JAC S2. Elctrical Wiring diagrams — part 2

Starting and Charging System

Starting and Charging System

8

Generator Charging Indicator Light not ON

Fault phenomenon: Charging
indicator light not on

Check

generator

wiring

harness

connector

B05-3

terminal, short circuit terminal
3 to ground

Check wiring harness resistance
between

generator

wiring

harness

connector

B05-3

terminal and combination meter
Resistance standard value: less
than 1Ω

Replace combination meter

Fault removed

Whether accord with
standard value

Observe whether
charging indicator
light is on

Replace generator

Maintain

wiring

harness

between

generator

wiring

harness

connector

B05-3

terminal

and

combination

meter and connector fault

Yes

Yes

No

No

Starting and Charging System

Starting and Charging System

9

Generator Charging Indicator Light Always On

Fault removed

Fault phenomenon: Charging
indicator light always on

Check

generator

wiring

harness

connector

B05,

disconnect connector B05

Check voltage of generator
wiring harness connector B05-
2 terminal
Voltage standard value: 11V-
14V

Check voltage of generator
wiring harness connector B05-
2 terminal
Voltage standard value: 11V-
14V

Whether accord with
standard value

Whether accord with
standard value

Replace generator

Maintain circuit fault between
generator B+ and battery and
state of generator fuse ESF13

Maintain

wiring

harness

between generator wiring
harness

connector

B05-2

terminal and fuse and state of
fuse

Maintain wiring harness
between generator wiring
harness connector B05-3
terminal and combination
meter

Observe whether
charging indicator
light is off

Yes

Yes

Yes

No

No

No

Starting and Charging System

Starting and Charging System

10

III、Disconnection and Connection of Battery Electrode

（I）Disconnection

1. Open engine cabin cover

2. Disconnect negative electrode of battery

1). Ensure ignition switch to be in “OFF”;

2). Loosen negative electrode nut ① of battery, and take
down negative electrode of battery;

3. Disconnect positive electrode of battery

1). Open electrode protection cover ②, loosen positive

electrode nut ③ of battery, and take down

positive electrode of battery；

（II）Connection

1. Connect positive electrode of battery

1). Ensure ignition switch to be in “OFF”;

2). Install positive electrode of battery, tighten nut ③, and close
positive protection cover

②;

Tighten torque

5~8N·m

Starting and Charging System

Starting and Charging System

11

2. Connect negative electrode of battery

1). Install negative electrode ① of battery,
tighten fixe nut of negative electrode;

Tighten torque

5~8N·m

3. Close engine cabin cover.

IV、Press plate of Battery

（I）Removal

1. Open engine cabin cover

2. Disconnect negative electrode of battery; refer to “Disconnection and connection of battery electrode”;

3. Remove press plate of battery;

1). Remove battery press rod nut ①, and take down press rod of battery and press plate of battery②;

（II）Installation

1. Install press plate of battery;

1). Install battery press rod and battery press plate ②, tighten
battery press plate nut ①;

Tighten torque

5~8N·m

2. Connect negative electrode of battery;

3. Close engine cabin cover;

Starting and Charging System

Starting and Charging System

12

V、Battery Assembly

（I）Removal

1. Open engine cabin cover;
2. Disconnect negative electrode of battery; refer to “Disconnection and connection of battery electrode”;
3. Disconnect positive electrode of battery; refer to “Disconnection and connection of battery electrode”;
4. Remove battery press plate; refer to “Removal of press plate of battery”;
5. Remove battery assembly;
1). Take down battery assembly;

S2-w4009b

（II）Installation

1. Install battery assembly;

1). Place battery assembly to battery pallet;

2. Install press plate of battery;
3. Connect positive electrode of battery;
4. Connect negative electrode of battery;
5. Close engine cabin cover;

（III）Inspection

1. Visually inspection
1). Check whether electrode is damaged; replace any damaged or electrode clamp deformed battery electrode;
2). Check whether battery baseplate and battery press plate or press rod are damaged; replace any damaged parts;
3). Check whether battery casing there is crack or other damage causing electrolyte leaking;
4). Check whether battery electrode is loose; replace any damaged parts;
5). Check test indicator observed hole (if equipped) inside battery, whether display battery condition. If battery
already discharged, please charge.

2. Voltage inspection

Starting and Charging System

Starting and Charging System

13

1). U>13.2V, please check electrical system;
2). 12.5V<U<12.9V, system is normal;
3). 11V<U<12.4V, please check charging system;
4). U<11V, indicates that battery is damaged or charging system fault, please check charging system and battery.

VI、Battery Pallet

（I）Removal

1. Open engine cabin cover;
2. Disconnect battery negative electrode; refer to “Disconnection and connection of battery negative electrode”;
3. Disconnect battery positive electrode; refer to “Disconnection and connection of battery electrode”;
4. Remove battery press plate; refer to “battery press plate”;
5. Remove battery assembly; refer to “battery assembly”;
6. Remove battery pallet;
1). Disconnect 4 buckles ① connected battery pallet and pipe
wiring harness;
2). Remove 2 connected bolts ② of battery pallet and lower
bracket of junction box;
3). Remove 4 bolts ③ of battery pallet and lower bracket hole of
pallet;
4). Remove fixed bolt ④ of battery pallet and vehicle body;
5). Take down battery pallet assembly;

（II）Inspection

1. Check battery pallet;
1). Check whether battery pallet corroded. If any, please clean with clean hot water.

（III）Installation

1. Install battery pallet;
1). Align battery pallet to installation hole of pallet lower bracket;
pre-tighten fixed bolt ④ connected battery pallet and vehicle
body;
Tighten torque 5~8N·m
2). Tighten 4 fixed bolts ③ connected battery pallet and pallet
lower bracket;
Tighten torque 12~15N·m
3). Tighten 2 bolts ② connected battery pallet and lower bracket
of junction box;

Tighten torque 5~8N·m
4). Connect 4 buckles ① connected battery pallet and pipe
wiring harness;


2. Install battery assembly;
3. Install battery press plate;
4. Connect battery positive electrode;
5. Connect battery negative electrode;
6. Close engine cabin cover;

Starting and Charging System

Starting and Charging System

14

VII、Generator

（I）Removal

1. Open engine cabin cover;

2. Disconnect battery negative electrode; refer to “Disconnection and connection of battery electrode”;

3. Remove engine intake hose; refer to “intake hose assembly”;

4. Remove air filter assembly; refer to “Air filter assembly”;

5. Remove electronic throttle valve; refer to “Electronic throttle valve”;

6. Remove intake manifold, refer to “intake manifold”;

7. Remove generator belt;

8. Remove generator

1). Disconnect generator wiring harness connector ①;

2). Remove fixed bolts ② of generator (power supply)
wiring harness connector
3). Remove lower nut ③ of generator, and take down
square-head

nut;

4). Remove generator regulating nut ④;

5). Rotate generator regulating nut ⑤ anticlockwise, and take down movable pin;

6). Take down generator;

（II）Installation

1. Install generator;

1). Place generator to installation position;

2). Install movable pin, tighten generator regulating nut ④;

Tighten torque

20~25N·m

3). Tighten generator regulating bot ⑤;

4). Install square-head bolt, and tighten fixed nut ③;

Tighten torque

42~52N·m

5). Install connected bolt ② of generator (power supply);

Tighten torque

10~14N·m

6). Connect engine wiring harness connector ①;

2. Install generator belt;

3. Install intake manifold;

4. Install electronic throttle valve;

5. Install air filter assembly;

6. Install engine intake hose;

7. Connect battery negative electrode;

8. Close engine cabin cover;

Starting and Charging System

Starting and Charging System

15

VIII、Starter

（I）Removal

1. Open engine cabin cover;

2. Disconnect battery negative electrode;

3. Remove engine intake hose; refer to “Intake hose assembly”;

4. Remove air filter assembly; refer to “Air filter assembly”;

5. Remove electronic throttle valve; refer to “Electronic throttle valve”;

6. Remove intake manifold; refer to “Intake manifold”;

7. Remove starter

1). Disconnect starter wiring harness connector①;

2). Remove fixed nut ② of starter (power supply) wiring

harness

connector;

3). Remove 2 fixed bolts ③ in upper and lower part of starter, and take down starter;

（II）Installation

1. Install starter

1). Tighten 2 fixed bolts ③ in upper and lower part of starter, and install starter;

2). Install fixed nut ② of started (power supply) wiring

harness

connector;

3). Connect wiring harness connector ① of starter;

Starting and Charging System

Starting and Charging System

16

2. Install intake manifold;

3. Install electronic throttle valve;

4. Install air filter assembly;

5. Install engine intake hose;

6. Connect battery negative electrode;

7. Close engine cabin cover.

Air-conditioning Device

Air-conditioning Device

17

Air-conditioning Device

I、Summary

（I）System outline

The vehicle applies manual control A/C system. A/C condenser applies supercooled type, thus improving cooling
performance. To enhance defrost performance, when choose mixing and defrost mode, it is manually switched to
A/C mode. Based on the vehicle speed, cooling water temperature, and different pressure of air conditioning
refrigerant, the condenser fan has two speed control modes - low and high speed control. The increase of the
blower air volume and the improvement of the air mixing capability will improve cooling and heating
performance.

Control Type and Performance Description of A/C Control Panel

A/C control applies manual control type, panel is integrated with rear defrost heating switch, panel illumination
applies backlight/LED, button symbol applies spray-paint laser engrave; button and knob function of A/C panel
are shown as picture below.

1. A/C switch 6. Intake internal and external circulation button
2. Defrost and demist mode button 7. Rear defrost button
3. Blowing rate regulating button 8. Temperature regulating button
4. Blowing face mode button 9. Blowing feet defrost mode button
5. Blowing face and feet mode button 10.Blowing feet mode button

System Component

1. A/C host assembly

A/C host assembly consists of blower, expansion valve, evaporator, heater and casing. Blower intakes external air and gets

into vehicle through evaporator and heater to realize A/C normal working.

2. Blower

Blower consists of motor and fan, using intake port air door motor to switch internal and external air circulation mode, and

intake internal air and external air. Function of intake port air door motor is realized by internal and external air button of

controller. When in internal circulation mode, intake from two intake port in the side; when in external circulation mode, intake

through filter on front guard cover of vehicle, at the same time using blower inletting air, and carry out heat exchange through

evaporator, refrigerated air getting into vehicle.

3. Speed regulating module

The system uses speed regulating resistance, totally divided 4 grade, not variable speed regulating.

4. Air door motor

Installed in blower assembly, controlled by A/C internal and external circulation selection button, drive internal and external

circulation air door to realize switch of air intake way.

A/C control panel (manual) diagrammatic sketch

Air-conditioning Device

Air-conditioning Device

18

5. Blower motor

Rotating fan forms A/C system required air quantity by vehicle power supply.

6. Evaporator temperature sensor

Detecting temperature of evaporator core, pass signal to controller to

prevent evaporator from freezing. It is installed in evaporator core. Sensor has a

negative temperature coefficient thermistor, thus resistance increase when

temperature decreases, and resistance decreases when temperature rises.

7. Evaporator and heater

Air sent by blower goes through evaporator and gets cooled, some air through the evaporator will be sent to heater core, and

the rest is supplied to upper portion of heater housing, according to opening and closing degree of temperature control damper. In

order to control indoor temperature regulation and air mixing, air from heater core will be mixed with the air of the upper portion

of the housing in the heater housing rear section. Controlled by the mode damper motor, the mixed air is sent to the required outlet

so as to realize the vehicle interior temperature regulation and defrost / defog function. In short, the heater assembly adjusts air

mixing, and controls temperature and wind direction.

8. Mode motor

Installed in the left part of the heater housing, controlled by signal of A/C panel (ETC) mode switch, it can start small motor

inside air door motor to adjust the position of mode air door. When motor starts, changes in the voltage difference will be sent to

ETC, and ETC will judge the feedback signal. When the air door moves to the required position, the motor will stop working.

9. Temperature motor assembly

Installed in the right part of heater housing, controlled by signal of A/C controller temperature knob, it can start small motor

to regulate position of temperature controlled air door. When motor starts, changes in the voltage difference will be reflected to

A/C controller, and A/C controller will judge the feedback signal. When air door moves to required position, motor will stop

working.

10. Condenser and drier

High temperature & high pressure gas refrigerant from compressor will be cooled down at normal temperature. Cooling of

the condenser relies on traveling wind and forced air volume of fan. This model uses a parallel flow condenser, combined with

drying bottles together. Undercooling can improve cooling performance, reducing the amount of refrigerant system needs, and also

reduce number of parts combining with drying bottles. When the system is contaminated, previously drying bottles would be

replaced. But for this model, you can just remove the cap of the lower part of the drying bottle and replace the desiccant.

11. Engine cooling system

After comparing inputted vehicle speed, A/C load, coolant temperature value, engine ECU is divided into two parts (high/low)

to control speed of cooling fan. When vehicle speed signal and coolant temperature sensor failure, driving cooling fan will be high

speed running at the same time. Cooling fan is integrated in front module, switching to high/low speed through collecting coolant

temperature, vehicle speed etc. related information.

Condenser fan equipped with 1.5 engine, when high speed, power is 180～220W; when low speed, power is 120～150W;

Condenser fan equipped with 1.3 engine, when high speed, power is 140～150W; when low speed, power is 120～130W.

12. Ternary pressure switch

Ternary pressure switch is to increase the medium pressure switch to conventional A/C binary pressure switch. When the

system pressure rises, the medium pressure switch is activated and sends signals to the engine control unit. At this moment, radiator

fan and condenser fan keep high speed; it can prevent performance degradation caused by the pressure rises. Also, air conditioning

systems will be protected when abnormal pressure (high/low pressure) occurs.

R-T Curve table

R

esi

st

an

ce

Air-conditioning Device

Air-conditioning Device

19

（II）Component Position

1. Condenser assembly 4. A/C host assembly

2. Exhaust pipe assembly 5. A/C controller assembly

3. Pipe and expansion valve assembly 6. Heating air inlet/outlet water pipe assembly

Air-conditioning Device

Air-conditioning Device

20

（III）Operating Principle

A/C control system operating principle

Refrigerating principle diagram

Wind speed
button

Temperature
sensor

A/C switch

Temperature
knob

Mode switch

Internal/external
circulation
switch

Internal/external
circulation motor

Blower

A/C clutch

Pressure
switch

Cooling/heating
regulating motor

Wind

direction

regulating motor

Feedback signal

Position signal

Position signal

Defrost request

Defrost feedback signal

A/C

control

module

When the vaporific refrigerant
vaporizes into gas, it can absorb the
heat from the air through the
evaporator by the use of blower.
(lower

down

the

surrounding

temperature)

Driven by the engine pulley,
it

can

turn

the

low

temperature and low pressure
gaseous refrigerant into high
temperature

and

high

pressure gas and send it to the
compressor, controlled by
the clutch.

Installed in the front of the car, it can turn the
gaseous refrigerant into high temperature and high
pressure liquid refrigerant.

The refrigerant rapidly
expands and turns into low
temperature

and

low

pressure liquid.

It can absorb the
moisture

in

the

refrigerant and store
the refrigerant.

Condenser

Expansion
valve

Receiver
drier

Evaporator

Air-conditioning Device

Air-conditioning Device

21

Air flow to be changed according to the following pattern

:

Wind control

Operating position

Operation

Wind speed

regulating

Rotate fan control button, clockwise rotating knob can increase fan speed,
anticlockwise rotating knob can decrease fan speed.

Rear window defrost

Pressing the button can open or close rear window defrosting function.

A/C

Pressing the button can open or close A/C compressor. When pressing A/C button,
indicator light on button will be on, which indicates A/C compressor already starts
and begins to refrigerate; pressing the button again can close A/C compressor. When
weather is hot, open vehicle window to exhaust hot air in vehicle, and then close
vehicle window. It is helpful to shorten required time of vehicle refrigerating, and
also helpful to improve system running efficiency.

Internal circulation

mode

This mode is to prevent external air from getting into vehicle. It can be used to
prevent external air and abnormal smell from getting into vehicle, or used to increase
or decrease air temperature inside vehicle more fast. Pressing this button can open or
close internal circulation mode. Using internal circulation mode for long time may
cause window fogging. If window fogging, select defrost mode.

Mode regulating

This mode guides some air flow to floor air outlet, and guides some air flow to
front windshield and side window to defrost.

Mode regulating

This mode guide most air flow to floor air outlet. Make sure there is no obstacle
under front seat to guide air flow to the back of carriage.

This mode guides some air flow to front air outlet of dashboard, and guides some
air flow to floor air outlet.

This mode guides air flow to front air outlet of dashboard.

This mode guide most air flow to front windshield and side window to demist. This
mode guide most air flow to front windshield and side window to defrost.

（IV）Maintenance Parameter/Technical Parameter

Item

State

Parameter

Remark

Refrigerant filling

amount

Replace pipe

30cc

When replacing compressor, subtract

The result that minus the amount of refrigerant oil
discharged from old compressor in the amount of
120ml is the required amount that needs to be
discharged from new compressor.

Replace condenser

30cc

Replace evaporator

30cc

△Note Even though there is no refrigerant discharged from removed compressor, don’t discharge more than 50ml
refrigerant from new compressor.

Air-conditioning Device

Air-conditioning Device

22

（V）Maintenance Note

△Warning Please obey to the following notes when checking and maintaining A/C system, or else it may cause vehicle
damage and personal injury.

1. Freezing point of refrigerant is low, and volatility is high, thus must use gloves and glasses in order to prevent phenomenon of
skin pernio and blindness due to contact with skin.

2. If refrigerant splashed to eyes or contact with skin, should clean contact part with clean water immediately, and must go to
ophthalmology department and dermatology department to consult. Don’t kneading eyes by eyes or handkerchief.

3. When do operation related to refrigerant, place must be ventilated. A large amount of refrigerant discharged in enclosed place
will cause hypoxia phenomenon.

4. Refrigerant discharged permitted amount: 1000ppm (ppm is volume of the material contained in the air of the one million

volume) (4184mg/ ㎡); when discharged amount too much, it may cause heart and cardiovascular system, immune system

abnormal or irritability; respiratory system abnormal or skin disease.

5. When doing operation related to refrigerant, make sure there is no foreign matter of moisture and dust around, this foreign
matter will flow into A/C system and will be harmful to system.

6. When doing operation related to refrigerant, must prepare gas leakagemeter. When R-134a refrigerant contact with high
temperature obstacle, it will produce harmful gas, therefore pay attention to prevent leakage.

7. A/C system of the vehicle must use R-134a refrigerant. If using other refrigerant, it will cause bad influence to system
component.

8. R134a refrigerant and R-12 refrigerant are imcompatible, thus little amount can’t be mixed.

9. When doing operation related to refrigerant, make sure there is no pyrophorus or combustible obstacle around vehicle, and pay
special attention that refrigerant jar will cause bomb in heat source.

10. R134a container is high pressure state, must not be placed in high temperature environment, and must check whether storage

environment temperature is under 52℃.

11. A/C component generally uses dustproof cover in order to prevent drainage, dust, moisture flowing in. Dustproof cover should
be removed before operating and sealed after operating.

12. Synthetic oil (PAG) with R-134a is more easier to absorb water than R-12, and absorptivity is 10 times higher than mineral oil
(MINERAL). Too much water will infect compressor, lubrication function and durability.

13. Influence of moisture to A/C system is very bad, therefore it’s better to avoid operation in rain day.

14. When A/C system re-installed after removed, should spread refrigeration oil to O-type seal ring, especially bolt-type
connection part, should first be installed manually and then assemble with two spanners.

15. When assembling flange-type connection part, should push pipe slightly and connect nut and bolt.

16. When installing A/C, assembling with torque more than required torque or force of clamping O-type seal ring too large will
cause refrigerant leakage, therefore operate according to required.

17. Hose can’t be distorted.

18. Don’t separate A/C system before recycling refrigerant absolutely. If separated before recycling, it will discharge refrigerant
and refrigeration oil under the influence of system pressure, and it may pollute environment.

19. When replacing A/C component, must fill refrigeration oil (type: PAG) when filling refrigerant and refrigeration oil.

（VI）Special Tool

No.

Tool No.

Tool name

Outside drawing

Use

1

Digital multimeter

Air-conditioning Device

Air-conditioning Device

23

No.

Tool No.

Tool name

Outside drawing

Use

2

High strength invisible lights

3

Pliers

4

R-134a manifold gauge

5

Halogen leak detector

6

Tracer color syringe

7

R134a tracer pigment

8

Micro thermometer

9

Forward flow control valve