JAC S2. Engine. Service Manual — part 2
Engine Mechanical System
Engine Mechanical System 17
type
HFC4GB2
.3D
Max torque(N·m)
1
4
6
Max torque r pm(r/min)
3500~4
500
idle (r/min)
750
±30
full load min fuel consumption (g/kw.h)
2
4
5
engine oil consumption ratio at rated power
≤ 0.15%
crankshaft rotation direction(facing power output ) anticlockwise
Starting method
Electric starting
Lubrication method
Mixed Type of pressure and spatter
Cooling method
Water cooling
New engine oil filling volume (L)
4
.
5
Outside dimension ( length × width× hight )mm
560×543×608
Net weight (kg)
8
8
Fuel type
93# and above
Engine oil type
Engine oil type
Environment temperature
Quality degree
SAE 5W/30
-30 ℃~ 30 ℃
SJ and above
SAE 15W/40
-20 ℃~ 40 ℃
SJ and above
Main parts specs
Part name
Technical characteristics
Engine oil filter
full flow type filter thread specs M20×1.5-6H
oil pump
Inner meshing rotors type
cooling water pump
centrifugal
Thermostat
wax type, initial temperature:82 ℃ ; full open temperature:95 ℃
Generator
Built-in regulator alternator specs 14V 90A
starter
Permanent magnet decelerating type starting voltage 12V, power
1.2kW
ignition plug
Iridium platinum alloy type
Oil pressure guide rail
No oil back
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Engine Mechanical System
Engine Mechanical System 18
items
Standard value
Extreme rate
camshaft
Camshaft height (mm)
Air intake
44.7054±0.1mm
Air exhaust
44.2836±0.1mm
Cylinder cover and valve
Cylinder pad surface flatness (mm)
Under 0.03
0.1
Cylinder cover whole height (mm)
112.9
~ 113.1
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Engine Mechanical System
Engine Mechanical System 19
Items
Standard value
Extreme rate
valve edge thickness (mm)
Intake valve
1.35
0.85
Intake valve
1.85
1.35
valve stem diameter (mm)
φ5.5
clearance between the valve guide and valve
stem (mm)
Intake
0.020
~ 0.036
0.10
Intake
0.030
~ 0.045
0.15
Valve taper angle
45°
~ 45.5°
Valve length (mm)
Intake valve
89.61
89.11
Intake valve
90.94
90.44
Valve spring free height(mm)
43.1
42.7
Valve spring load /installation height (N)/ (mm)
152/33.4
310/25.2
Valve springs verticality
小于 2°
4°
Contact width of the valve seat(mm)
0.9
~ 1.3
valve guide inner diameter(mm)
φ5.5
Valve guide projection amont (mm)
13±0.3
Oil pump gear tip clearance (mm)
0.06
~ 0.18
0.2
Oil pump side clearance (mm)
0.04
~ 0.11
0.15
Oil pump shell clearance (mm)
0.10
~ 0.18
0.2
Piston skirt diameter(mm)
74.968
~ 74.978
Top compression ring side clearance (mm)
0.03
~ 0.07
0.10
Second compression ring side clearance (mm)
0.02
~ 0.06
0.1
Top compression ring opening clearance(mm)
0.15
~ 0.30
0.8
Second compression ring opening clearance (mm)
0.30
~ 0.50
0.8
compound oil ring opening clearance (mm)
0.20
~ 0.50
1.0
piston pin outer diameter(mm)
18.002
~ 18.005
Connecting rod journal clearance (mm)
0.02
~ 0.04
0.1
Connecting rod
big head clearance (mm)
0.10
~ 0.25
0.4
Crankshaft axial clearance(mm)
0.09
~ 0.27
crankshaft main journal diameter (mm)
46.004
~ 46.029
Connecting journal diameter (mm)
39.982
~ 40.0
crankshaft main journal neck clearance (mm)
0.02
~ 0.04
Cylinder pad surface flatness (mm)
0.03
以下
Cylinder total height(mm)
280
Cylinder cylindricity (mm)
0.007
bore inside diameter (mm)
75.000
~ 75.015
Clearance between the piston and cylinder (mm)
0.02
~ 0.04
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Engine Mechanical System
Engine Mechanical System 20
Main inspection and adjustment parameters
Valve clearance (mm)
Intake valve 0.22±0.03
exhaust valve0.30±0.03
emission standard
euro
V
Oil pressure
Idle oil pressure >100kPa
Oil temperature
≤ 135 ℃
Water temperature
≤ 110 ℃
Spark plug electrode clearance
0.7
~ 0.8mm
Sealant
Seal location
No. Sealant
Crankshaft rear oil seal component - body
1 DowCorning 3-0115 Gasket sealant adhesive
2 Threebond 1217G
3 Ksetra-ksetrajna new 1590
oil sump - engine body - Crankshaft rear oil seal
component
4 DowCorning 3-0115 Gasket sealant adhesive
5 Threebond 1217G
6 Ksetra-ksetrajna new 1590
Sprocket wheel cover –engine body –cylinder
cover
7 DowCorning 3-0115 Gasket sealant adhesive
8 Threebond 1217G
9 Ksetra-ksetrajna new 1590
Bowl type plug - cylinder cover
10 Loctite 12086 bowl type plug sealant
Crankshaft signal wheel bolt
11 Loctite 262 threaded fastening adhesive
water temperature sensor
12 Ksetra-ksetrajna new 1243
thread
sealant
oil pressure switch
13 Ksetra-ksetrajna new 1243
thread
sealant
Lubricant
Engine oil type
Environment Temperature
Quality degree
SAE 5W/30
-30 ℃~ 30 ℃
SJ and abve
SAE 15W/40
-20 ℃~ 40 ℃
SJ and abve
(IV)Torque parameter
Key parts torque table
No.
item
torque (N·m)
remark
1
Main bearing cap bolt
(35±2)N·
m+60°
~ 64°
M9×1.25×74.5
2
connecting rod bolt
5N·
m → 10N·
m →
13N·
m+45°+45°
M6×0.75×33
3
The camshaft bearing cover bolts
11±1
M6×1×35
4
The camshaft front end bearing cap bolts
20±1
M8×1.25×30
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Engine Mechanical System
Engine Mechanical System 21
No.
item
torque (N·m)
remark
5
Cylinder cap bolt
(24.5±2)N·
m+180°
~
184°
M9×1.25×143.5
6
The crankshaft pulley bolt
(50±2)N·
m+(60±2)°
M14×1.5×54
7
Flywheel bolt
100±5
M11×1.25×25
8
Exhaust camshaft sprocket bolt
88±10
M12×
30
9
Valve timing adjuster bolt
70±5
M10×
41
10
Crankshaft rear oil seal bolt
7.6±0.6
M6×10 E8
11
Rear ear stud
18.4±1.4
M8×20 E10
12
Intake manifold bolt
18±1.0
M8×40 E10
13
Oil sump bolts
11±1.0
M6×12 E8
14
Sprocket cover boltsⅠ
39.5±3.0
M10×90 E14
15
Sprocket cover boltsⅡ
39.5±3.0
M10×50 E14
16
Sprocket cover boltsⅢ
8.4±0.6
M6×30 E10
17
M6×20 E10 type bolt
8.4±0.6
M6×20 E10
18
M6×12 E10 type bolt
8.4±0.6
M6×12 E10
19
M6×45 E10 type bolt
8.4±0.6
M6×45 E10
20
M6×25 E10 type bolt
8.4±0.6
M6×25 E10
21
M6×12 E8 type bolt
8.4±0.6
M6×12 E8
22
Cylinder head cover bolt
9±1.0
M6×27 E10
23
Oil filter Bracket bolt
20±1
M8×30 E12
24
Warm wind backwater pipe bolt
7.6±0.6
M6×20 E8
25
Oil pressure guide rail bolt
18.4±1.4
M8×35 E12
26
Main oil passage cloggingⅠ
60±5
内 VI 角 M20
27
Main oil passage cloggingⅡ
35±5
内 VI 角 M12
28
drain screw
25±5
内 VI 角 M12
29
oil passage clogging
20±2
内 VI 角 M10
30
VVT oil passage clogging
44±5
M14×1.5×14
31
Oil drain plug
39±5
M14×1.5×14
32
Fixed rail bolt components
10±2
M6×1×1
2
33
Moving rail bolt components
23.5±4.5
M8×1.25×15
34
Starter bolt
24±3
M8×
55
35
oil pressure switch
10±2
R
1/8
36
Spark plug
25
~ 30
M
1
4
37
Exhaust manifold double-headed stud
12±2
M8×1×1
2
38
Q1840816(Exhaust manifold bracket bolts )
20
~ 25
M8×
16
39
Catalysts insulation cap nut
10±1
M6
×1
40
The crankshaft signal wheel bolt
12.5±2.5
M
6
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Engine Mechanical System
Engine Mechanical System 22
41
water temperature sensor
20±4
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Engine Mechanical System
Engine Mechanical System 23
No.
Item
Torque (N·m)
remark
42
Hall sensor bolt
8~10
Inner six flower M6×1×16
43
knock sensor bolts
20±4
Inner six flower M8×1.25×30
44
Exhaust manifold nut
35±2
M8
45
Throttle self-drilling bolt
8~10
Inner six flower M6×1×25
46
square-head bolt
47±5
M10×1.25×90
47
idle pulley bolt
49±9
M10×1.25×38
48
Oil filter
After Installation surface contact,
rotate 3/4 rounds or
(11±1) N·m
49
idle pulley assembly
50±5
M10×1.5
Standard component torque
No.
item
torque(N·m)
remark
1
M6
9
~ 11
2
M8
20
~ 25
3
M10
30
~ 50
4
M12
60
~ 80
(V)Precautions of maintenance
general precautions
1. Precautions of exhausting engine coolant
1). Exhaust engine coolant after engine cools off.
2. Precautions of disconnecting fuel pipe
1). Make sure there is no matters that could trigger spark or fire before working.
2). Release fuel pressure before disconnecting and dissolving.
3). After disconnecting pipe, gag the opening in case fuel will leak.
3. Precautions of removing and disassembly.
1). Please use special maintenance tools when it is required. Be safe, do not disobey the
instructions.
2). Be careful enough not to damage the matching surface and sliding suface.
3). If necessary, gag the opening of engine system with adhesive tape or something similar in case
foreign matters will get inside.
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Engine Mechanical System
Engine Mechanical System 24
4). Label and tidy the dissolved components in order, which is helpful to troubleshoot and
reassembly.
5). The basic principle of loosening nut and screw is: loosen the outer ones first, then those on
the diagonal, and so on. Please follow the appointed order if it is instructed.
4. Precautions of inspection /maintenance and replacement
1). Check the components thoroughly before maintenance or replacement. Please replace if
necessary.
5. Precautions of assembly
1). Use torque wrench to tighten nut and screw.
2). The basic principle of tightening nut and screw is: tighten the center ones first, then those on
the diagonal, with the same force. Please follow the appointed order if it is instructed.
3). Replace new pad, oil seal or “O”type ring.
4). Wash, clear and dry every component thoroughly. Check carefully if engine oil or coolant
pipe is blocked.
5). Try not to damage sliding surface or matching surface, clear foreign matters like kerf or dust
thoroughly. Smear sliding surface with engine oil before assembly.
6). When refill engine coolant after drilling, release air in the pipe.
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Engine Mechanical System
Engine Mechanical System 25
7). Start the engine and increase the rpm to check if there is leakage with engine coolant, fuel
engine oil and intake/exhaust after maintenance.
6. Those parts need to be tightened with certain degree
1). Tighten the following engine parts finally with angle wrench:
·Cylinder cap bolt
· Main bearing cap bolt
· Rod cap nut
2). Please do not tighten finally according to torque value.
3). Torque of these components is applicable for pre –tighten procedures.
4). Make sure the clear thread and base surface and smear engine oil
Precautions of sealant
1. Remove sealant
1). After removing fixing nut and screws, separate matching surface with scraper and remove the
old sealant.
△Caution Be careful not to damage matching surface. Insert scraper, and then knock side
surface to slide as per the drawing. Please use rubber hammer knock component
slightly to remove when it is hard to use scraper. Please be careful not to damage
matching surface if it is unavoidable to use tools like screwdriver.
2. Employing procedures of sealant
1). Clear the old sealant sticked to the application surface and matching surface of gasket with
scraper.
△Caution Clear the old sealant thoroughly off the groove of application surface of sealant, fixed
bolts and bolt hole.
2). Wipe the application surface and matching surface of sealant with unleaded gasoline, clear
attached water, grease and foreign matter.
3). Put the sealant with appointed size at appointed place.
△Caution
。If there is groove to put sealant, please put the sealant in the groove. Generally,
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Engine Mechanical System
Engine Mechanical System 26
put the sealant into the inner side of bolt hole, occasionally, outside, for the bolt hole. Install
and connect components within 5 mins after smear the sealant. Please clear the blot if there is
blot on the sealant. Please do not tighten again bolt and nut after installation.
Refill engine oil and engine coolant 30 mins after installation
△Caution Please operate according to the instruction if there is special instruction.
(VI)Special tool
No.
Tool
Outside figure
Instruction
1
fork clamp
Fixed camshaft timing gear
2
pin
use with fork clamp
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Engine Mechanical System
Engine Mechanical System 27
No.
Tool
shape drawing
Description
3
The flywheel stop
Fixed
flywheel
4
Valve spring
compressor
Compression valve spring
5
Oxygen sensor sleeve
Remove and install the oxygen sensor
6
oil sump disassemble
tool
Disassemble oil sump
7
Valve oil seal installer
Install valveoil seal
8
Crankshaft front oil
seal guide
Play the role of guiding when installing
crankshaft front oil seal
9
Crankshaft front oil
seal installer
Install engine crankshaft front oil seal
10
Crankshaft rear oil seal
installer
Install crankshaft rear oil seal
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Engine Mechanical System
Engine Mechanical System 28
No.
Tool
shape drawing
Description
11
Piston pin location tool
Install and disassembly piston pin
12
guide sleeve
Use together with piston pin location tool
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Engine Mechanical System
Engine Mechanical System 29
II failure diagnosis
(I)Diagnosis analysis table
No. Failure
description
Reason analysis
Solution
1
Starter does not
rotate
The connection of battery electrode becomes
loose or battery is low
tighten or charge
circuit is disconnected
check and repair
Starter has damage
Repair or change
2
Spark plug does not
ignite
ground connection is poor
repair
Ignition coil damage
change
spark plug clearance is not appropriate or burnt Adjust or change
Electronic ignition system has fault
Repair or change
3
failure in oil supply
system
gasoline pump is insufficient in oil supply
Repair or change
Petrol hose and fuel filter clogging
Clear
4
Cylinder
compression
pressure decreases
cylinder pad rupture
replace
Valve clearance adjustment is improper or
damaged
adjust/ repair or change
piston/
piston ring/cylinder wear
Repair or change
valve seal is poor
Repair
5
underpower during
running
the adjustment between acceleration pedal and
Throttle Valve is not appropriate
Adjust
cylinder compression pressure decreases
1. check if valve/spark plug/cylinder
pad leaks
2. cylinder grind
fuel supply not sufficient
Adjust or repair
air intake not sufficient
check intake system
exhaust clogging
check exhaust system, and clear the
carbon deposition
spark plug clearance inappropriate or damaged adjust or change
6
There is combustion
knock inside the
engine
bearing bush wear/ crankshaft cam wearing
Replace
Crankshaft/connecting rod axial diameter and
piston pin wear off greatly
Replace or repair
Piston ring damage
change
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Engine Mechanical System
Engine Mechanical System 30
valve clearance is inappropriate
Adjust
crankshaft thrust clearance is too big
Adjust
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Engine Mechanical System
Engine Mechanical System 31
No. Failure description
Reason analysis
soluti
on
7
engine overheating
Thermostat failure
Change
generator belt(water pump belt ) tensile
force not enough
Adjust
coolant not enough or water pipe block
Supplement or clear
Water pump clearance inappropriate or
damaged
Repair or replace
Radiator is blocked by incrustation
Repair or replace
Engine oil not enough
supplement
oil circuit blocked or oil pump damaged
clear or replace
spark plug clearance inappropriate or there
is carbon
deposition
clear or adjust
exhaust pipe blocked
tighten or clear
cylinder pad damaged
Replace
clutch slide
repair or replace
8
Excessive consumption of
engine oil
valve oil seal wear or damaged
Replace
Valve and valve duct wear
Replace
Oil ring wear or damaged
Replace
piston ring is wrongly opened according to
regulation
Replace
cylinder pad damaged
Replace
engine overheating
、inner pressure
increase
、part of the engine oil drained
out through exhaust exit
check related parts and excluded
oil return is not smooth in respiratory
system of cylinder cover shield, leading
engine oil goes into intake system through
respiratory hose
replace or clear cylinder cover
shield
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Engine Mechanical System
Engine Mechanical System 32
(II)diagnose flow chart
Engine overheating
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