JAC S2. Engine. Service Manual — part 11

Engine ignition system

Engine fuel system 139

IV、I level muffler assembly

(I)Disassembly

1. Lift car

2. Disassemble I level muffler assembly

1). Disassemble 2 lifting eyes connecting I level muffler and car body.

2). Disassemble 2 fixing bolts connecting I level muffler and II level
catalyst.

3). Disassemble 2 fixing bolts connecting I level muffler and
II level muffler.

4). Take off I level muffler.

3. Disassemble seal gasket II

1). Take off seal gasket II from I level muffler

(II)Installation

1. Install seal gasket II

1). Install seal gasket II to I level muffler.

2. Install I level muffler assembly

1). Install I level muffler to car rubber bearing, install lifting eye.

2). Install 2 fixing bolts connecting I level muffler and II level catalyst

Tightening torque:

6±1N·m

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3). Install 2 fixing bolts connecting I level muffler and II level muffler.

Tightening torque:

6±1 N·

m

3. Get the car down

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V、II level muffler assembly

(I)Disassembly

1. Lift car

2. Disassemble II level muffler assembly

1). Disassemble 1

hang soft gasket (near car rear) connecting II

level muffler and car body.

2). Disassemble 1

hang soft gasket (near middle of the car)

connecting II level muffler and car body.

3). Disassemble 2 fixing nuts connecting I level muffler and II
level muffler.

4). Take off II level muffler.

3. Disassemble seal gasket II

1). Take off seal gasket II from II level muffler.

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(II)Installation

1. Install seal gasket II

1). Install seal gasket II to II level muffler.

2. Install II level muffler assembly

1). Install II level muffler assembly to hang soft gasket on the car
body(near middle of the car).

2). Install II level muffler assembly to hang soft gasket on the car
body(near car rear)

3). Install 2 fixing nuts connecting I level muffler and II level
muffler.

Tightening torque:

6±1N·m

3. Get the car down

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VI、Thermal baffle assembly

(I)Disassembly

1. Lift car

2. Disassemble

thermal baffle I

1). Disassemble 4 fixing nuts of

thermal baffle I and car

body( near front exhaust pipe assembly) .

2). Disassemble 2 fixing nuts of

thermal baffle I and car body(near

II level catalyst)

3). Take off thermal baffle I.

3. Disassemble

thermal baffle II

1). Disassemble 2 fixing nuts of

thermal baffle II and car body(on

top of I level muffler).

2). Disassemble 2 fixing nuts and 1 bolts of thermal baffle II and
car body.

3). Take off thermal baffle II

。

4. Disassemble

thermal baffle III

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1). Disassemble 2 fixing nuts of

thermal baffle III and car body(chassis base on left side of car body)

2). Disassemble 2 fixing nuts of

thermal baffle III and car

body(chassis base on right side of car body)

3). Take off thermal baffle III

。

(II)Installation

1. Install thermal baffle III

1). Install2 fixing nuts of

thermal baffle III and car body(chassis

base on right side of car body)

Tightening torque: (6±1) N·m

2). Install2 fixing nuts of

thermal baffle III and car body.(chassis

base on left side of car body)

Tightening torque: (6±10 N·m

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2. Install thermal baffle II

1). Install 2 fixing nuts and 1 fixing bolts of thermal baffle II and car body.

Tightening torque: (6±1) N·m

Tightening torque: (45~55) N·m

2). Install 2 fixing nuts of thermal baffle II and car body(on top

of I level muffler)

。

Tightening torque: (6±1) N·m

3. Install thermal baffle I

1). Install 2 fixing nuts of thermal baffle I and car body(near II level

catalyst)

。

Tightening torque: (6±1) N·m

2). Install 4 nuts of thermal baffle I and car body(near front

exhaust pipe assembly).

Tightening torque: (6±1) N·m

4. Get the car down

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VII、Exhaust manifold

(I)Disassembly

1. Open engine cover

2. Disconnect battery cathode cable, refer to battery cable disconnect and connect

3. Disassemble front oxygen sensor, refer to front oxygen sensor

4. Disassemble thermal shroud of front exhaust manifold

1). Disassemble 5 fixing bolts of upper thermal shroud of exhaust

manifold, take off upper thermal shroud of exhaust manifold.

5. Disassemble exhaust manifold bracket

1). Disassemble 4 fixing bolts of exhaust manifold bracket

2). Take off exhaust manifold bracket

6. Disassemble exhaust manifold and exhaust manifold gasket

1). Disassemble 2 fixing bolts of exhaust manifold and front

exhaust pipe assembly, disconnect exhaust manifold and front

exhaust pipe assembly.

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2). Disassemble 5 fixing nuts connecting exhaust manifold and

cylinder cover, take off exhaust manifold components and

exhaust manifold gasket.

△

Caution

Disassemble bolts of exhaust manifold while its hot,

may damage bolts or cylinder cover, so must wait

to disassemble after engine cools off!

3). Take off exhaust manifold and exhaust manifold bracket.

(II)Check

1. Check

exhaust manifold

1). Check

if matching surface of

exhaust manifold is misshaped.

(III)Installation

1. Install exhaust manifold and exhaust manifold bracket

1). Replace with new exhaust manifold seal gasket and exhaust

manifold, tighten 5 fixing nuts of exhaust manifold and

cylinder cover.

Tightening torque:

35±2N·m

2). Replace the seal gasket between exhaust pipe and exhaust

manifold, install and tighten 2 fixing nuts of front exhaust pipe

and exhaust manifold.

Tightening torque:

45±7N·m

2. Install exhaust manifold bracket

1). Install 4 fixing bolts of exhaust

manifold bracket

Tightening torque:

22.5±2.5N·m

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3. Install upper thermal shroud of exhaust manifold

1). install and tighten 5 fixing bolts of upper thermal shroud of exhaust
manifold.

Tightening torque:

10±1N·m

4. Install front oxygen sensor

5. Connect battery cathode cable

6. Close engine cover

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Engine fuel system

I. Overview

(I.) Structure overview

Exploded diagram

17

8

9

18

7

6

1115

4

10

1

12

5

16

14

3

2

13

1.Fuel tank assy

2. I Fuel tank strap I
3. II Fuel tank strap II
4. Fuel inlet tube assy

5. Fuel return nylon tube assy
6. Fuel evaporation nylon tube assy
7. Fuel pump assy
8. Fixing snap ring of fuel pump
9. Flange sealing ring of fuel pump

10. Fuel filling tube assy

11. Plastic fuel cap assy
12. Hexagon bolt and spring washer
combination component
13. Metal hexagon flange locknut
14. Hexagon bolt and
spring washer combination component

15. Binding bolt of filling port

16. Fuel filter assy
17. Fuel access cap

18. Fuel heat insulation panel

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2

1

4

5

3

1. Fuel pipleline assy I

2. Fuel pipeline assy II

3. Carbon tank assy
4. Carbon tank bracket

5. Hexagon bolt and spring washer combination component

System description

The fuel supply system is to supply fuel to engine under various conditions through the fuel

injector. The electric fuel pump inside the fuel tank has pumped the fuel into distribution pipeline

and then the fuel pressure adjuster has adjusted the pressure to meet with the injector requirement.

1. Fuel tank

The fuel tank is made of HDPE materials and fixed to the chassis by 2 metal straps.

2. Filling cap of fuel tank

Attention:

Make sure use the same functional filling cap with the original cap during replacement;
otherwise it may cause the major failure of fuel system.

The filling tube has a one-way filter on filling cap.

3. Fuel pump

The electric turbo fuel pump inside the modular fuel transmitter is controlled by the ECM through

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its relay. It will supply the fuel in advance to ensure the fuel pressure inside tube meeting with the

system requirement. It carries with independent fuel reservoir can in order to guarantee the normal

supply of fuel during low level fuel or violent operation.

4. Fuel pressure adjustor assy

The fuel pressure adjuster integrated in the fuel pump is mainly for adjusting the fuel volume flew into the

tube so that control the pressure at injector.

5. Electric fuel pump filter screen

The filter screen has the below functions as the primary filter

- Filter off pullutants

- Enlong the fuel pump service life.

It should clean or replace the filter screen when the output pressure of fuel pump was unduly low.

6. Fuel filter assy

The fuel filter assy fixed on fuel tank at the left side of chassis consists of paper filter core, which

can filter off particles inside fuel that may damage the fuel system.The fuel filter can stand with the

maximum fuel system pressure, temperature variation and fuel additives.

7. Fuel level sensor assy

The fuel level sensor assy consists of 1 floater and the wires arm assy and is fixed on fuel tank.

It transmits the variable circuit resistance to the instruments meter according to the contact

position of sliding plate. The circuit wires harness stretches from variable resistance plate to the

connector of fuel pump.

8. Fuel distribution tube

The fuel distribution tube consists of the below parts

- Tube of distributing and transporting fuel to each injector

- 4 independent injectors.

The fuel distribution tube has been installed on intake manifold and works for distributing the
fuel to each injector corresponded with each cylinder.

9. Fuel Injector

The fuel injector is a solenoid valve controlled by the ECU of engine. The constant closed ball

valve will be opened to let fuel flow through the director panel to the outlet of injector when the

injector coil is powered on by engine ECU. The fluid director panel controls the fuel volume and

generates dual thin cone fuel mist around the outlet of injector through the holes on it. The fuel has

been injected further from the outlet to 2 intake valve channels where make the fuel a further step of

gasification. If the fuel injector had the below problems, it would cause the power failure

- The fuel injector can’t be opened

- The fuel injector gets stuck in the opening position

- The fuel injector has leakage

- The resistance of injector coil is unduly low. The normal resistance range: 11.6~12.4Ω

(II) System theory

Fuel evaporation system theory

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The fuel evaporation system is to reduce the quantity of hydrocarbon exhausted into air by the

force of active carbon stored in the carbon tank.

When the engine is off or filling fuel into the tank, the fuel steam evaporated in the confined fuel

tank would be sucked and stored into the carbon tank. When the engine is on, the fuel steam inside

carbon tank has been transported to intake manifold through the cleaning tube. The flow rate of fuel

steam controlled by solenoid valve of carbon tank is in proportion to air flow rate. The solenoid

valve of carbon tank is controlled by ECU.

During deceleration and idling, the solenoid valve of carbon tank will close the cleaning tube.

The fuel steam control valve is installed on fuel pump to prevent from over fuel steam getting

into carbon tank.

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(III) Torque parameters

Kep components torque table

SN Item

Torque (Nm)

Remarks

1

Fuel pressure guiding rack bolt

18.4±1.4

M8×35 E12

2

Master fuel passage plug I

60±5

Inner hexagonal M20

3

Master fuel passage plug II

35±5

Inner hexagonal M12

4

VVT fuel passage plug

44±5

M14×1.5×14

(IV) Service attention matters

Warning

It must abide by the below regulation during replacing or dismantling the parts of fuel system.：

1. Place the warning label “NO SMOKING” in working place
2. Make sure the good ventilation condition and prepare the carbon dioxide extinguisher
3. The discharged fuel must be filled into the container and store at a safe place.
4. Dismantle the fuel tube parts, please carry out the below operations
1) Disconnect the cathode wire of battery
2) Release the fuel pressure inside tube
5. Do not twist the fuel tube during installation.
6. Carry out operations on the flat ground.
7. Make sure the fuel tube joint connected tightly and free from interference with other adjacent
parts.
8. Do not tighten the jump ring of tube overly

9. Check and confirm if it had fuel leakage at each joints by the below steps after the fuel tube
connected

1) Turn the ignition key to ON gear and then check if it had leakage at each joint
2) Starting engine and ratcheting up the RPM to check if it had leakage at each joint

10. Prepare the wiping cloth and container in advance in case of fuel leakage
11. Avoid the open fire and spark

12. Please stay away from the fire source for the dismounted parts
13. Keep the junction place clean and cover it by plastic bag keeping from impurities getting inside.