JAC S2. Engine. Service Manual — part 9

Engine cooling system

Engine intake system 107

△

Caution

If measured value exceeds regulated range, please replace thermostat.

Engine cooling system

Engine intake system 108

3). Check the biggest lift stroke

of thermostat valve

：≥ 8mm。

△

Caution

If measured value exceeds regulated range, please replace thermostat.

(III)Installation

1. Install thermostat

1). Replace thermostat seal ring, install thermostat into installation hole.

2. Install inlet of water pump

1). Clean the connection surface of inlet of water pump
and cylinder body.

2). Install water pump water inlet onto cylinder body,
tighten fixing bolts.

3). Connect inlet of water pump and outlet of radiator.

3. Fill cooling liquid

4. Connect battery cathode cable

5. Close engine cover

Engine cooling system

Engine intake system 109

XI、Pulley of water pump

(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 water pump pulley

1). Disassemble 4 fixing bolts of water

pump pulley

2). Remove water pump

pulley

Engine cooling system

Engine intake system 110

(II)Installation

1. Install water pump pulley

1). Put water pump pulley onto cylinder body, tighten fixing bolts.

Tightening torque: 8.4±0.6N·

m

2. Install alternator belt

3. Install engine assembly

4. Install transmission assembly

5. Install right driving axle assembly

6. Install left driving axle assembly

7. Install right front wheel

8. Install left front wheel

9. Install starter

10. Install clutch working cylinder

11. Install back-up lamp switch

12. Install battery tray

13. Install battery

14. Install air filter assembly

15. Install water inlet and outlet assembly of warm wind

16. Install pipe and expansion valve assembly

17. Install intake hose

18. Fill Freon, refrigerant oil

19. Fill coolant

20. Fill engine oil

21. Fill transmission lubricant

22. Fill clutch hydraulic oil

23. Install engine right front cover shield

24. Install left front cover shield

25. Connect battery cathode cable

26. Close engine cover

Engine cooling system

Engine intake system 111

XII、water pump

(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 water pump pulley, refer to water pump pulley

28. Disassemble water pump

1). Disassemble 4 fixing bolts of

water pump

2). Take off water pump

and seal ring

(II)Check

1. Check water pump

1). Check if there is severe rust, water seal leakage or corrosion in water pump.

2). Check if there is poor operation caused by big clearance.

3). Check if bearing of water pump is blocked or damaged, please replace if necessary.

Engine cooling system

Engine intake system 112

(III)Installation

1. Install water pump

1). Clean seal surface of water pump.

2). Replace with new seal ring of water pump.

△

Caution

Seal ring of water pump is one-off component, must

replace new seal ring of water pump whenever
disassembly or installation.

3). Tighten 4 fixing bolts of water pump.

2. Install water pump 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, refer to intake
hose assembly

19. Fill Freon, refrigerant oil

20. Fill coolant

21. Fill engine oil

22. Fill transmission lubricant

23. Fill clutch hydraulic oil

24. Install engine right front cover
shield

25. Install left front cover shield

26. Connect battery cathode cable

27. Close engine cover

Engine cooling system

Engine intake system 113

XIII、warm wind backwater steel tube

(I)Disassembly

1. Open engine cover

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

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

4.

Disassemble air filter bracket

II

, refer to air filter bracket

II

5.

Disassemble electronic throttle valve, refer to electronic throttle valve

6.

Disassemble intake manifold, refer to intake manifold

7.

Disassemble

warm wind backwater steel tube

1).

Disassemble 2 bolts connecting

warm

wind backwater steel tube and water pump.

2).

Disassemble 1 bolts connecting

warm wind backwater

steel tube and cylinder cover.

3). Disconnect warm wind backwater steel tube and warm wind water inlet and outlet.

4). Take off warm wind backwater steel tube.

Engine cooling system

Engine intake system 114

(II)Installation

1. Install warm wind backwater steel tube

1). Connect warm wind backwater steel tube and warm wind water inlet and outlet.

2).

Install bolts connecting warm

wind backwater steel tube and
cylinder cover.

3).

Install bolts connecting warm

wind backwater steel tube and water

p
u
m
p
.

2. Install intake manifold

3. Install electronic throttle valve

4. Install air filter bracket II

5. Install air filter assembly

6. Connect battery cathode cable

7. Close engine cover

Engine intake system

Engine intake system 115

Engine intake system

I

、Summary

(I)structure overview

System description:

Intake system is composed by air filter, throttle valve, intake manifest and related pipes. Intake

control system is to accomplish tasks like idle control, variable valve control and electronic throttle valve control through control air

intake volume, so as to improve the stability while engine idle working, or improve power, reduce oil consumption and exhaust

pollution.

Idle control

：electronic control system can control idle working of engine automatically, ECU can measure many factors like engine

working temperature and loading through various sensors, define the best idle rotation, and control the air intake volume while idle through

electronic throttle valve automatically, finally control idle rpm. Which enables engine with stable idle rpm under all kinds circumstances,

avoid unstable idle or motor shut down, try to lower the oil consumption while idle and control exhaust.

Electronic throttle valve control

： in all engines equipped with electronic throttle valve, ECM can measure the operation to pedal by

driver through all kinds of sensors, meanwhile, through engine rpm and speed, calculate and define the best valve opening degree under

that condition, control its open through electronic throttle valve operator, making sure car gets the most efficient oil consumption,

improve safety and comfort. Besides, gasoline engine electric control system can also allow TCS/CC through electronic throttle valve.

(II)system principle

air filter can filter the air into the engine by filter the impurity out, which can protect engine.

Electronic throttle valve provides the best control method through ECM according to driver’s

intension, insures engine’s fuel economy.

Intake of engine is a very complicated process, the smoothness of air can influence the efficiency of engine. Eddy

intake manifold used on our engine is convenient for engine to form eddy, improve its volumetric

efficiency.

(III)torque parameter

Key parts torque table

No.

Item

torque(N·m)

Remark

1

air filter installation bolts

8
～
1
2

2

hoop

4
～
6

3

Fixing bolts of intake manifold and and intake manifold bracket

2
2
.
5
±
2
.
5

4

Fixing bolts of intake manifold

1
8
±
1
.
0

(IV)Fault diagnosis

Diagnosis table

No. Fault description

Reason analysis

Solution

Engine intake system

Engine intake system 116

1

Leakage in intake
system

sealing gasket of intake manifold and cylinder cover is
damaged intake manifold

replace

intake manifold and electronic throttle valve is
damaged

replace

seal ring of intake pressure temperature sensor is
damaged

replace

connecting surface of flange is irregular

If necessary , repair or replace related
parts

leakage in connecting position between parts in
intake system

Replace the leaked parts

Engine intake system

Engine intake system 117

II、Intake manifold assembly

(I)Disassembly

1. Open engine cover

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

3. Disassemble upper cover of front bumper, refer to upper cover of front bumper

4. Disassemble intake rigid tube

1). Disconnect the connecting hoop of intake rigid

tube and intake hose.

2). Disassemble 2 fixing bolts between intake rigid tube
and front bumper.

3). Take off intake rigid tube.

5. Disassemble intake hose

1). Disconnect the connecting hoop between intake hose
and lower cap of air filter.

2). Take off intake hose.

Engine intake system

Engine intake system 118

(II)Installation

1. Install intake hose

1). Install intake hose to the lower cap of air filter, tighten hoop.

Tightening torque: 4

～ 6 N·m

2). Connect the intake rigid tube and intake hose, tighten hoop.

2. Install intake righd tube

1). Put intake righd tube into intake righd tube installation hole,
tighten fixing bolts.

Tightening torque: 8

～ 12 N·m

3. Install upper cover of front bumper

4. Connect battery cathode cable

5. Close engine cover

Engine intake system

Engine intake system 119

III、Air filter assembly

(I)Disassembly

1. Open engine cover

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

3. Disassemble air filter assembly

1). Disconnect the connecting hoop between intake hose assembly and
air filter.

2). Loosen the connecting hoop of air filter assembly and air filter

assembly exit pipe, disconnect them.

3). Disassemble 2 fixing bolts of air filter assembly and air filter
bracket II.

4). Disassemble2 fixing bolts of air filter assembly and air filter
bracket I.

5). Take off air filter assembly

Engine intake system

Engine intake system 120

(II) Disassembly

1. Disassemble

air filter assembly

1). Disassemble the connecting bolts of upper and lower shell of

air filter, take out the air filter core.

△

Caution

Need to take out the air filter core slowly, avoiding

dust scattered.

△

Caution

Cover filter body with wet cloth while cleaning the

filter core.

(III)Check

1. Check air filter core

1). See by eyes if the intake side of filter core is too dirty, if yes,

blow clear the filter core from the exhaust side or change filter

core.

(IV)Assembly again

1. Assemble air filter assembly

1). Install air filter core, connect upper and lower shell of air filter

with screws and tighten.

Tightening torque: 8

～ 12 N·m

(V)Installation

1. Install air filter assembly

1). Connect air filter assembly and air filter exhaust pipe assembly,

tighten hoop.

Tightening torque: 4

～ 6 N·m

Engine intake system

Engine intake system 121

2). Put the air filter assembly into its installation hole, tighten

fixing bolts connecting air filter and air filter bracket I.

Tightening torque: 8

～ 12 N·m

3). tighten fixing bolts connecting air filter and air filter
bracket II.

Tightening torque: 8

～ 12 N·m

4). Connect air filter assembly and intake pipe assembly,
tighten hoop.

Tightening torque: 4

～ 6 N·m

2. Connect battery cathode cable

3. Close engine cover

Engine intake system

Engine intake system 122

IV、Air filter exhaust pipe assembly

(I)Disassembly

1. Open engine cover

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

3. Disassemble air filter exhaust pipe assembly

1). Loosen the connecting hoop of air filter assembly and air filter

exhaust hose, disconnect them.

2). Loosen the steel-belt-type elastic strap, remove respirator

ventilation ducting out of air filter exhaust pipe.

3). Loosen ring clamp, take off air filter exhaust pipe assembly

from electronic throttle valve.

(II) Check

1. Check air filter exhaust pipe assembly

1). Check if air filter exhaust pipe is cracked, damaged or worn, replace if necessary.