble phenomenon occurs just after adding the fuel. Yes Change fuel No Next step Check whether the ignition sequence of engine and ignition timing is in line with the specification. Yes Next step No Repair ignition timing 9 Check whether the operation of the exhaust pipe is smooth. No Repair or replace the exhaust pipe 10 Turn on the ignition switch and check whether the power supply and earthing are normal. Yes Diagnosis help No Repair related circuit 1 2 3 4 5 6 7 8 Check air filter for blockage. Dismantle the idle adjustor to check whether there is carbon deposit in the air throttle body, idle adjustor and idle bypass air passage. Check whether the intake pressure sensor, air throttle position sensor and its circuit are normal. 238 Maintenance Manual for J2 Sedan Electronic Control System of Engine Trouble phenomenon 13: Powerlessness and poor performance during acceleration General trouble position: 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. General diagnosis procedure: No. Operating Steps Detection Results Yes Repair No Next step Yes Repair air intake system No Next step 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 when idling is at about 260kPa. Disconnect vacuum hose from pressure regulator to see whether fuel pressure is about 300kPa. Yes Next step No Repair fuel supply system Yes Next step 4 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, and start the engine to check whether the strength of high-voltage spark. No Repair ignition system 5 Check the spark plug of each cylinder to observe whether its model and gap is in compliance with the specification. Yes Next step No Adjust or replace Dismantle the idle adjustor to check whether there is carbon deposit in the air throttle body, idle adjustor and idle bypass air passage. Yes Wash the related components No Next step Yes Next step No Repair circuit or replace sensor Dismantle the fuel injector and check whether there is leakage or blockage in the fuel injector with cleaning analyzer special for fuel injector. Yes Failure of replacement No Next step Check fuel condition and observe whether the trouble phenomenon occurs just after adding the fuel. Yes Change fuel No Next step Check whether the ignition sequence of engine and ignition timing is in line with the specification. Yes Next step No Repair ignition timing 11 Check whether the operation of the exhaust pipe is smooth. No Repair or replace exhaust pipe 12 Turn on the ignition switch and check whether the power supply and earthing are normal. Yes Diagnosis help No Repair related circuit 1 2 3 6 7 8 9 10 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. Subsequent Steps Check air filter for blockage. Check whether the intake pressure sensor, air throttle position sensor and its line are normal. 239 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 P0202 Open-circuit of 2# fuel injector control circuit P0203 Open-circuit of 3# 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 P0264 Short-circuit of 2# cylinder fuel injector control circuit to ground P0265 Short-circuit of 2# cylinder fuel injector control circuit to power supply P0267 Short-circuit of 3# cylinder fuel injector control circuit to ground P0268 Short-circuit of 3# cylinder fuel injector control circuit to power supply DTC Information Introduction of Malfunction Codes (UAES) P0300 Detection of misfire in various cylinders P0301 Detection of misfire in 1# cylinder P0302 Detection of misfire in 2# cylinder P0303 Detection of misfire in 3# cylinder P0321 No detection of missing tooth BM signal after certain angle rotation of crankshaft P0322 No pulse signal of speed sensor (open-circuit or short-circuit) P0327 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) DTC Information Introduction of Malfunction Codes (UAES) P2178 Out-of-lower-limit of air-fuel ratio closed-loop control self-learning (Medium load zone) P2195 Aged upstream oxygen sensor P2196 Aged upstream oxygen sensor P2270 Aged downstream oxygen sensor P2271 Aged downstream oxygen sensor
