JAC S2. Engine. Service Manual — part 6
Engine Mechanical System
Engine Mechanical System 59
11). Tighten the bolts of crankshaft bearing cap according to the
order.
12). Smear the thread and fixing surface of bolts of main bearing
cap with engine oil. Tighten main bearing cap screws step by
step.
Torque
(35±2)N·m+60°
~ 64°。
13). After installing main bearing cap screws, make sure crankshaft
can be rotated by hands flexibly.
7
3
1
5
9
8
4
2
6
10
4.
Assemble piston connecting rod components
1). Smear the engine oil to the outer circle of piston pin.
2). Install piston and connecting rod to piston pin installation base.
△
Caution
While installing piston pin, make sure the direction
mark of piston top is the same with the direction of
connecting rod.
3). Install piston pin with press machine
△
Caution
If the Pressure distribution load exceeds the
regulation, please replace piston pin and piston
assembly and connecting rod, or replace both.
Standard value
:(108±54)N·m
4). Install piston ring with piston ring expander
△
Caution
Be careful not to damage piston while installing
piston ring.
△
Caution
Be careful not to damage piston due to excessive
expansion
3ml
guide sleeve
B
guide
sleeve
A
Piston
expander
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Engine Mechanical System
Engine Mechanical System 60
A
B
5). Install grommet of oil ring into piston ring groove, then install
annulus of oil ring.
△
Caution
Do not use piston expander to hold loop, otherwise it
may cause scraper to crack.
6). After installing oil ring body, check if it can slide towards 2
directions.
7). Install gaseous ring with piston expander, the identification sign on
the gaseous ring
should be towards top of piston.
8). Install pitman box to connecting rod and connecting rod cap.
△
Caution Before installing pitman box, smear its surface with
engine oil.
△
Caution should use special tools to install the
pitman box to
guarantee the installation location: as shown in the
following drawing
, the length difference between
A and Bis less than 0.5mm
。
5. Install piston connecting rod component
1). Rotate the crankshaft journal of the to-be-installed connecting
rod to the bottom center.
2). Smear the cylinder bore/piston and crankshaft journal with
engine oil.
3). Install the connecting rod to the corresponding cylinder hole
according to the mark on the connecting rod.
△
Caution
Make sure the forward mark on top of
piston towards front.
4). Use piston guiding tool, put the piston connecting rod assembly
from cylinder fire surface into the guiding tool, and press the
piston into cylinder with rubber stick.
△
Caution
Please do not let the connecting rod big end
damage cylinder wall and crankshaft journal.
5). Install the connecting rod bearing cap of cylinder 2 which is
marked with no. 2.
6). Install and tighten the bolts of connecting rod bearing cap of
cylinder 2.
Torque
5N·
m → 10N·
m → 13N·
m+45+45°
7). Install the piston connecting rod component of other 3
cylinders in the same way.
△
Caution
Before installing bolts, smear engine oil to its
thread and base surface.
△
Caution
After installing piston connecting rod assembly,
rotate crankshaft to check if it can be rotated
flexibly.
6. Install cylinder cover assembly
7. Install alternator adjusting arm bracket
8. Install engine rear lifting lug
9. Install camshaft
10. Install timing chain
11. Install chain wheel compartment cover
12. Install crankshaft front oil seal
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Engine Mechanical System
Engine Mechanical System 61
13. Install cylinder cover shield component
14. Install oil sump assembly
15. Install oil level gauge component
16. Install crankshaft pulley
17. Install water pump pulley
18. Install idle wheel
19. Install compressor assembly
20. Install alternator
21. Install alternator belt
22. Install engine oil pressure switch
23. Install
pressure regulating valve
24. Install
knocking sensor
25. Install crankshaft position sensor
26. Install camshaft position sensor
27. Install water temperature sensor
28. Install absolute pressure sensor
29. Install electronic throttle valve
30. Install carbon tank solenoid valve
31. Install PCV valve
32. Install exhaust manifold
33. Install intake manifold
34. Install air filter bracket II
35. Install air filter bracket I
36. Install vacuum servo steel tube
37. Install warm wind backwater pipe
38. Install
oil pressure guide rail component
39. Install spark plug
40. Install ignition coil
41. Install engine assembly
42. Install transmission assembly
43. Install right driving axle assembly
44. Install left driving axle assembly
45. Install right front wheel
46. Install left front wheel
47. Install starter
48. Install clutch working cylinder
49. Install back-up lamp switch
50. Install battery tray
51. Install battery
52. Install air filter assembly
53. Install water inlet and outlet assembly of warm wind
54. Install pipe and expansion valve assembly
55. Install intake hose
56. Fill Freon, refrigerant oil
57. Fill coolant
58. Fill engine oil
59. Fill transmission lubricant
60. Fill clutch hydraulic oil
61. Install engine right front cover shield
62. Install left front cover shield
63. Connect battery cathode cable
64. Close engine cove
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Engine lubricating system
Engine intake system 62
Engine lubricating system
I. Overview
(I) Structure overview
System description
The air intake system consists of oil sump, engine oil filter and engine oil pressure switch.
1. The oil sump is installed at the bottom of crankcase and the oil pump abstracts the engine oil from the
sump that flows through 2 oil galleries to cylinder and cylinder head respectively after the oil filter. The
oil in one gallery flows to connecting rod then to piston and cylinder through crank oil passage; the other
one flow to camshaft lubricating air valve assy then returns to the sump in the end.
2. This model has adopted the rotary fuel pump, its shell, inner and outside roller and relief valve are
integrated on the cover of sprocket wheel housing, and the inner rotor is driven by the gear installed on
crankshaft. The oil pump extracts the oil from the sump and transports it to every part of engine. A
filtering net is installed at the inlet of oil pump, the congestion of filter will cause oil pump unable to feed
oil further to cause the lubricating system failure in working, under this case, it would cause the engine
mechanical parts damaged. When the engine rotation speed is too high, the output pressure of oil pump
exceeds the limits; the relief valve will open when the surplus oil flows back to the oil inlet chamber of
pump. In normal oil-supply conditions, the relief valve stays closed.
(II) System principle
Lubricating system description
The oil filter is installed on cylinder body and the engine oil flows upward through filter from the down
oil gallery, after being filtered clean, the oil returns to cylinder body through the upper gallery. The front
oil gallery feeds oil to each cylinder head, main bearing oil gallery, OCV solenoid valve, camshaft
position actuator.
The oil gallery of each cylinder head distributes the oil to cylinder head and camshaft bearing journal. The
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Engine lubricating system
Engine intake system 63
engine oil reaches to the OCV solenoid valve actuator through the OCV filter and oil chamber. The OCV
solenoid valve is for controlling the air inlet camshaft position actuator while the ECM controls OCV
solenoid valve. When the OCV is power on, it directs the engine oil up flowing through cylinder head and
front camshaft bearing cover. The engine oil gets into the holes drilled on camshaft journal through the oil
gallery of camshaft bearing cover and flows into the front part of the mounting surface of air inlet
camshaft; then it flows to the oil gallery of camshaft position actuator.
The OCV solenoid valve directs the pressurized engine oil to the relative galleries working on the inner
blades of camshaft position actuator that will cause the air-inlet camshaft rotating against sprocket wheel.
During idling, the inner lock pin fixes the inner rotor at the outside shell of air-inlet camshaft position
actuator and during start-up, it maintains the air-inlet camshaft position actuator at the original place. The
OCV solenoid valve directs engine oil to release lock pin and starts working of air-inlet camshaft position
actuator.
Lubricating system schematic diagram
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Engine lubricating system
Engine intake system 64
(III) Technical and service data
Item
Specification
Tooth tip clearance
0.06 ~ 0.18mm
Side clearance 0.04 ~ 0.11mm
Shell body clearance 0.10 ~ 0.18mm
Output pressure of oil pump 0.6MPa (87psi)
Relief valve opening pressure 0.4~0.5MPa ( 58~72.5psi)
(IV) Torque parameters
Key component torque table
SN Item
Torque (N·m)
Remarks
1
Pressure switch
10±2
2
Drain plug
39±5
3
Engine oil filter
11±1
4
Oil suction filter fixed bolt
8.4±0.6
5
Oil sump bolt
11±1
6
Oil dipstick tube components
8.4±0.6
II. Failure diagnosis
(I.) Diagnosis analysis table
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Engine lubricating system
Engine intake system 65
SN Failure
phenomenon
Failure causes analysis
Solution
1
Engine oil
leakage
Oil level too high
Drain out the excessive oil
Oil of over-high pressure
Check oil filter or pressure
by-pass valve for
congestion or failure
Engine ventilation system gets
congested or has failure
Check and clean the PCV
valve and its relevant tubes
Improper tightening of fasteners
Change the damaged parts
and tighten them at the
regulated torque
Relative parts has rupture or crack Change the damaged parts
Sealing surface wearout, sealing
mat in poor installation
Repair or replace the
damaged parts
(II) Diagnosis procedures table
Engine oil of over-low pressure
Engine oil over-consumption
III. Engine oil drainage and filling
1. Open engine hood
2. Disconnect the cathode wires of battery
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Engine lubricating system
Engine intake system 66
3. Drain out the engine oil
1). Screw off the cover of engine oil port on cylinder head.
2). Take down the drain plug and gasket and drain the oil into the container
Attention: The engine oil temperature may be high and be careful with burning.
Attention: The draining-out time shall be more than 15min.
3). Clean drain plug and change the new liner during installation.
Tighten torque (39±5)N•m
4. Dismantle the oil filter
1). Take down the oil filter by the wrench
5. Install oil filter
1). Smear few engine oil on the O type ring of oil filter.
2). When the O type ring gets contact with the flange of filter bracket and screw in 3/4 round by the
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Engine lubricating system
Engine intake system 67
special wrench.
Tightening torque (11±1)N•m
6. Filling engine oil
1). Fill in the clean engine oil
2). Install oil filling port cover.
7. Check if the engine oil has leakage
1). Start the engine.
2). Check if the filter and drain plug have oil leakage
IV. Engine oil pressure switch
(I) Dismantlement
1. Open the engine hood.
2. Disconnect the cathode wires of battery
3. Dismantle the air filter assy
4. Dismantle the electric throttle
5. Dismantle the air-intake manifold
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Engine lubricating system
Engine intake system 68
6. Dismantle the engine oil pressure switch
1). Disconnect the wires connector of engine oil pressure switch
2). Dismantle the oil pressure switch by the special sleeve.
3). Take down the oil pressure switch.
(II) Installation
1. Install the oil pressure switch
1). Smear the sealing glue on the thread of oil pressure switch.
2). Tighten the oil pressure switch
Tighten torque (10±2)N•m
3). Connect the wires connector of oil pressure switch and check and make sure it’s in good connection.
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Engine lubricating system
Engine intake system 69
2. Install air intake manifold
3. Install the electric throttle.
4. Install the air filter assy
5. Connect the cathode wires of battery
6. Close the engine hood
V. Oil filter
(I) Disassembly
1. Open the engine hood
2. Disconnect the cathode wires of battery
3. Dismantle the oil filter
1). Dismantle the oil filter by the special wrench
Attention: Use the JAC original oil filter
Attention: Be caution of the hot engine oil.
Attention: Prepare a wiping cloth for wiping off the splash-out or leaked out engine oil
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Engine lubricating system
Engine intake system 70
(II) Installation
1. Install the engine oil filter
1). Smear few engine oil on the O type ring of oil filter.
2). When the O type ring gets contact with the flange of filter bracket and screw in 3/4 round by the
special wrench.
Tightening torque (11±1)N•m
Attention: It must use the special wrench to tighten the oil filter. It may have the leakage problem due to
insufficient torque as tighten the filter manually.
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Engine lubricating system
Engine intake system 71
2. Connect the cathode wires of battery
3. Close the engine hood.
VI. Oil filter components
(I) Disassembly
1. Open the engine hood
2. Disconnect the cathode wires of battery
3. Dismantle the oil filter components
1). Screw off the 3 fixed bolts
2). Take down the oil filter components and its bracket mat.
(II) Installation
1. Install the oil filter components
1). Install the 3 fixed bolts
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Engine lubricating system
Engine intake system 72
2. Connect the cathode wires of battery
3. Close the engine hood
VII. Oil sump assy
(I) Disassembly
1. Open the engine hood
2. Disconnect the cathode wires of battery
3. Dismantle the front left cover of engine
4. Dismantle the front right cover of engine
5. Drain out the engine oil
6. Dismantle the oil sump assembly
1). Loosen the 16 fixed bolts at the reverse sequence of the shown in below diagram
2). Take down the oil sump by the special device
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Engine lubricating system
Engine intake system 73
Attention: Do not damage the matching surface
(II) Installation
1. Install the oil sump assy
1). Clean the shell and mounting surface.
2). Smear the sealing glue on oil sump
3). Tighten the 16 fixed bolts and nuts according to the sequence shown by the below diagram
Tighten torque: (11±1)N•m
2. Fill in the engine oil
3. Install the front left cover of engine
4. Install the front right cover of engine
5. Connect the cathode wires of battery
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Engine lubricating system
Engine intake system 74
6. Close the engine hood
VIII. Suction filter
(I) Disassembly
1. Open the engine hood
2. Disconnect the cathode wires of battery
3. Dismantle the front left cover of engine
4. Dismantle the front right cover of engine
5. Drain out the engine oil
6. Dismantle the oil sump assy
7. Dismantle the suction filter
1). Screw off the 3 fixed bolts
2). Take down the suction filter
(II) Installation
1. Install the suction filter
1). Install the fixed bolts of suction filter
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