JAC S2. Engine. Service Manual — part 4

Engine Mechanical System

Engine Mechanical System 29

IX、Crankshaft rear oil seal and cover plate

(I)Disassembly

1. Open engine cover

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

3. Disassemble engine left front cover, refer to engine cover

4. Disassemble engine right front cover, refer to engine cover

5. Drain clutch hydraulic oil, refer to the drain and fill of clutch hydraulic oil

6. Drain transmission lubricant, refer to the drain and fill of transmission lubricant

7. Disassemble battery, refer to battery

8. Disassemble battery tray, refer to battery tray

9. Disassemble back-up lamp switch, refer to back-up lamp switch

10. Disassemble clutch working cylinder, refer to clutch working cylinder and oil intake pipe assembly

11. Disassemble starter, refer to starter

12. Disassemble left front wheel, refer to wheel

13. Disassemble right front wheel, refer to wheel

14. Disassemble left driving axle assembly, refer to driving axle assmbly

15. Disassemble right driving axle assembly, refer to driving axle assmbly

16. Disassemble transmission assembly, refer to transmission assembly

17. Disassemble clutch cover and platen assembly, clutch driven plate,

refer to Disassemble clutch cover and platen assembly, clutch

driven plate

18.Disassemble flywheel component

19. Disassemble Crankshaft rear oil seal and cover plate

1). Disassemble 8 fixing bolts of

crankshaft rear oil seal and cover

plate

2). Remove crankshaft rear oil

seal and cover plate

(II)Installation

1. Install crankshaft rear oil seal and cover plate

1). Smear DowCorning 3-0115 sealant or relevant products to the

installation surface on the back side of cylinder.

2). Smear lubricant to the connection part of oil seal mouth and

Engine Mechanical System

Engine Mechanical System 30

crankshaft, please be careful not to scratch oil seal while

installation.

3). Install fixing bolts of crankshaft rear

oil seal and cover plate

Torque

(7.6±0.6) N·m

Engine Mechanical System

Engine Mechanical System 30

2. Install flywheel component

3. Install clutch cover and platen assembly, clutch driven plate

4. Install right driving axle assembly

5. Install left driving axle assembly

6. Install right front wheel

7. Install left front wheel

8. Install starter

9. Install clutch working cylinder

10. Install back-up lamp switch

11. Install battery tray

12. Install battery

13. Fill transmission lubricant

14. Fill clutch hydraulic oil

15. Install engine right front cover

16. Install engine left front cover

17. Connect battery cathode cable

18. Close engine cover

Engine Mechanical System

Engine Mechanical System 31

X、Crankshaft front oil seal

(I)Disassembly

1. Open engine cover

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

3. Release fuel system pressure, refer to release fuel system pressure

4. Disassemble engine left front cover, refer to engine cover

5. Disassemble engine right front cover, refer to engine cover

6. Drain clutch hydraulic oil, refer to the drain and fill of clutch hydraulic oil

7. Drain transmission lubricant, refer to the drain and fill of transmission lubricant

8. Drain engine oil, refer to drain and fill of engine oil

9. Drain coolant, refer to replace coolant

10. Recycle freon, refrigerating oil, refer to freon, refrigerating oil

11. Disassemble intake hose, refer to intake hose assembly

12. Disassemble pipe and expansion valve assembly, refer to pipe and expansion valve assembly

13. Disassemble water inlet and outlet assembly of warm wind, refer to disassemble water inlet and outlet assembly of warm wind

14. Disassemble air filter assembly, refer to air filter assembly

15. Disassemble battery, refer to battery

16. Disassemble battery tray, refer to battery tray

17. Disassemble back-up lamp switch, refer to back-up lamp switch

18. Disassemble clutch working cylinder, refer to clutch working cylinder and oil intake pipe assembly

19. Disassemble starter, refer to starter

20. Disassemble left front wheel, refer to wheel

21. Disassemble right front wheel, refer to wheel

22. Disassemble left driving axle assembly, refer to driving axle assmbly

23. Disassemble right driving axle assembly, refer to driving axle assmbly

24. Disassemble transmission assembly, refer to transmission assembly

25. Disassemble engine assembly, refer to engine assembly

26. Disassemble alternator belt, refer to alternator belt

27. Disassemble crankshaft pulley, refer to crankshaft pulley

28. Disassemble crankshaft front oil seal

1). Pry off crankshaft

front oil seal

Engine Mechanical System

Engine Mechanical System 32

(II)Installation

1. Install crankshaft front oil seal

1). Put into crankshaft front oil seal

2. Install crankshaft pulley

3. Install alternator belt

4. Install engine assembly

5. Install transmission assembly

6. Install right driving axle assembly

7. Install left driving axle assembly

8. Install right front wheel

9.Install left front wheel

10. Install starter

11. Install clutch working cylinder

12. Install back-up lamp switch

13.Install battery tray

14. Install battery

15. Install air filter assembly

16. Install water inlet and outlet assembly of warm wind

17. Install pipe and expansion valve assembly

18. Install intake hose

19. Fill Freon and refrigerant oil

20. Fill coolant

21. Fill engine oil

22. Fill transmission lubricant

23. Fill clutch hydraulic oil

24. Install engine right front cover

25. Install engine left front cover

26. Connect battery cathode cable

27. Close engine cover

Engine Mechanical System

Engine Mechanical System 33

XI、Timing chain

(I)Disassembly

1. Open engine cover

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

3. Release fuel system pressure, refer to release fuel system pressure

4. Disassemble engine left front cover, refer to engine cover

5. Disassemble engine right front cover, refer to engine cover

6. Drain clutch hydraulic oil, refer to the drain and fill of clutch hydraulic oil

7. Drain transmission lubricant, refer to the drain and fill of transmission lubricant

8. Drain engine oil, refer to drain and fill of engine oil

9. Drain coolant, refer to replace coolant

10. Recycle freon, refrigerating oil, refer to freon, refrigerating oil

11. Disassemble intake hose, refer to intake hose assembly

12. Disassemble pipe and expansion valve assembly, refer to pipe and expansion valve assembly

13. Disassemble water inlet and outlet assembly of warm wind, refer to disassemble water inlet and outlet assembly of warm wind

14. Disassemble air filter assembly, refer to air filter assembly

15. Disassemble battery, refer to battery

16. Disassemble battery tray, refer to battery tray

17. Disassemble back-up lamp switch, refer to back-up lamp switch

18. Disassemble clutch working cylinder, refer to clutch working cylinder and oil intake pipe assembly

19. Disassemble starter, refer to starter

20. Disassemble left front wheel, refer to wheel

21. Disassemble right front wheel, refer to wheel

22. Disassemble left driving axle assembly, refer to driving axle assmbly

23. Disassemble right driving axle assembly, refer to driving axle assmbly

24. Disassemble transmission assembly, refer to transmission assembly

25. Disassemble engine assembly, refer to engine assembly

26. Disassemble alternator belt, refer to alternator belt

27. Disassemble alternator, refer to alternator

28. Disassemble compression assembly, refer to compression assembly

29. Disassemble idle wheel, refer to idle wheel

30. Disassemble water pump pulley, refer to water pump pulley

31. Disassemble crankshaft pulley, refer to crankshaft pulley

32. Disassemble oil level gauge component, refer to oil level gauge component

33. Disassemble

oil sump assembly, refer to oil sump assembly

34. Disassemble cylinder cover assembly, refer to cylinder cover assembly

35. Disassemble crankshaft front oil seal, refer to crankshaft front oil seal

36. Disassemble chain wheel compartment cover, refer to chain wheel compartment cover

Engine Mechanical System

Engine Mechanical System 34

37. Disassemble timing chain

1). Disassemble 2 fixing bolts of automatic take-up,

remove automatic take-up

2). Disassemble 1 fixing bolts of dynamic rail components,
remove dynamic rail components.

3). Disassemble 2 fixing bolts of orbit determination

4). Rotate crankshaft to loosen timing chain

5). Remove orbit determination

38. Disassemble exhaust

crankshaft chain

1). Disassemble 1 fixing bolt of exhaust crankshaft chain wheel.

2). Remove exhaust crankshaft chain wheel

3). Remove timing chain

Engine Mechanical System

Engine Mechanical System 35

(II)Installation

1. Install timing chain

1). Adjust the TDC mark of cylinder 1 of crankshaft
signal wheel to vertical direction

2). Confirm 3 chain marks of timing chain.

链条正时标记

链轮正时标记

链轮正时标

记

3). Install timing chain, mark the first timing when aligning to
crankshaft timing chain.
4). Adjust timing chain, mark the second timing when aligning to

valve timing adjuster.

链条正时标记

链轮正时标记

链轮正时标记

2. Install exhaust cam

shaft chain

1). Install fixing bolts of exhaust cam shaft chain, rotate exhaust

cam shaft, align to the third timing mark.

△

Caution

there is only one circle on exhaust cam shaft chain,

which should be aligned to timing chain, not 2
circles.

Torque

(88±10)N·

m

2). Install orbit determination
3). Tighten fixing bolts

Torque

(10±2)N·

m

Engine Mechanical System

Engine Mechanical System 36

4). Install dynamic rail components

5). Tighten fixing bolts

Torque

(23.5±4.5)N·m

6). Install automatic take-up, tighten bolts.

△

caution when installing automatic take-up, please be sure to avoid slippage phenomenon of timing chain, check if 3 timing

marks are aligning to each other, making sure timing chain isn’t malposition.

Torque

(10±1)N·

m

3. Install chain wheel compartment cover

4. Install crankshaft front oil seal

5. Install cylinder cover component

6. Install oil sump assembly

7. Install oil level gauge pipe component

8. Install crankshaft pulley

9. Install water pump pulley

10. Install idle wheel

11. Install compression assembly

12. Install alternator

13. Install alternator belt

14. Install engine assembly

15. Install transmission assembly

16. Install right driving axle assembly

17. Install left driving axle assembly

18. Install right front wheel

19. Install left front wheel

20. Install starter

21. Install clutch working cylinder

22.

关 Install back-up lamp switch

23. Install battery tray

24. Install battery

25. Install air filter assembly

26. Install water inlet and outlet assembly of warm wind

27. Install pipe and expansion valve assembly

28. Install intake hose

29. Fill Freon/ refrigerant oil

30. Fill coolant

Engine Mechanical System

Engine Mechanical System 37

31. Fill engine oil

32. Fill transmission lubricant

33. Fill clutch hydraulic oil

34. Install engine right front cover

35. Install engine left front cover

36. Connect battery cathode cable

37. Close engine cover

Engine Mechanical System

Engine Mechanical System 38

XII、camshaft

(I)Disassembly

1. Open engine cover

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

3. Release fuel system pressure, refer to release fuel system pressure

4. Disassemble engine left front cover, refer to engine cover

5. Disassemble engine right front cover, refer to engine cover

6. Drain clutch hydraulic oil, refer to the drain and fill of clutch hydraulic oil

7. Drain transmission lubricant, refer to the drain and fill of transmission lubricant

8. Drain engine oil, refer to drain and fill of engine oil

9. Drain coolant, refer to replace coolant

10. Recycle freon, refrigerating oil, refer to freon, refrigerating oil

11. Disassemble intake hose, refer to intake hose assembly

12. Disassemble pipe and expansion valve assembly, refer to pipe and expansion valve assembly

13.Disassemble water inlet and outlet assembly of warm wind, refer to disassemble water inlet and outlet assembly of warm wind

14. Disassemble air filter assembly, refer to air filter assembly

15. Disassemble battery, refer to battery

16. Disassemble battery tray, refer to battery tray

17. Disassemble back-up lamp switch, refer to back-up lamp switch

18. Disassemble clutch working cylinder, refer to clutch working cylinder and oil intake pipe assembly

19. Disassemble starter, refer to starter

20. Disassemble left front wheel, refer to wheel

21. Disassemble right front wheel, refer to wheel

22. Disassemble left driving axle assembly, refer to driving axle assembly

23. Disassemble right driving axle assembly, refer to driving axle assembly

24. Disassemble transmission assembly, refer to transmission assembly

25. Disassemble engine assembly, refer to engine assembly

26.Disassemble alternator belt, refer to alternator belt

27. Disassemble alternator, refer to alternator

28. Disassemble compression assembly, refer to compression assembly

29.Disassemble idle wheel, refer to idle wheel

30. Disassemble water pump pulley, refer to water pump pulley

31. Disassemble crankshaft pulley, refer to crankshaft pulley

32. Disassemble oil level gauge component, refer to oil level gauge component

33. Disassemble

oil sump assembly, refer to oil sump assembly

34. Disassemble cylinder cover assembly, refer to cylinder cover assembly

35. Disassemble crankshaft front oil seal, refer to crankshaft front oil seal

36. Disassemble chain wheel compartment cover, refer to chain wheel compartment cover

Engine Mechanical System

Engine Mechanical System 39

37. Disassemble timing chain, refer to timing chain

38. Disassemble camshaft

1). According to the opposite order of the table, remove 3 bearing

cap bolts of the front camshaft.

2). Remove camshaft front bearing cap.

3

1

2

3). According to the opposite order of the table, loosen exhaust

camshaft bearing cap one by one, loosen from half round to

one round.

4). Disassemble exhaust camshaft bearing cap, remove exhaust
camshaft.

5

1

3

7

6

2

4

8

5). According to the opposite order of the table, loosen intake

camshaft bearing cap one by one, loosen from half round to

one round.

6). Disassemble intake camshaft bearing cap.

39. Disassemble valve timing adjuster

1). Disassemble 1 fixing bolt of valve timing adjuster.

2). Remove valve timing adjuster.

3). Remove intake camshaft.

Engine Mechanical System

Engine Mechanical System 40

40. Disassemble mechanic tappet

1). Remove 16 mechanic tappets

△

caution

In case forget the location of tappet, mark on the

removed tappet and at the location of relevant
installing location.

(II)Check

1. Measure the height of camshaft

2). Intake

：(44.7054±0.1)mm ；

Exhaust

：(44.2836±0.1)mm

Please replace camshaft if the measured
values doesn’t conform with the above standard values.

(III)Installation

1. install mechanic tappets

1).Put the mechanic tappets into the cylinder

according to the mark

Engine Mechanical System

Engine Mechanical System 41

2. Install camshaft

1). Smear engine oil to the journal and cam of camshaft.

2). Install intake camshaft, tighten fixing bolts of intake camshafat

bearing cap according to the order in the table.

Torque

(11±1) N·

m

。

3).Install exhaust camshaft, tighten fixing bolts of exhaust camshafat bearing cap

according to the order in the table.

Torque

(11±1) N·m

5

1

3

7

6

2

4

8

4). Install camshaft front bearing cap according to the order in the table, tighten 3

bolts.

Torque

(20±1) N·m

3

1

2

3. Install valve timing adjuster

1). Install the fixing bolts of valve timing
adjuster

Torque

(70±5)N·

m

4. check valve clearance

Engine Mechanical System

Engine Mechanical System 42

1). Measure valve clearance at A position in the drawing.

2). If valve clearance isn’t within the standard, need to be adjusted.

3). Rotate crankshaft 360°clockwise, making 4 cylinders piston at
the compression TDC position.

4). Measure valve clearance at B position in above drawing.

EX

△

Caution

Be sure to note down measure value,

which is key parameters for calculating the suitable
tappet mark.

5. Check mechanic tappet

1). Remove the mechanic tappet where the valve clearance is
disqualified, and adjust the valve clearance.

2). Use micrometer caliper, measure the thickness of removed
mechanic tappet.

3).

。According to the measured valve clearance and thickness of

old tappet, calculate the thickness of new tappet, to make sure

valve clearance reaches within the regulated range.

Intake thickness of new tappet = thickness of old tappet +[ measured
valve clearance -0.22mm]

Exhaust thickness of new tappet = thickness of old tappet
+[ measured valve clearance -0.30mm]

Engine Mechanical System

Engine Mechanical System 43

6. Install timing chain

7. Install chain wheel compartment cover

8. Install crankshaft front oil seal

9. Install cylinder cover shield component

10. Install oil sump assembly

11.Install oil level gauge component

12. Install crankshaft pulley

13.Install water pump pulley

14. Install idle wheel

15. Install compressor assembly

16. Install alternator

17. Install alternator belt

18. Install engine assembly

19. Install transmission assembly

20. Install right driving axle assembly

21. Install left driving axle assembly

22. Install right front wheel

23. Install left front wheel

24. Install starter

25. Install clutch working cylinder

26. Install back-up lamp switch

27. Install battery tray

28. Install battery

29. Install air filter assembly

30. Install water inlet and outlet assembly of warm wind

31. Install pipe and expansion valve assembly

32. Install intake hose

33 . Fill Freon, refrigerant oil

34. Fill coolant

35. Fill engine oil

36. Fill transmission lubricant

37. Fill clutch hydraulic oil

38. Install engine right front cover shield

39. Install left front cover shield

40. Connect battery cathode cable

41. Close engine cover