Engine Volume

Maintenance Manual of Tojoy Sedan Contents
Engine Volume
Chapter 1 Mechanical Part of Engine ............................................................................1
Section 1 Engine Body ...................................................................................................................1
I. General Precautions ....................................................................................................1

II. Precautions on Sealant................................................................................................2
III. Preparation ..................................................................................................................4
IV. Engine Assembly .........................................................................................................7
V. Drive Belt ...................................................................................................................11
VI. Air Cleaner and Air Duct ............................................................................................13
VII. Intake Manifold and Exhaust Manifold .......................................................................16
VIII. Exhaust System.........................................................................................................20
IX. Timing Belt Mechanism..............................................................................................22
X. Rocker Arm and Camshaft.........................................................................................28
XI. Cylinder Cover ...........................................................................................................32
XII. Valves ........................................................................................................................37
XIII. Cylinder Body Assembly ............................................................................................43
XIV. Diagnosis of Common Troubles.................................................................................58
XV. Maintenance Parameters...........................................................................................60
Section II Engine Lubrication System ...........................................................................................64
I. Precautions................................................................................................................64
II. Preparation ................................................................................................................65
III. Engine Oil ..................................................................................................................66
IV. Oil Filter .....................................................................................................................68
V. Oil Pan and Engine Oil Pump ....................................................................................70
Section III Cooling System of Engine............................................................................................75
I. Precautions................................................................................................................75
II. Cooling Circuit ...........................................................................................................77
III. Engine Coolant ..........................................................................................................78
V. Radiator Cooling Fan .................................................................................................83
VI. Water Pump...............................................................................................................84
VII. Thermostat Sub-assembly .........................................................................................85
VIII. Water Piping Sub-assembly.......................................................................................88
IX. Trouble Analysis ........................................................................................................89
X. Maintenance Parameters...........................................................................................90
Section IV Fuel Supply System of Engine ....................................................................................91
I. General Precautions ..................................................................................................91

II. Preparation ................................................................................................................92
III. Fuel System...............................................................................................................92
IV. Fuel Injector and Guide Rail ......................................................................................93
V. Fuel Filter...................................................................................................................97
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VI. Fuel Pump Assembly .................................................................................................99

VII. Fuel Tank Assembly ................................................................................................103
VIII. Acceleration Control Device.....................................................................................105
Section V Emission Control System of Engine ...........................................................................107
I. Fuel Evaporation System.........................................................................................107

II. Forced Ventilating System of Crankcase .................................................................111
Chapter 2 Electrical Part of Engine ........................................................................... 114

Section 1 Ignition System ...........................................................................................................114
I. Ignition coil...............................................................................................................114
II. Diagnosis of Common Troubles...............................................................................117
III. Maintenance Parameters.........................................................................................117
Section 2 Starting and Charging System ....................................................................................118
I. Basic Diagram of Starting and Charging System.....................................................118

II. Storage Battery........................................................................................................118
III. Starting System .......................................................................................................121
IV. Charging System .....................................................................................................129
Chapter III Electronic Control System of Engine......................................................135

Section I Precautions..................................................................................................................135
I. Precautions of Supplement Restraint System (SRS) ...............................................135

II. General Precautions ................................................................................................135
III. Precautions in Maintenance.....................................................................................135
IV. Precautions of On-board Diagnosis (OBD) System .................................................136
Section II Structural Principle and Overhaul of Engine Control System ......................................139
I. System Illustration ...................................................................................................139

II. Multiple-point Fuel Injection System ........................................................................139
III. On-board Diagnosis System ....................................................................................143
IV. Engine Trouble Diagnosis........................................................................................147
Section III Structural Principle and Overhaul of Engine Electronic Elements..............................153
I. Intake Manifold Absolute Pressure (MAP) Sensor...................................................153

II. Engine Coolant Temperature (ECT) Sensor ............................................................155
III. Air Throttle Position Sensor (TPS)...........................................................................157
IV. Camshaft Position Sensor (CMP) ............................................................................159
V. Crankshaft Position Sensor (CKP)...........................................................................160
VI. Heated Oxygen Sensor (HO2S) ..............................................................................162
VII. Fuel Injector (INJ) ....................................................................................................164
VIII. Stepper Motor (IAC).................................................................................................165
IX. Knock Sensor (KS) ..................................................................................................167
X. Air Conditioner Switch and Relay ............................................................................168
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XI. Carbon Canister Solenoid Valve..............................................................................168

XII. Ignition Coil ..............................................................................................................171
XIII. Electric Fuel Pump...................................................................................................172
XIV. Electronic Control Module (ECM) of Engine ............................................................173
Section IV Trouble Diagnosis Procedures for Engine Control System........................................177
I. Diagnosis by Trouble Code......................................................................................177

II. Diagnosis by Trouble Phenomena ...........................................................................205
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Mechanical Part of
Maintenance Manual of Tojoy Sedan Engine
Chapter 1 Mechanical Part of Engine

Section 1 Engine Body
I. General Precautions
1. Precautions on Discharging Engine Coolant
Discharge the engine coolant after the engine has cooled down.
2. Precautions on Disconnecting Fuel Pipeline
1) Before the operation, ensure that the operating area is free of objects which may cause combustion
or sparks.
2) Before disconnecting and disassembling the fuel pipeline, release the fuel pressure.
3) After disconnecting the fuel pipeline, plug the opening to prevent fuel leakage.
3. Precautions on Dismantlement and Disassembly
1) Use special tools when the instructions require so. Always pay attention to safe operation, and
forcible operations or operations against the instructions shall be forbidden.
2) Take particular care not to damage the matching face or the sliding face.
3) Use the adhesive tape or its equivalent to seal the opening of engine system so as to prevent the
entry of foreign bodies, if necessary.
4) For the purpose of troubleshooting and reassembly, methodically mark and neaten the
disassembled parts.
5) When loosening the bolts and nuts, follow this basic principle: “outmost ones first, diagonal ones
second, and so on”. Conduct the operation in compliance with the loosening sequence, if the
sequence is specified.
4. Precautions on Check, Repair and Replacement
Thoroughly check the parts before the repair or replacement. Check the substitutive parts by the same
means, and then replace them, if necessary.
5. Precautions on Assembly and Installation
1) Use the torque spanner to screw up the nuts and bolts.
2) When screwing up the nuts and bolts, follow this basic principle: screw up the central nuts and bolts
with the same tightness and in steps, and then carry out the same operation with the internal and
external diagonal ones. Perform the operation in accordance with the screwing sequence, if it is
specified.
3) Replace the liner, oil seal or O-ring with new ones.
4) Thoroughly rinse, clean and dry every part. Carefully check the engine oil pipeline or engine coolant
pipeline for obstruction.
5) Never damage the sliding face and the matching face. Completely eliminate the foreign bodies,
such as the cloth scraps or the dust. Before the assembly, slick the sliding face with the engine oil.
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Mechanical Part of
6) In case of draining and then adding the engine coolant, release the air from the pipes first.
7) After the repair, start the engine and raise its speed to check it for leakages of the engine coolant,
fuel, engine oil and tail gas.
6. Parts Needed to Be Screwed Up with Specified Angle
1) Use the angle spanner to finally screw up the following engine parts:
- Cylinder cover bolt
- Bolt of main bearing cap
- Connecting rod nut
2) Do not conduct the final tightening in accordance with the torque values.
3) The torque values for these parts are applied to the pre-tightening steps.
4) Ensure that the surfaces of threads and pedestal are clean and coated with the engine oil.
II. Precautions on Sealant

Fig.1.1.001
1. Removal of Sealant
After dismounting the fixing nuts and bolts, use the

scraper to detach the matching faces and remove
the old sealant.
Slide
Attention: Knock
■ Do not damage the matching faces.
■ Insert the scraper, and then knock its side to

slide it as shown in the figure.
■ For the positions where it is difficult to use the

scraper, lightly knock the parts to dismount
Fig.1.1.002
them with a plastic hammer.
Scraper
■ If you have no choice but to use the tools such
as a screwdriver, be carefull not to damage
the matching faces.
2. Application Steps of Sealant
1) Use a scraper to remove the attached old

sealant from the application and matching
faces of liner.
Attention:
■ Thoroughly remove the old sealant from the

surfaces of groove, fixing bolt and bolt hole
where the sealant was applied.
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Mechanical Part of
2) Wipe the matching faces and application faces of sealant with the unleaded petrol, and eliminate the
attached water, lubricating grease and foreign bodies.
3) Put the sealant (with the specified size) in the

specified position. Fig.1.1.003
Attention:
■ Put the sealant into the groove for it, if any.
■ Generally, the sealant is put inside the bolt Fig.1.1.004 Inner

hole; however, it is occasionally put outside Side
the bolt hole.
■ Install the matching elements within 5minutes

Groove Bolt Hole
after the sealant has been applied.
■ Eliminate the dirt from the sealant, if any.
■ Do not re-screw down the nuts or bolts after

their installation. Inner Side
■ Add the engine oil and the engine coolant

30min after the installation has been finished.
Attention:
■ Conduct the operation in accordance with the

instructions specified in this manual.
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Mechanical Part of
III. Preparation
1. Maintenance Tools
List of Special Tools

No. Tool Appearance Code Description
Used to fix
1 End forked clamp the camshaft
timing gear
JAC-T1D001
Used together
2 Pin with the end
forked clamp
Used to install
Locating tool for
3 and dismantle
piston pin
the piston pin
JAC-T1F005
Used together
with the
4 Guide sleeve
locating tool
for piston pin
Used to fix
5 Flywheel chock JAC-T1F011
the flywheel
Used to
Valve spring
6 JAC-T1F012 compress the
compressor
valve spring
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Mechanical Part of
Used to install
Oxygen sensor and dismantle
7 JAC-T1F015
sleeve the oxygen
sensor
Used to
Dismantlement
8 JAC-T1F017 dismantle the
tool for oil pan
oil pan
Used to install
Installer for valve
9 JAC-T3F001 the valve oil
oil seal
seal
Used to install
Installer for
10 JAC-T3F002 the camshaft oil
camshaft oil seal
seal of engine
Functioning as
Guide for front oil a guide during
11 seal of JAC-T3F003 the installation
crankshaft of front oil seal
of crankshaft
Used to install
Installer for front
the front oil seal
12 oil seal of JAC-T3F004
of engine
crankshaft
crankshaft
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Mechanical Part of
Installer for rear Used to install

13 oil seal of JAC-T3F005 the rear oil seal
crankshaft of crankshaft
2. List of Auxiliary Materials for Assembling Engine
List of Auxiliary Materials for Assembling Engine
No. Name Application Specification and Grade

5W-30 (for winter of north) or
Engine 15W-40 (for summer of north and
1 Used during filling or assembly
oil whole year of south); quality grade:
SJ or above
Silica Engine oil pump, water pump, oil pan and rear
2 LT5699 or equivalent
gel oil seal housing of crankshaft
Oil pressure switch, draining screw plug and
3 Sealant LT243 or equivalent
flywheel bolt
Coolant temperature sensor and water
4 Sealant LT648 or equivalent
temperature warning switch
5 Petrol RON93# unleaded petrol or above
6 Sealant Double-head bolt LT271 or equivalent
3. List of Auxiliary Materials for Assembling Cylinder Cover
List of Auxiliary Materials for Assembling Cylinder Cover
No. Name Present Material and Model Assembly Position

5W-30 (for winter of north) or 15W-40 (for Valve head, camshaft, rocker,
1 Engine oil summer of north and whole year of south); rocker shaft, and camshaft oil
quality grade: SJ or above seal
2 Sealant LT271 or equivalent Double-head bolt
Guide sleeve of spark plug, bowl
3 Sealant LT962T or equivalent patch of cylinder body/cover,
connecting pipe nozzle
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Mechanical Part of
IV. Engine Assembly

1. Precautions on Installation and Dismantlement
Caution:
Operation in violation of the following instructions may incur body injury!
■ Park the vehicle on even and firm ground.
Attention:
■ Always pay attention to safe operation, and do not conduct forcible operations or operations against
the instructions.
■ Do not start the operation before the exhaust system and engine coolant have fully cooled down.
■ If the necessary items or operations are not mentioned in the chapter or section of engine, see the
corresponding chapters.
■ Use the special lifting fulcrum all the time, and select lifters as appropriate.
2. Preparation for Dismounting Engine and Transmission Assembly
1) General
Dismount the engine and transmission assembly from the vehicle first, and then detach the engine and
the transmission.
2) Preparation
① Release the fuel pressure. See “Release of Fuel Pressure”.
② Discharge the engine coolant from the radiator. See “Replacement of Engine Coolant”.
③ Discharge the engine oil, transmission oil and clutch oil. See "Engine Oil", “Transmission Oil” and
“Clutch Pipeline”.
④ Recycle the cooling agent in cooling pipeline.
⑤ Discharge the power steering fluid. See “Power Steering Fluid”.
Attention:
■ Perform this step after the engine has cooled down.
■ Do not splash the engine coolant onto the drive belt.
⑥ Dismount the following parts:
■ Engine trimming cover. See “Intake Manifold”.
■ Engine hood assembly. See “Engine Hood”.
■ Front wheels and tyres. See “Wheels and Tyres”.
■ Engine deflectors (left and right).
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Mechanical Part of
■ Air duct and air cleaner assembly. See “Air Duct”.
■ Storage battery, storage battery base and storage battery base support. See “Storage Battery”.
■ Radiator assembly and radiator fan. See “Radiator”.
3. Dismantlement of Relevant Elements inside Engine Compartment
① Disconnect the following pipelines and put them aside.
Attention:
Use plugs to prevent leakage when disconnecting the pipelines.
■ Inlet pipe of oil injector. See “Oil Injector”.
■ Vacuum hose of braking vacuum booster on engine side. See “Braking Vacuum Booster”.
■ PVC hose. See “Fuel Evaporation Control System”.
■ Oil inlet pipe joint of clutch. See “Hydraulic Pipeline of Clutch”.
■ Oil inlet pipe and oil return pipe of power steering pump; fixing support of oil pipe. See “Power
Steering Pump”.
■ Low and high-pressure pipes at air compressor. See “air compressor”.
② Dismount the throttle wiredrawing. See “Throttle Wiredrawing”.
③ Dismount the steering fluid reservoir.
④ Dismount the gear shifting/selecting wiredrawing. See “Gear Shifting/Selecting Control Mechanism”.
⑤ Disconnect the wire harness connectors and wire harness buckles of the following parts and then
take them away:
■ Oxygen sensor
■ Engine coolant temperature sensor
■ Crankshaft position sensor
■ Camshaft position sensor
■ Vehicle speed sensor
■ Idle stepping motor
■ Air throttle position sensor
■ PCV valve
■ Absolute intake pressure sensor
■ Ignition coil
■ Oil injector
■ Knock sensor
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Mechanical Part of
■ Generator
■ Starter
■ Air conditioner switch
4. Dismantlement of Elements Relevant to Vehicle Chassis
① Dismount the front drive shaft. See “Front Drive Shaft”.
② Dismount the front exhaust pipe. See “Exhaust System”.
③ Dismount the engine supporting beam. See “Engine Supporting Beam”.
5. Dismantlement
Fig.1.1.005
① Mount the hanger on the engine hooks (front and
rear). See Figures 1.1.005 and 1.1.006.
② Lift the engine and fix it in place.
③ Use the manual lifting table or the equivalent tools to

firmly support the bottom of engine and transmission
assembly, and adjust the lifting tension.
Attention:
■ It is permissible to place a soft pad on the supporting

Fig.1.1.006
surface so as to ensure a totally stable state.
④ Detach the left, right, front and rear suspensions of

engine. See “Engine Suspension”.
⑤ Carefully lower the engine and transmission

assembly.
When carrying out the operation, note the following:
■ Ensure that the vehicle is not disturbed.
■ Ensure that all connecting parts have been

disconnected.
■ Remember that the vehicle’s center of gravity may

change. If necessary, use the jack to support the
rear lifting point and to prevent the falling.
6. Detachment
① Dismount the power steering pump assembly and the air conditioner compressor assembly from the
engine and transmission assembly. See “Power Steering Pump”.
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Mechanical Part of
② Dismount the starter. See “Starter”.

③ Use the lifter to lift the engine and the transmission, and then detach them.
Attention:
■ Before and during lifting, always ensure that no wire harness is connected.
7. Installation
Please note the following and perform the installation steps which are contrary to dismantlement steps.
1) Do not damage the soft pad of engine suspension. Meantime, avoid splashing engine oil onto the
soft pad.
2) Ensure that all engine suspensions have been properly fixed. Then, screw down the nuts and bolts.
8. Check after Installation
1) Check whether there is any leakage.
The steps for checking oil and fluid leakage, lubricating oil leakage and the exhaust leakage are listed as
follows:
■ Before starting the engine, check the levels of engine coolant and engine oil. If the levels are lower
than the required amount, refill engine coolant and engine oil to the specified positions.
■ Carry out the following steps to check whether fuel leakage is present.
- Turn the ignition switch to the “ON” position, and check whether there is fuel leakage at the
connecting parts.
- Start the engine, and recheck whether there is fuel leakage at the connecting parts during the
engine acceleration.
■ Run the engine and check whether there is abnormal noise or shake.
■ Thoroughly warm up the engine, and ensure that there is no fuel leakage, exhaust leakage or any oil
and fluid (including engine coolant and engine oil) leakage.
■ Discharge or feed air from/to the corresponding pipelines and hoses.
■ After the engine has cooled down, recheck the levels of oils and fluids (including engine oil and
engine coolant). If necessary, refill them to the specified levels.
2) General of Check Items
List of Leakage Check Items
Item Before Engine During Engine After Engine

Startup Operation Shutdown
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission oil, brake fluid, power steering Level Leakage Level
fluid and clutch fluid
Fuel Leakage Leakage Leakage
Exhaust — Leakage —
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Mechanical Part of
V. Drive Belt
1. Check of Drive Belt
Caution:
■ Be sure to perform this operation after the engine shutdown.
1) Check whether there are crack, abrasion and smear on the belt. Replace the belt, if necessary.
2) Check the flexibility at the belt midpoint between belt

Fig.1.1.007
pulleys.
■ It is necessary to recheck the belt when the engine is
cold or 30 minutes after the engine has shut down.
■ When measuring the flexibility, apply a force of 98N to
the marked point.
■ If the flexibility exceeds the limit value, adjust the belt.
Note:
Belt flexibility value: 7~10mm
Attention:
■ During the belt flexibility check immediately after the installation, adjust the flexibility to the specified
value first, then rotate the crankshaft for more than two cycles, and finally readjust the flexibility to
the specified value lest the flexibility between belt pulleys would change.
2. Adjustment of Tension
List of Tension Adjustment
Part Adjustment Method

Generator belt Adjust the adjusting bolt on generator
Belts of power steering pump and air conditioner
Adjust the adjusting bolt on power steering pump
compressor
Attention:
■ After the replacement, adjust the belt flexibility to make the new belt adapt to the belt pulley groove.
■ During the belt flexibility check immediately after the installation, adjust the flexibility to the specified
value first, then rotate the crankshaft for more than two cycles, and finally readjust the flexibility to
the specified value lest the flexibility between belt pulleys would change.
■ When installing the belt, ensure the proper engagement between it and the belt pulley groove.
■ Do not splash the engine oil or engine coolant onto the belt.
■ Do not excessively coil or bend the belt.
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Mechanical Part of
3. Generator Belt Fig.1.1008

1) Loosen the engine kingpin bolt and the
generator nut. Then, use the adjusting bolt to
regulate the tension.
2) Screw down the kingpin bolt and the generator Fig.1.1.00

nut.
■ Tightening torque: 34~54N·m
4. Belt of Power Steering Pump

Fig.1.1.010
1) Loosen fixing bolt and adjusting bolt of the power
steering pump.
2) Select the adjusting rod to regulate the tension.
3) Lock the adjusting rod bolt and the fixing bolt of power
steering pump.
5. Dismantlement of Drive Belt
1) Completely loosen every belt in accordance with the
instructions specified in “Tension Adjustment”.
2) Dismount the belt of power steering pump first, and
then the generator belt.
6. Installation of Drive Belt

1) Mount the belt onto the belt pulley in the installation steps which are contrary to the dismantlement
steps.
Attention:
■ Ensure that the belt has properly engaged with the belt pulley groove.
■ Ensure that no engine oil or engine coolant has splashed onto any belt and any belt pullet groove.
2) Ensure that the tension of every belt is within the standard range. See “Check of Drive Belt”.
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Mechanical Part of
VI. Air Cleaner and Air Duct
1. Elements
Diagram of Element Positions
1- Front Intake Pipe; 2- PVC Hose; 3- Intake Hose; 4- Air Cleaner Assembly
2. Intake Pipe Fig.1.1.011

1) Dismantlement
① Dismount the fixing bolt of front intake pipe,

and take down the front intake pipe assembly.
■ Tightening torque: 8~12 N·m
② Dismount the locking bolt on upper cover of air Fig.1.1.012

cleaner.
13
Mechanical Part of
③ Disconnect the locking clamp of intake hose,

and then take down the upper cover and the Fig.1.1.013
intake hose.
Fig.1.1.014
④ Dismount the fixing bolt of air cleaner base,

Fig.1.1.015
and then take down the base.
2) Check after Dismantlement
Check whether there is any crack or abrasion on the air duct assembly. If any, replace the air duct
assembly.
3) Installation
Perform the installation steps which are contrary to the dismantlement steps.
Attention:
■ Properly mount every joint, and screw up the clamp.
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Mechanical Part of
3. Replacement of Filter Core of Air Cleaner
1) Dismantlement Fig.1.1.016
① Loosen the locking bolt on upper cover of air

cleaner, and lift the upper cover.
② Dismount the filter core of air cleaner. Fig.1.1.017
■ It is required to periodically clean or replace the filter core of air cleaner in compliance with
recommended period. See “Periodical Maintenance”.
■ Blow the filter core of air cleaner from its back side with compressed air, till nothing is blown off.
3) Installation
■ Perform the installation steps which are contrary to the dismantlement steps.
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Mechanical Part of
VII. Intake Manifold and Exhaust Manifold
Decomposition Diagram of Intake and Exhaust Manifolds
1- Absolute intake pressure sensor; 2- Carbon canister solenoid valve; 3- Carbon canister solenoid valve
support; 4- Knock sensor support; 5- Engine lifting lug; 6- Intake manifold support; 7- Intake manifold; 8-
Intake manifold gasket; 9- Adiabatic pad for exhaust; 10- Oxygen sensor; 11- Exhaust manifold; 12-
Exhaust manifold gasket
1. Intake Manifold
1) Dismantlement
Caution:
■ Do not discharge the engine coolant when the engine is hot, lest you would be scalded.
① Discharge the engine coolant. See “Engine Coolant”.
② Release the fuel pressure. See “Release of

Fig.1.1.018
Fuel Pipeline Pressure”.
③ Dismount the engine trimming cover.
■ Tightening torque: 8~1 2 N·m
④ Dismount the air cleaner assembly. See “Air

Cleaner Assembly”.
⑤ Disconnect the wire harness connectors of the

following parts:
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Mechanical Part of
■ Absolute intake pressure sensor
■ Oil injector
■ Throttle valve position sensor
■ Idle stepping motor
■ Controlling carbon canister solenoid
⑥ Disconnect the following hose joints:
■ Water hose joint (insert a plug to prevent the engine coolant leakage)
■ PCV hose
■ Vacuum hose of braking vacuum booster on intake manifold side
■ Vacuum hose on carbon canister solenoid side
■ Small circulating water hose for throttle valve body
⑦ Disconnect the throttle wiredrawing from the throttle valve body. Dismount the fixing bolt of throttle
valve body and the vacuum hose on carbon canister solenoid (on the side of throttle valve body),
and then take down the throttle valve body assembly.
⑧ Dismount the oil injector assembly. See “Oil Injector”.
■Tightening torque: 10~13 N·m
⑨ Dismount the fixing bracket of intake manifold and Fig.1.1.019

engine cylinder body.
■ Tightening torque: M8 15~20 N·m M10 27~33 N·m
⑩ Dismount the fixing bolt and nut of intake manifold.

⑪ Take down the intake manifold and the intake manifold Fig.1.1.020
gasket.
Check whether there are cracks or other damages on the

intake manifold and whether the matching face is distorted.
If this is the case, repair or replace the intake manifold.
17
Mechanical Part of
3) Installation
Attention:
■ Do not reuse the non-reusable parts.
■ Before starting the engine, check the level of engine coolant. If the level is lower than the required
amount, refill engine coolant to the specified position.
■ Carry out the following steps to check whether fuel leakage is present.
- Turn the ignition switch to the “ON” position, and check whether there is fuel leakage at the
connecting parts.
- Start the engine, and recheck whether there is fuel leakage at the connecting parts during the
engine acceleration.
■ Thoroughly warm up the engine, and ensure that there is no fuel leakage and engine coolant
leakage.
■ After the engine has cooled down, recheck the level of engine coolant. If necessary, refill engine
coolant to the specified level.
2. Exhaust Manifold
1) Dismantlement
Caution:
■ Perform this operation after the exhaust system has completely cooled down.
① Disconnect the wire harness connectors of front oxygen sensor. Dismount the front oxygen sensor
with special tools, if necessary.
Attention:
■ Do not damage the oxygen sensor.
■ It is forbidden to use any oxygen sensor which has dropped to the hard ground from a height above
0.5m. Such an oxygen sensor shall be replaced.
② Dismount the fixing bolt for adiabatic pad of

Fig.1.1.021
exhaust manifold, and then take down the
adiabatic pad.
18
Mechanical Part of
③ Disconnect the connection between three-way

Fig.1.1.022
catalytic converter and exhaust manifold.
④ Dismount the fixing bolt of exhaust manifold, and then take down the exhaust manifold.
■ Tightening torques: For M8, 15~20N·m;

Fig.1.1.023
For M10, 27~33N·m
Check whether the matching face of exhaust

manifold is distorted.
3) Installation
Perform the installation steps which are contrary to

the dismantlement steps.
Attention:
■ Do not reuse the non-reusable parts.
■ Do not excessively screw up the oxygen

sensor, lest it would be damaged.
19
Mechanical Part of
VIII. Exhaust System
1. Elements
Diagram of Exhaust System
1- Rear muffler; 2- Lifting lug; 3- Front muffler; 4- Front exhaust pipe; 5-Three-way Catalytic Converter;
6- Corrugated pipe; 7-Rear oxygen sensor
2. Check of Exhaust System
Check whether the exhaust pipe, the three-way catalytic converter, the muffler and the fixing devices are
properly installed and whether there is any leakage, crack, damage or aging.
■ Repair or replace the damaged part, if necessary.
3. Dismantlement and Installation
Attention:
■ Do not have you hand cut by the edge of adiabatic pad.
■ Do use regular exhaust system parts or equivalent products.
■ Perform the operation after the exhaust system has completely cooled down, for the temperature of
exhaust system remains hot when the engine has just shut down.
1) Dismantlement
Disconnect every joint and fixed part.
2) Installation
■ Replace the exhaust pipe liner when reassembling the exhaust system each time.
■ Repair or replace the seriously distorted adiabatic pad. Eliminate the accumulations from the
adiabatic pad.
20
Mechanical Part of
■ When mounting the adiabatic pad, try to avoid wide clearance or blockage and intervention between
the adiabatic pad and each exhaust pipe.
■ Eliminate the sediments from the sealed face of each joint. Such joints shall be firmly connected to
avoid gas leakage.
■ Pre-tighten the fixing nuts and bolts on exhaust manifold side and those on vehicle side. Check
whether there is any intervention between parts, and then tighten the parts with the specified torque.
■ When mounting the fixing rubber, avoid excessive upward/downward and leftward/rightward twist or
stretch of it.
3) Check after Installation
■ Confirm the clearance between rear muffler and rear bumper.
■ During the engine operation, check the connecting position of exhaust pipe for air leakage and
abnormal noise.
■ Ensure that the fixing support and the fixing rubber have been properly mounted. Do not subject
them to excessive force. Improper installation may lead to considerable noise and shake.
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Mechanical Part of
IX. Timing Belt Mechanism

1. Elements
Diagram of Timing Belt Mechanism

1- External upper housing of timing belt 2- External lower housing of timing belt 3- Timing belt
4- Tension spring 5- Tension pulley of timing belt 6- Crankshaft timing gear
7- Bolt for camshaft timing bolt 8- Camshaft timing gear 9- Support 10- Right suspension of engine
2. Dismantlement and Installation of Timing Belt

Fig.1.1.024
1) Dismantlement
① Dismount the fixing bolt of water pump belt
pulley.
Note: It is permissible to perform the
dismantlement by means of the friction force of
drive belt when the drive belt has not been
removed yet.
22
Mechanical Part of
② Dismount the support. Fig.1.1.025
③ Dismount the fixing bolt of upper timing

Fig.1.1.026
housing, and then take down the upper timing
housing.
④ Rotate the crankshaft, and align the timing

Fig.1.1.027
mark on camshaft timing gear with that on
cylinder cover side.
Attention:
■ Regularly (clockwise) rotate the crankshaft

only.
■ When the upper marks align with each other,

ensure the timing mark on crankshaft belt disc
and that on lower timing housing align with
each other. See Fig.1.1.028. Fig.1.1.028
⑤ Fix the camshaft timing gear with an end fork

clamp, dismount the fixing bolt of crankshaft
belt disc, and take down the crankshaft belt
disc.
■ Tightening torque: 165N·m
23
Mechanical Part of
⑥ Dismount the fixing bolt of lower timing Fig.1.1.029

housing, and then take down the lower timing
housing.
■ Tightening torque: 10~1 2 N·m
⑦ Appropriately loosen the fixing bolt for tension

Fig.1.1.030
pulley of timing belt, use the pliers to clamp
the extending end of tension pulley spring,
dismount the bolt from the stop block of
engine oil pump housing, and then take down
the tension pulley spring.
⑧ Dismount the tension pulley of timing belt.
Note:
■ If the timing belt is intended to be reused, then before the tension pulley of timing belt is taken down,
make an arrow mark on the timing belt to represent the rotation direction prior to dismantlement.
This mark functions to avoid the failure to properly mount the timing belt.
⑨ Take down the timing belt.
① Timing belt
Fig.1.1.031
Check the timing belt for the following defects. If
the defects are present, replace the timing belt.
■ The rubber of back side hardens (The rubber
of back side is smooth, inelastic and hard
insomuch that no trace appears when it is
scratched with a nail).
■ There are cracks on the rubber surface of
back side.
■ The canvas tears, and (or) the canvas
separates from the rubber.
24
Mechanical Part of
■ There are cracks at tooth root. Fig.1.1.032 Crack Crack
■ There are cracks at the side face of belt.
■ The side face of belt is abnormally abraded. Separation

Crack
Side
■ The tooth no longer exists.
Attention:
If the shape of side face of belt looks like a blade Tooth Root with
Cracks
edge, this face shall be considered normal.
During the initial stage of abnormal tooth abrasion,

the canvas fiber becomes loose, the rubber Fig.1.1.033 Round Angle at Edge
structure disappears, the whiteness fades, and the
canvas structure appears unidentifiable. During the
final stage of such abrasion, the canvas gets
abraded and the rubber is exposed.
Abnormal Abrasion
(Exposed Core)
Fig.1.1.034
Abraded Canvas and
Exposed Rubber
No Teeth
② Tension Pulley
Fig.1.1.035
Check whether the unstable rotation, the play, and
the abnormal noise appear on the tension pulley. If
any, replace the tension pulley.
25
Mechanical Part of
③ Timing Housing
Check whether there are cracks or other damages on the timing housing. If any, replace the housing.
3) Installation
Fig.1.1.036
① Align the timing mark on camshaft timing gear
with that on cylinder cover side.
② Align the timing mark on crankshaft timing Fig.1.1.037

gear with that on engine oil pump housing.
③ Lock the tension pulley of timing belt at the Fig.1.1.038

position shown in the figure.
④ Hook an extending end of tension pulley Fig.1.1.039

spring with the hooked part of tension pulley of
timing belt, and then mount the tension pulley
onto the engine oil pump housing.
26
Mechanical Part of
⑤ Clamp the other extending end of tension

pulley spring, and hook it with the lug of Fig.1.1.040
engine oil pump housing as shown in the
figure.
⑥ Move the tension pulley of the timing belt in

the direction shown in Fig.1.1.040, and then
firmly tension the belt.
⑦ Keep the tensioned side of timing belt as it is,

and mount the timing belt into the crankshaft
timing gear, the camshaft timing gear and
tension pulley of timing belt in sequence. Fig.1.1.041
⑧ Loosen the fixing bolt for tension pulley of

timing belt for1/4~1/2 circle so as to subject
the timing belt to the tension of tension pulley
spring.
⑨ Rotate the crankshaft for 2 circles in the

normal (clockwise) direction, and check
whether the timing marks align with each
other.
Attention:
■ In this way, the tension evenly acts on the timing belt by virtue of the crankshaft drive torque. The
crankshaft must be rotated in the direction forementioned, and the anticlockwise rotation shall not
be carried out on the crankshaft.
⑩ Screw down the fixing mounting bolt for tension pulley of timing belt.
⑪ Mount the lower timing housing, the crankshaft belt disc, the upper timing housing and the support.
⑫ Mount the water pump belt pulley.
27
Mechanical Part of
X. Rocker Arm and Camshaft

1. Elements
Decomposition Diagram of Rocker Arm and Camshaft

1- PCV hose 2- Filler port cover 3- PCV valve 4- PCV valve pad 5- Valve chamber cover 6- Valve chamber
cover pad 7- Sealing gasket for spark plug conduit 8- Front oil seal of camshaft 9- Rocker arm and rocker arm shaft
assembly (for intake) 10- Rocker arm and rocker arm shaft assembly (for exhaust) 11- Rocker arm A 12- Rocker arm
B 13- Rocker arm shaft 14- Adjusting screw 15- Adjusting nut 16- Rocker arm C 17-Rocker arm shaft
18-Adjusting screw 19- Adjusting nut 20- Camshaft

1) Dismantlement
① Dismount the engine trimming cover. See “Intake Manifold”.
② Dismount the ignition coil and the high-pressure wire. See “Ignition Coil”.
③ Disconnect the fixing joint of throttle wiredrawing and high-pressure oil pipe of power steering pump.
④ Disconnect the wire harness connectors of PVC hose and camshaft position sensor.
28
Mechanical Part of
⑤ Dismount the valve chamber cover from the cylinder cover.

⑥ Dismount the valve chamber cover pad from the valve chamber cover, and take down the seal
gasket of spark plug conduit from the spark plug conduit.
⑦ Dismount the timing belt. See “Timing Belt Mechanism”.
⑧ Dismount the camshaft timing gear.
a. Lock the camshaft timing gear at the corresponding position with a special tool shown in
Fig.1.1.042.
b. Loosen the bolt for camshaft timing gear.
■ Tightening torque: 78~98N.m

Fig.1.1.042
c. Take down the camshaft timing gear.
⑨ Dismount the camshaft position sensor JAC-T1D001
support from the rear end of cylinder cover.

Attention:
■ Carefully perform the operation so as not to
damage the elements.
⑩ Dismount the front oil seal of camshaft with
proper tools.
Attention:
■ Do not damage the matching face of cylinder cover and camshaft.
⑪ Dismount the fixing bolt of rocker arm shaft, and then take down the intake and exhaust rocker arms
and the rocker arm shaft assembly.

Fig.1.1.043
a. Loosen these elements in sequence as shown in
Fig.1.1.043.
b. Loosen them in steps, and then take them down.
Note: The dismounted parts shall be placed in
sequence.
⑫ Take out the camshaft from the cylinder cover.
Fig.1.1.044
① Camshaft
■ Measure the height of the cam of the camshaft.
Standard value for intake: 37.298mm
Standard value for exhaust: 37.161mm
Limit value for intake: 36.80mm
Limit value for exhaust: 36.66mm
29
Mechanical Part of
Replace the camshaft, if the measured value exceeds the limit value.
② Rocker Arm and Rocker Arm Shaft
■ Check whether there is abnormal abrasion on the rocker arm and the rocker arm shaft.
■ Check whether there is blockage in the engine oil hole. If any, clean the hole.
3) Installation
① Mount the camshaft.
Attention:
■ It is necessary to apply engine oils to the journal and the cam of camshaft.
■ Pay attention to the mounting direction of camshaft.
② Mount the rocker arm and rocker arm shaft assembly.
a. Place one side (whose inclined plane is larger) of rocker arm shaft towards the timing belt side.
b. Place one side (with oil hole) of rocker arm shaft Timing Belt Side
towards the cylinder cover. Fig.1.1.045
c. Pay attention to the assembly marks on rocker
arm and the rocker arm shaft, and then mount the
assembly on the cylinder cover.
③ Mount the camshaft position sensor support.
Attention:
Identification
■ Apply a layer of sealant to the flange of rear end Mark
cover.
■ Screw down the fixing bolt after the support has Fig.1.1.046
been fully mounted. JAC-T3F002
④ Mount the front oil seal of camshaft with the
special tool shown in Fig.1.1.046.
⑤ Mount the camshaft timing gear.

Fig.1.1.047
a. Lock the camshaft timing gear at the
corresponding position with special tools shown
JAC-T1D001
in Fig.1.1.047.
b. Screw down the camshaft timing gear to the
specified torque.
JAC-T1D001
30
Mechanical Part of
⑥ Please note the following and perform the installation steps which are contrary to the dismantlement
steps.
■ Eliminate all sealant from the cylinder cover before mounting the valve chamber cover.
■ Ensure that the valve chamber cover pad has been placed into the mounting slot for valve chamber
cover intact.
■ Check whether all parts have been mounted in position.
■ Check the level of engine oil before starting the engine. If the engine oil is less than the required
volume, replenish it to the specified level, .
■ Run the engine and then check it for abnormal noise and shake.
■ Ensure that there is no engine oil leakage after thorough engine warm-up.
■ Recheck the level of engine oil after the engine has cooled down. Replenish the engine oil to the
specified level, if necessary.
3. Valve Gap
1) Check
Perform the following checks when you are dismounting or replacing the relevant parts of camshaft or
the rocker arm and rocker arm shaft assembly, or when the engine abnormally runs due to the change of
valve gap.
① Dismount the valve chamber cover. See “Camshaft”.
② Measure the valve gap in the following steps.
a. Fix the compression stroke TDC (Cylinder 1). See Fig.1.1.045.
Clockwise rotate the crankshaft belt disc, and align the timing marks with each other as shown in
Fig.1.1.028. Meanwhile, confirm that the rocker arm of Cylinder 1 can slightly rock. If it can not rock,
rotate the crankshaft for another circle.
b. Measure the gap between valve adjusting screw and valve stem head with a feeler gauge.
Valve Gap:
For intake valve, 0.14±0.03mm
For exhaust valve, 0.19±0.03mm
c. Rotate the crankshaft belt disc for a circle.
③ If the measured value exceeds the standard value, adjust the valve gap. See “Adjustment”.
2) Adjustment
① Loosen the adjusting nuts, and unscrew the adjusting screw.
② Insert the feeler gauge (whose width value is equivalent to the standard valve gap value) between
the adjusting screw and the valve stem head.
③ Fix the adjusting nut, then gradually tighten the adjusting screw till it is not easy to draw the feeler
gauge, and finally screw down the adjusting nut.
31
Mechanical Part of
④ Reconfirm that the valve gap is within the standard range.
⑤ If it is not, repeat Steps 1~4 till it falls within the standard range.
⑥ Rotate the crankshaft by hand, refer to the standard value, and confirm that the valve gap in cold
state falls within the standard value. See “Check”.
⑦ Mount all the dismounted parts in the installation steps which are contrary to dismantlement steps.
See “Installation”.
⑧ Warm up the engine, and then check it for abnormal noise or shake.
XI. Cylinder Cover
1. On-vehicle Maintenance
1) Check the cylinder pressure:
① Thoroughly warm up the engine. Then, shut down the engine.
② Release the fuel pressure. See “Release of Fuel Pressure”.
③ Disconnect the fuse wire of fuel pump, lest the fuel squirts during the measure.
④ Dismount the engine trimming cover. See “Intake Manifold”.
⑤ Dismantle the high-pressure wires and the spark plugs from all cylinders. See “Ignition Coil”
and ”Spark Plug”.
⑥ Mount a cylinder pressure gauge (with joint) on the spark plug hole.
⑦ Tread the accelerator pedal to the end, and turn the ignition switch to the “START” position to start
the engine. After the instrument finger appears stable, read the compression pressure and the
engine speed. Perform these steps and to check other cylinders.
■ Standard pressure: 1500kPa
■ Minimum pressure: 1200kPa
■ Tolerable pressure difference between cylinders: ≤150kPa
Attention:
■ It is required to obtain the specified engine speed always by the storage battery which is fully
charged.
■ Check the valve gap and other relevant parts (such as the valve, the valve seat, the piston, the
piston ring, the cylinder diameter, the cylinder cover and the cylinder cover pad), if the compression
pressure value is lower than the minimum value. Re-measure the compression pressure after the
check. If the pressures in some cylinders are low, add some engine oil to the spark plug holes of
such cylinders and then check the cylinder pressures again.
■ The piston ring may have been abraded or damaged, if the cylinder pressure rises after the engine
oil is added. Check the piston ring, and replace it if necessary.
32
Mechanical Part of
■ The valve may have been faulty, if the compression pressure is still low after the adding of engine oil.
Check whether the valve is damaged. Replace the damaged valve or valve seat.
■ The cylinder cover pad must be leaky, if the compression pressures in two neighboring cylinders are
low and even keep low after the adding of engine oil. Replace the cylinder cover pad.
⑧ After the check, remount the dismounted parts.
⑨ Start the engine, and confirm that the engine runs smoothly.
2. Elements
Diagram of Cylinder Cover
1) Dismantlement
① Release the fuel pressure. See “Release of Fuel Pressure”.
② Discharge the engine coolant and engine oil. See “Replacement of Engine Coolant” and
“Replacement of Engine Oil”.
Attention:
■ Perform these steps after the engine has cooled down.
■ Do not splash the engine coolant and the engine oil onto the drive belt.
③ Dismount the following elements and the relevant parts:
33
Mechanical Part of
■ Drive belt. See “Drive Belt”.

■ Timing belt. See “Timing Belt Mechanism”.
■ Engine trimming cover. See “Intake Manifold”.
■ Valve chamber cover. See “Rocker Arm and Rocker Arm Shaft”.
■ Intake manifold. See “Intake Manifold”.
■ Exhaust manifold. See “Exhaust Manifold”.
■ Thermostat housing. See “Thermostat Components”
■ Oil rule conduit.
④ Loosen the cylinder cover bolt with the special

tool shown in Fig.1.1.048. Fig.1.1.048
The dismantlement steps are contrary to the steps Fig.1.1.049

shown in Fig.1.1.049
A：Intake side
B：Exhaust side
: Front end of engine
⑤ Dismantle the cylinder pad.

① Cylinder Cover Bolt
Measure the length of cylinder cover bolt.
■ Limit value:103.2mm.
Replace the cylinder head bolt, if the measured value exceeds this limit value.
② Cylinder Cover
■ Check whether there are cracks or other damages on the cylinder cover.
■ Check whether there is any blockage in the water channel and the oil channel. If any, clean the
water channel and the oil channel.
34
Mechanical Part of
■ Check the planeness of cylinder cover.
Note: Check the planeness of cylinder body as well when performing this check. See “Planeness of
Cylinder Body”.
a. Wipe away the engine oil from the cylinder cover, and eliminate the sealant and the sedimentary
carbon.
Attention:
■ Do not let the impurities fall into the water channel and oil channel of cylinder cover.
b. Measure the planeness in six directions at Fig.1.1.050

several positions on bottom surface of cylinder
cover.
Standard value: below 0.03mm
Height of cylinder cover (new): 120±0.1mm
If the measured value of planeness exceeds the
standard value, grind or replace the cylinder cover
according to the specification.
Attention:
■ The total grindable tolerance of matching surface between cylinder cover and cylinder body shall
not be greater than 0.2mm.
3) Installation Fig.1.1.051
① Mount the new cylinder cover pad.
② Screw down the cylinder cover bolts in
numerical sequence shown in Fig.1.1.051,
and then mount the cylinder cover in the
following steps.
A: Intake side
B: Exhaust side
: Front end of engine
a. Mount the washer as shown in Fig.1.1.052.

Fig.1.1.052
b. Apply the engine oil to the washer, which is at
the threaded portion of bolt.
35
Mechanical Part of
c. Screw down the bolts in the sequence shown in

Fig.1.1.053
Fig.1.1.053 till the tightening torque for each bolt
reaches 49N·m.
d. Fully unscrew these bolts.
e. Re-screw down these bolts in the sequence shown in

Fig.1.1.053 till the tightening torque for each bolt
reaches 20±2N·m. Timing Belt Side
f. Paint marks on the bolt head and the cylinder cover Fig.1.1.054
(see Fig.1.1.054).
g. Screw each bolt for 90° according to the tightening

sequence.
h. Screw each bolt for a further 90°, and then check

whether the painted marks on bolt head and cylinder
cover align with each other.
Painting
Attention: Mark
■ If the tightening angle of the bolts is less than 90°, the

bolts will not hold enough force to fix the cylinder
cover.
■ If the tightening angle of the bolts is more than 90°, it is necessary to dismount them and then
remount them.
i. If the old cylinder cover bolts are replaced during the maintenance, the maintenance shall be
performed in sequence from “a” to “h”.
j. If the old cylinder cover bolts are not replaced during the maintenance, the maintenance shall be
performed in sequence “a, b, e, f, g and h”.
③ Then, perform the installation steps which are just contrary to the dismantlement steps.
The steps for checking oil leakage, lubricant leakage and tail gas leakage are listed as follows:
■ Before starting the engine, check the engine oil/coolant level. If the level is less than the required
value, replenish the engine oil/coolant till the specified level is reached.
■ Perform the following steps to check whether the oil leakage occurs:
- Turn the ignition switch to the “ON” position (when engine is shut down). With the oil pressure acting
on the oil pipe, check whether there is fuel leakage at the joint.
- Start the engine. With the engine accelerating, recheck whether there is fuel leakage at the joint.
■ Run the engine to check whether the abnormal noise or shake appears.
36
Mechanical Part of
■ Thoroughly warm up the engine, and confirm there is no fuel leakage, tail gas leakage or any
oil/fluid (including engine oil and engine coolant) leakage.
■ After the engine has cooled down, recheck the level of oil/fluid (including engine oil and engine
coolant) level. Replenish the oil/fluid to the specified level, if necessary.
XII. Valves
1. Elements
Diagram of Valve Elements
1- Cylinder cover bolt 2- Cylinder cover assembly 3-Cylinder pad 4- Valve lock plate
5- Retaining seat for intake valve spring 6- Valve spring 7- Valve conduit 8- Valve retainer
9- Intake valve 10- Exhaust valve 11- Cylinder cover
37
Mechanical Part of
2. Disassembly and Assembly
1) Disassembly
① Dismount the spark plug with the spark plug sleeve.
② Dismount the valve lock plate, the valve spring and the valve spring seat.
■ Compress the valve spring with the valve

Fig.1.1.055 JAC-T1F001
spring compressor.
Attention:
■ Pay attention to the position of upper dead

point of piston.
■ Label the dismounted valve, valve spring and

Fig.1.1.056
other parts, and write down their
JAC-T1F012
corresponding cylinder numbers and positions
■ Store the parts reliably.
③ Dismount the valve oil seal.

Fig.1.1.057
④ See “Replacement of Valve Seat” to replace
the valve seat, if required.
⑤ See “Valve Conduit” to replace the valve

conduit, if required.
2) Assembly
① Mount the valve conduit, if it has been dismounted. See “Valve Conduit”.
② Mount the valve seat, if it has been dismounted. See “Valve Seat”.
③ Mount the valve oil seal.
a. Mount the valve spring seat.
38
Mechanical Part of
b. Mount the new valve oil seal with the special tool shown in Fig.1.1.058.
Attention: Fig1.1.058
JAC-T3F001
■ The valve oil seal shall not be reused.
■ The valve oil seal must be mounted with the

proper special tool.
④ Mount the valve.
⑤ Mount the valve spring.
Note: The element with painted mark shall be mounted upwards.
⑥ Mount the retaining seat for valve spring.
⑦ Mount the valve lock plate.
■ Use the valve spring compressor during the installation.
■ After the installation, lightly knock the edge of valve stem with a rubber hammer to check the
mounting condition.
⑧ Mount the spark plug with the spark plug sleeve.
3) Check after Disassembly Fig.1.1.059

1. Valve
■ Check whether the contact between valve Good
surfaces is proper. Trim the surface of valve

seat, if the contact is uneven or incomplete.
Bad Bad
■ Check the thickness of valve edge. Replace

Fig.1.1.060
the valve, if the measured value is less than
the specified value. Contact
(required to be
at the center of
Standard values: surface)
Thickness of
For intake valve: 1.35mm edge
For exhaust valve: 1.85mm
Limit values:
39
Mechanical Part of
For intake valve: 0.85mm
■ Check the total length of valve. Replace the valve, if the measured value is less than the specified
value.
Standard values:
Limit values:
2. Valve Spring
■ Check the free height of valve spring. Replace the valve spring, if the measured value is less than
the specified value.
Standard value: 50.87mm
Limit value: 50.37mm Perpendicularity

Fig.1.1.061
■ Check the perpendicularity of valve spring.
Replace the valve spring, if the measured
value is greater than the limit value.
Free Height
Standard value: 2°
Limit value: 4°
3. Valve Conduit
Fig.1.1.062
■ Check the gap between the valve conduit and
the valve stem. Replace the corresponding
parts, if the measured value exceeds the limit Valve Conduit
value.
For intake valve conduit
Standard value: 0.020~0.036mm Outer Diameter of Valve Stem

Inner Diameter of Valve Conduit
Limit value: 0.10mm
For exhaust conduit
Standard value: 0.030~0.045mm
Limit value: 0.1mm
40
Mechanical Part of
■ Replacement of Valve Conduit

a. Push out the valve conduit towards the cylinder side by the press.
b. Bore the valve conduit hole on cylinder head till the hole matches the air conduit whose size is to be
extended.
Attention:
■ Do not mount the valve conduits with the same sizes of the valve conduit holes.
Diameter of valve conduit hole:

Fig.1.1.063
For the hole diameter of 10.605~10.615mm,
extend the size of valve conduit by 0.05mm.
For the hole diameter of 10.805~10.815mm,
For the hole diameter of 11.055~11.065mm, Protrusion
Height
c. Press the valve conduit till its protrusion height
reaches the specified value.

Attention:
■ The valve conduit must be mounted from the upside of cylinder head.
■ The lengths of valve conduits on intake and exhaust sides shall be different.
■ After pressing the valve conduit, insert a new valve, and then whether the new valve slides
smoothly.
4. Valve Seat
■ Check the valve protrusion height between the end face of valve stem and the surface of valve
spring seat. Replace the valve seat, if the measured value exceeds the limit.
End Face of
Standard values: Valve Stem
Fig.1.1.064
Valve Protrusion
For exhaust valve: 54.10mm Height
Limits:
Surface of Valve
For intake valve: 53.71mm Spring Seat
■ Correct the valve seat.

a. Before correcting the valve seat, check the gap between valve conduit and valve. Replace the valve
conduit, if necessary.
41
Mechanical Part of
b. Correct the valve seat by the proper special tool or the valve seat grinder till the specified seat
surface width and angle are met.
c. After correcting the valve seat, grind the valve

and the valve seat by the grinding cream. Fig.1.1.065
Then, check the protrusion height of valve
stem (refer to the forementioned check steps
of valve seat)
■ Replacement of Valve Seat Fig.1.1.066

a. Cut away the replaced valve seat from its
inner side in order to decrease the wall
thickness. Then, dismount the valve seat.
Cut Away
b. Rebore the valve seat hole on cylinder cover Fig.1.1.067

till the hole matches the selected valve seat
with a extended diameter. See “Maintenance
Parameters” for the detailed size. Valve Seat
Height
c. Do not have the cylinder head hole scratched
by the valve seat cooled by the liquid nitrogen
before it is pressed.
Inner Diameter of Extended Hole
d. Correct the valve seat till its width and angle
meet the specifications (see the operation
instruction of valve seat correction).
42
Mechanical Part of
XIII. Cylinder Body Assembly
1. Element
Disassembly Diagram of Cylinder Body Assembly
1— Flywheel bolt 2— Flywheel assembly 3— Upper division plate 4— Crankshaft oil seal 5— Crankshaft oil
seal housing 6— Bearing cap bolt 7—Fourth bearing cap 8— Bearing cap 9— Intermediate bearing cap 10—
Lower main bearing shell 11— Intermediate main bearing shell (lower) 12— Crankshaft 13—Upper main bearing
shell 14— Intermediate main bearing shell (upper) 15— Knock sensor 16— Engine oil pressure switch 17—
Cylinder body
1) Disassembly
① Dismount the engine assembly from the vehicle, and then detach the transmission from the engine.
See “Engine Assembly” for the detailed dismantlement steps.
② Dismount the following engine accessories. See relevant chapters for the detailed dismantlement
steps.
■ Intake and exhaust manifolds of engine
■ Drive belt
43
Mechanical Part of
■ Generator
■ Timing belt mechanism of engine
■ Water pump
■ Water pump components
■ Support racks of power steering pump, generator and air conditioner compressor
■ Ignition coil
③ Fix the whole engine.
④ Discharge the engine oil. See “Replacing the engine oil”
⑤ Dismount the flywheel assembly. Fix the flywheel by the special tool, and then dismount the fixing
bolt and the upper division plate.
■ Tightening torque: For flywheel: 127~137N·m
For upper division plate: 8~12N·m
Attention:
■ Do not place the signal plate of crankshaft position sensor on flywheel downwards.
■ Loosen the fixing bolts in diagonal sequence.
⑥ Dismount the following systems. See the relevant chapters for the detailed dismantlement steps.
■ Cylinder head
■ Engine oil pump housing
■ Oil pan
⑦ Dismount the knock sensor.
Attention:
■ Do not drop or knock the sensor.
⑧ Dismount the rear oil seal housing.
■ Insert the screwdriver between the crankshaft and the rear oil seal housing to perform the
dismantlement.
Attention:
■ On dismounted, the rear oil seal must not be reused and shall be replaced by a new one.
⑨ Dismount the piston and connecting rod assembly.
Before dismounting the piston and connecting rod assembly, check the gap at the big end of connecting
rod. See “Check after Disassembly” hereinafter.
44
Mechanical Part of
a. Rotate the crankshaft, and place the journal side of crankshaft (which is corresponding to the
connecting rod to be dismounted.) at the center of bottom.
Note: For the purpose of easy reassembly, mark a Fig.1.1.068

sequence number on the side face of big end of
dismounted connecting rod. Sequence
Number of
b. Dismount the connecting rod cover. Cylinder
■ Tightening torque: 16.7±2N·m+90°~94°
c. Push out the piston and connecting rod
assembly from the cylinder head side by the
rubber hammer or the equivalent tool.
Attention:
■ Do not have the cylinder wall and the crankshaft journal damaged by the big end of connecting rod.
⑩ Dismount the connecting rod bearing shell from the connecting rod and the connecting rod cover.
Attention:
■ Identify their mounting positions, and properly place them to avoid confusion.
⑪ Dismount the piston ring from the piston.

Before dismounting the piston ring, check the side gap of piston ring. See “Check after Disassembly”
hereinafter.
Attention:
Fig.1.1.069
■ Use the piston ring expander.
Piston Ring
⑫ Dismount the piston ring from the connecting Expander
rod by the following means:
a. Insert the push rod (a special tool) from the
front arrow-marked side, and then mount the
guide sleeve D.
b. Let the front mark of piston face upwards, and
then mount the piston and connecting rod
Push Rod
Fig.1.1.070
assembly on the mounting base of piston pin
(a special tool).
Front Mark
c. Extrude the piston ring by the press. Front
Mark
d. Detach the connecting rod and the piston from

Guide Sleeve D
the piston and connecting rod assembly.
Base
Attention:
■ After dismounting the piston pin, place the
piston together with the piston pin and the
connecting rod.
45
Mechanical Part of
■ It is forbidden to place the pistons, the piston pins and the connecting rods of different cylinders
together.
Dismount the crankshaft bearing cap.
Before loosing the crankshaft bearing cap, measure the axial gap of crankshaft. See “Check after
Disassembly” hereinafter.
Loosen the bolts of crankshaft bearing cap in the Sequence Number of

Fig.1.1.071 Bearing Cap
following sequence.
■ Tightening torque: 34±2N·m+30°~34°
■ In Fig.1.1.071:
For the upper row, 4→8→10→6 →2
For the lower row, 1→5→9 →7→3
During the dismantlement, it is allowable to jiggle Fig.1.1.072

the crankshaft bearing cap forwards and
backwards by the bolts of crankshaft bearing cap.
See Fig.1.1.072.
Dismount the crankshaft.
2) Check after Disassembly

Fig.1.1.073
① Axial Gap of Crankshaft
Measure the gap between intermediate main

bearing shell and crankshaft arm when the cranks
moves frontward or backwards to the end with the
scale indicator.
Limit: 0.25mm
If the measured value exceeds the limit, replace the intermediate main bearing shell, and then
remeasure the gap. Replace the crankshaft if the remeasured value is still higher than the limit.
46
Mechanical Part of
② Gap of Big End of Connecting Rod
Measure the gap between the connecting rod and

Fig.1.1.074
the crankshaft by the feeler gauge.
Limit: 0.4mm
If the measured value exceeds the limit, replace

the connecting rod, and then remeasure the gap.
Replace the crankshaft if the remeasured value is
still higher than the limit.
③ Side Gap of Piston Ring

Fig.1.1.075
Bad
Measure the side gap between piston ring and
piston ring groove by the feeler gauge.
Standard values: Feeler

Gauge
For 1st piston ring, 0.03~0.07mm Good
For 2nd piston ring, 0.02~0.06mm

Feeler Gauge
Limits:
Piston Ring
st
For 1 piston ring, 0.1mm
For 2nd piston ring, 0.1mm
If the measured value exceeds the limit, replace the piston ring, and then remeasure the gap. Replace
the piston if the remeasured value is still higher than the limit.
④ End Gap of Piston Ring
Ensure that the inner diameter of cylinder stays Fig.1.1.076Piston

Pressed and Fixed
within the specified range. Feeler
Gauge
Piston
See "Cylindricality of Cylinder" Ring
Lubricate the piston and the piston ring by the new

engine oil, then insert the piston ring till the piston
reaches the middle part of cylinder, and measure
the end gap of piston ring by the feeler gauge. Piston
Ring
Measured Point
Standard values:
For 1st piston ring, 0.20~0.35mm
For 2nd piston ring, 0.35~0.50mm
47
Mechanical Part of
Limits:
For 1st piston ring, 0.8mm
For 2nd piston ring, 0.8mm
If the measured value exceeds the limit, replace the piston ring, and then remeasure the gap. Bore to
extend the inner diameter of cylinder and use the corresponding piston and piston ring if the remeasured
value is still higher than the limit.
⑤ Planeness of Cylinder Body
Clean the pad on the surface of cylinder body, and eliminate the engine oil, sediment, carbon or other
contaminants.
Attention:
■ Do not have the pad sheet fall into the engine oil or engine coolant.
Ruler
■ Measure the planeness of cylinder body in the Fig.1.1.077
different directions at six positions by ruler and
the feeler gauge.
Standard values: below 0.03mm
Limits: below 0.1mm

Feeler
If the measure value exceeds the limit, replace the Gauge
cylinder body.
⑥ Cylindricality of Cylinder Fig.1.1.078
Measure the abrasion, ovality and cylindricality of

cylinder bore of each cylinder at six different
positions by the dial indicator.
Standard values:
For inner diameter of cylinder, 71.0mm
For cylindricality, below 0.01mm
⑦ Diameter of Piston Skirt

Fig.1.1.079
Use the dial indicator for outer diameter to check
whether the piston skirt is distorted.
Standard values:71.0mm
Dial Indicator
48
Mechanical Part of
⑧ Gap between Piston and Cylinder Bore
Calculate the gap through the piston skirt and the inner diameter of cylinder.
(Gap) ＝ (inner diameter of cylinder) － (diameter of piston skirt)
Standard values: 0.02~0.04mm
If the calculated value exceeds the limit, replace the piston and piston ring assembly.
⑨ Boring of Cylinder
a. The piston with extended size to be used shall be determined in accordance with the cylinder which
has the widest bore.
Pistons of the following extended sizes, i.e. 0.25mm, 0.50mm, 0.75mm and 1.00mm, are applicable.
b. Measure the diameter of piston to be used.
After boring the cylinder, it is required to make the Fig.1.1.080

gap between piston and cylinder meets the
standard value. The piston diameter shall be
measured at the position shown in the figure.
c. Calculate the boring size based on the piston

diameter.
[Boring size] ＝ [outer diameter of piston] ＋ [gap

between piston and cylinder (0.02~0.04mm)] －
[grinding tolerance (0.02mm)]
d. Boring each cylinder till it obtains the calculated boring size.
Attention:
■ To avoid the distortion due to heat during the boring course, bore the cylinders in the following
sequence: Cylinder 2 → Cylinder 4 → Cylinder 1 → Cylinder 3
e. Grind the cylinder till it meets the final processing size (outer diameter of piston ＋ gap between
piston ring and cylinder)
⑩ Diameter of Main Crankshaft Journal

Measure the main crankshaft journal by the dial indicator for outer diameter.
Replace the main bearing shell if the measured value exceeds the standard value.
49
Mechanical Part of
⑪ Diameter of Main Journal of Connecting Rod

Measure the diameter of main journal of
Fig.1.1.081 Dial Indicator
connecting rod by the dial indicator for outer
diameter.
Standard values:42.0mm
Replace the connecting rod bearing shell if the
measured value exceeds the standard value.
⑫ Gap of Connecting Rod Bearing Shell
Note: Use the plastic wire gauge to perform the
measurement.
a. Wipe the engine oil from the connecting rod
journal and the connecting rod bearing shell.
b. Put the plastic wire gauge on the connecting
Fig.1.1.082
rod journal, and asset it to a length equal to
bearing shell width. The plastic wire gauge
must be placed at the center of connecting rod
journal and be parallel with the axial line of
connecting rod journal.
c. Lightly put the connecting rod cover to its
specified place, and screw down the bolt till it
meets the specified torque.
d. Dismount the bolt, and gradually take down the connecting rod cover.
e. Measure the pressed portion of plastic wire gauge at the widest point by the scale which is printed
on the plastic wire gauge bag.
Standard values:0.02~0.04mm
Limits:0.1mm
⑬ Ovality and Cylindricality of Crankshaft
Measure the sizes of each main crankshaft journal
Fig.1.1.083
and main connecting rod journal at four different
positions as shown in the figure.
■ The difference between “X” and “Y” of “A” and
“B” represents the ovality.
■ The difference between “A” and “B” of “X” and
“Y” represents the cylindricality.
Limits:
For ovality, equal to or less than 0.05mm
For cylindricality: equal to or less than 0.05mm
50
Mechanical Part of
Calibrate or replace the crankshaft if the measured value exceeds the limit.
⑭ Gap of Crankshaft
a. Wipe away the engine oil from the crankshaft journal and the inner surface of bearing shell.
b. Mount the bearing shell.
c. Set the plastic wire gauge till its width equals Fig.1.1.084
to the width of bearing shell. Then, put the
gauge on the journal along the axial line of
journal.
d. Lightly mount the crankshaft bearing shell
cover, and screw down the bolt till it meets the
specified torque.
e. Dismount the bolt and lightly take down the
crankshaft bearing shell cover.
f. Measure the pressed portion of plastic wire
gauge at the widest point by the scale which is
printed on the plastic wire gauge bag.
Standard values: 0.02~0.04mm Fig.1.1.085

Plastic Wire
Limits:0.1mm Gauge
Attention:
Fig.1.1.086 Round-angle Rolling Area
■ The connecting rod journal and main journal of
crankshaft shall be rolled but needn't to be
machined to the reduced size.
⑮ Flywheel
Check whether the flywheel and the signal disk are
distorted or cracked.
Attention:
■ Do not disassemble the flywheel.
■ Do not place the signal disk of flywheel
downwards.
■ Do not damage or scratch the signal disc
during the operation.
■ Do not magnetize the signal disk during the
operation. Replace the flywheel if the disc has
been magnetized.
51
Mechanical Part of
3) Assembly
① Blow away the engine oil and engine coolant from the cylinder body, the cylinder bore and the
crankcase. Eliminate the foreign bodies.
Attention:
■ Use the goggles to protect your eyes.
② Mount the main and the intermediate bearing shells according to the following instruction.
Attention:
■ Select the bearing shells (See the table below) in accordance with the identification marks or the
color codes of crankshaft. If the crankshaft can not be identified, measure the axial diameter of
crankshaft, and then select the corresponding bearing shell to match the crankshaft.
Comparison Table between Crankshaft Identification Marks/ Color Codes and Bearing Shells
Bore of Cylinder Body
Crankshaft Journal Bearing Shell
Bearing Hole
Color Identification Identification
Range Journal Diameter Identification Mark
Code Code Mark
0 1
1 Yellow I 47.995~48.000 1 2
2 3
0 2
2 Colorless II 47.988~47.995 1 3
2 4
0 3
3 Yellow III 47.980~47.985 1 4
2 5
■ The identification mark representing the bore Fig.1.1.087

of cylinder body bearing shell is printed at the
shown position by figure 1 in front of engine. It
is required to select and mount the bearing
shell according to these marks.
■ Select the bearing shell from the
forementioned table on the basis of referring to
the identification marks.
■ Every upper bearing shell but the intermediate
Fig.1.1.088 With Groove
bearing shell is grooved. However, the
Without
intermediate bearing shell has the supporting Groove
flange and the upper and lower portions of
Lower Bearing Shells (No.1,
intermediate are the same. Lower Bearing Shells No, 2, No.4 and No.5)
(No.1, No, 2, No.4 and Without
■ All lower bearing shells are free of groove. No.5)
Groove
a. Eliminate the dust, the dirt and the engine oil

from the matching surface between cylinder Upper and Lower Intermediate Bearing Shell
body and main bearing cap. (No.3)
b. Mount the intermediate and the upper bearing

shells onto the cylinder body
52
Mechanical Part of
c. Pay attention to the mounting direction of bearing shell during the operation.
■ The bearings shell with oil hole and groove shall be placed near the cylinder body, whereas those
without oil hole and groove shall be close to the main bearing cap.
■ Before mounting the bearing shell, apply the engine oil onto the surface of bearing shell. The back
side of bearing shell shall not be coated with the engine oil but shall be thoroughly rinsed.
■ During the installation, align the flange of bearing shell with the cut of cylinder body and main
bearing cap.
■ Ensure that the engine oil hole on cylinder body aligns with that on corresponding bearing shell.
③ Mount the crankshaft onto the cylinder body.
When rotating the crankshaft by hand, check whether the rotation of crankshaft is smooth.
④ Mount the main bearing cap. Arrow Points to Timing Bearing Cap
Fig.1.1.089
Belt Side No
■ The main bearing cap can be identified through

the identification mark.
■ Mount the main bearing caps the in numerical

sequence from the timing bet side.
■ The arrow must point to the timing belt side.
⑤ Screw down the bolts for main bearing cap in

numerical sequence shown in the right figure.
a. Apply the new engine oil onto the thread and fixing surface of bolts for main bearing cap.
b. Screw down the bolts for main bearing cap in steps.
■ Tightening torque: 34±2N·m
c. Clockwise rotate all bearing cap bolts by 30°.
■ After mounting the bolts for main bearing cap, ensure that the crankshaft can be rotated smoothly by
hand.
■ Check the axial gap of crankshaft. See “Axial Gap of Crankshaft”.
⑥ Mount the piston onto the connecting rod

according to the following instructions. Fig.1.1.090
a. Measuring the following lengths (See the figure).
A： Size from piston flange to piston flange outside
Piston
Connecting
B： Size from piston flange to piston flange inside Rod
Pin
Piston
C： Length of piston pin.

D： Thickness of small end of connecting rod.
b. Introduce the measured values to the following
formula:
53
Mechanical Part of
L ＝ [(A － C) － (B － D)]／2
c. Insert the push rod (a special tool) into the piston pin, and then mount the guide sleeve A (also a
special tool).
d. When mounting the piston and the connecting rod, keep the front marks on the same side surface.
e. Apply the engine oil onto the outer circle of piston pin.
f. Press the guide sleeve A, the piston pin and the push rod in sequence to the front mark side.
g. Screw the guide sleeve B into the guide

sleeve A. The value of gap between these two
guide sleeves is obtained by 3mm plus the Fig.1.1.091
value L calculated from Step 2.
h. With the front mark facing downwards, mount
the piston and the connecting rod to mounting
base of piston pin.
i. Mount the piston pin by the press. Guide Guide
Sleeve B Sleeve A
Attention:
■ If the pressing load value exceeds the specified value, replace the piston pin and piston assembly
or/and the connecting rod.
Standard value: 108±54N·m
⑦ Mount the piston pin.
Attention:
■ When mounting the piston ring, do not damage the piston.
■ Do not damage the piston ring due to the excessive expansion.
a. Mount the oil ring Steel Sheet

Fig.1.1.092 Ring
a) Mount the spacer ring for oil ring into the piston ring
groove, and then install the upper and lower steel sheet
rings.
Attention:
■ The spacer ring and the steel sheet ring may be
installed in a discretionary direction.
The upper and lower steel sheet rings are identical. Spacer Ring
■ Sizes and colors of spacer rings and steel sheet rings
List for Sizes and Colors of Spacer Rings and Steel Sheet Rings
Size Color
Standard Colorless
Extended by 0.50mm Blue
Extended by 1.00mm Yellow
54
Mechanical Part of
b) To install the steel sheet ring, mount one end of the steel sheet ring into the groove by hand, and
then press the rest portion of such a ring till it is in position. See Fig.1.1.093.
Attention:
Fig.1.1.093
■ Do not install the steel sheet ring by the piston
ring expander, or else the ring may rupture.
c) After installing the steel sheet rings, check
whether they can move smoothly in two
directions. Piston Ring
Expander
b. Mount the first and second piston rings.

Use the piston ring expander to mount the first and second piston rings, with the identification marks
facing upwards (on the piston top side).
Note:
Identification Mark 1T
Identification marks: Fig.1.1.094
Identification Mark 2T Size Mark
For the first piston ring, 1T

For the first piston ring, 2T
1st Piston Ring
Attention:
2nd Piston
Ring
■ The following size marks are carved on the
piston rings.
List for Size Marks of Piston Rings

Size Size Mark
Standard None
Extended by 0.50mm 50
Extended by 1.00mm 100
⑧ Mount the connecting rod bearing rod onto the connecting rod and the connecting rod cover.
■ Confirm the identification marks on crankshaft and connecting rod at the positions shown in the
following figure, and select the bearing shell according to the following table.
List for Identification Marks of Crankshafts, Connecting Rods and Bearing Shells
Identification Mark of Crankshaft Identification Mark of Connecting Rod Identification Mark of Bearing Shell
1 (White) 1
I (Yellow) 2 (Colorless) 1
3 (Yellow) 2
1 (White) 1
II (Colorless) 2 (Colorless) 2
3 (Yellow) 3
55
Mechanical Part of
1 (White) 2
III (White) 2 (Colorless) 3
3 (Yellow) 3
No.1 No.2 No.3 No.4 No.5

Fig.1.1.095 Journal Journal Journal Journal Journal
Classification Mark
of Main Journal
(Crankshaft Front)
Classification Mark
of Crankshaft Pin
No.1 No.2 No.3 No.4

Crankshaft Crankshaft Crankshaft Crankshaft
Pin Pin Pin Pin
■ Before mounting the connecting rod bearing shell,

Fig.1.1.096
apply the engine oil onto the surface of bearing. Do
not spread the engine oil to the back side of bearing,
but thoroughly rinse the back side.
⑨ Mount the piston and connecting rod assembly onto
the crankshaft.
■ Place the crankshaft journal (which is corresponding
to the connecting rod to be mounted) at the just
center of bottom.
■ Apply the enough engine oil onto the cylinder bore,
the piston and the crankshaft journal.
■ Align the air ring opening with the oil ring opening.
Fig.1.1.097
See Fig.1.1.097. Steel Sheet No.1 Piston
Ring Ring
■ Align the cylinder body position with the mark on
connecting rod to be mounted, and then perform the
installation. Piston Pin
■ Ensure that the front mark on piston top faces the

timing belt side, and then press the piston and
connecting rod assembly into the cylinder from the No.2 Piston Ring Steel Sheet
Ring
cylinder upside.
■ Make the piston ring with front mark facing the front Fig.1.1.098
end of engine by the piston ring compressor or the
appropriate tool, and then mount the piston ring
onto the piston head.
Attention:
■ Do not damage the cylinder wall or the crankshaft
journal by the big end of connecting rod.
56
Mechanical Part of
⑩ Mount the connecting rod cover.
When operating, align the marks which are made

during the disassembly, and mount the connecting Fig.1.1.099
rod cover onto the connecting rod. If the
connecting rod cover is new and unmarked, the
bearing shell locking gaps shall be kept at the
same side.
⑪ Screw down the connecting rod nut. Locking Gap
Attention:
■ If the cylinder head has been installed before

mounting the connecting rod nut, it is required
to dismount the spark plug first.
■ When reusing the bolt, check whether it is scratched. The absence of thread scratch on bolt can be
proved only by the fact that it is allowable to smoothly screw the nut throughout its complete thread.
Or else, the bolt must be replaced.
■ Before mounting the nut, apply the engine oil onto its threaded portion and the seat face.
a. Mount the nut onto be bolt, and screw down them by hand. Later, alternately screw down the nuts to
ensure the correct installation of connecting rod cover.
■ Tightening torque: 16.7±2.0N·m
b. Make the painting mark on the top of each nut. Fig.1.1.100 Painting Mark
See Fig.1.1.100. Painting
Mark
c. Clockwise rotate the nut by 90°~94° from the

painting mark. Make the painting mark on the
bolt, too.
d. Rotate the nut till its painting mark aligns with Nut Bolt
that of bolt.
Attention:
■ The tightening force may be insufficient if the rotation angle of nut is less than 90°.
■ If the rotation angle of nut is more than 94°, completely loosen the nut and then redo the tightening
steps.
■ After screwing down the connecting rod nut, ensure that the crankshaft rotates smoothly.
57
Mechanical Part of
⑫ Mount the rear oil seal housing (with the rear oil seal of crankshaft installed) onto the cylinder body.
Press the rear oil seal onto the housing by the special Oil Seal
JAC-T3F005
tool. See Fig.1.1.10. Fig.1.1.10
⑬ Install the knock sensor.
Attention:
■ Do not screw down the nut when grasping the joint.
■ If the knock sensor is shaken, replace it with a new
one. Oil Seal Housing
Note:
Ensure that there is no foreign body at the matching surface of cylinder body or the back side of knock
sensor.
Notice the following items. Then, perform the installation which is just contrary to the dismantlement
steps.
■ Flywheel
Alternately screw down the fixing bolts till their tightening torques meet the specified values
XIV. Diagnosis of Common Troubles
List for Diagnosis of Common Troubles
Trouble Possible Cause Troubleshooting
The cylinder pad is leaky. Replace the cylinder pad.
The piston ring is damaged or abraded. Replace the piston ring.
Low cylinder pressure The cylinder or the piston is abraded. Repair or replace the piston or the
cylinder body.
The valve seat is abraded or damaged. Repair or replace the valve seat.
The volume of engine oil is insufficient. Check the volume of engine oil.
The engine oil pressure sensor is at fault. Replace the sensor.
The engine oil filter is jammed. Replace the filter.
Low engine oil
The gear or cover of engine oil pump is damaged. Replace it.
pressure
The viscosity of engine oil is low. Check and replace the engine oil.
The plunger of engine oil pressure switch is constantly open. Repair it.
The bearing gap is wide. Replace the bearing.
High engine oil The plunger of engine oil pressure switch is constantly closed. Repair it.
pressure
The engine supporting bolt loosens. Screw down it.
The transmission mounting support loosens. Screw down it.
The engine support loosens Screw down it.

Engine quiver
The adiabatic pad for engine is damaged. Replace it.
The supporting adiabatic pad for engine is damaged. Replace it.
The adiabatic pad for transmission is damaged. Replace it.
58
Mechanical Part of
The engine oil is thin (the oil pressure is low). Replace the engine oil.
Noise from valve The valve or the valve conduit is damaged or Replace the valve or the valve conduit.
abraded.
The volume of engine oil is insufficient. Check the volume of engine oil.
Noise from connecting rod bearing
The engine oil is thin (the oil pressure is low). Replace the engine oil.
shell and the main bearing shell
The bearing gap is wide. Check and then determine the cause.
Noise from gear belt The tension is improper. Regulate the tension.
The radiator or the radiating pipe is leaky. Repair or replace it.
The water tank cover is not sealed. Screw down or replace the cover.
Poor cooling performance The thermostat is leaky. Replace the thermostat pad.
The radiator is leaky. Repair or replace it.
The water pump is leaky. Replace it.
Jam in radiator The coolant contains the impurities. Replace the coolant.
The water tank cover is not strictly sealed. Replace it.
The cooling system is jammed. Rinse or replace it.
The thermostat is at fault. Replace it.
The belt skids. Adjust or replace it.

High temperature of coolant
The water pump is at fault. Replace it.
The sensor is at fault. Repair or replace it.
The fan is at fault. Repair or replace it.
The coolant is insufficient. Add the coolant
The thermostat is at fault. Replace it.

Low temperature of coolant
The sensor or the wire harness is at fault. Repair or replace it.
The sensor or the starter is at fault. Repair or replace it.
Ineffective fan
The fan relay or the wire harness is damaged. Repair or replace it.
The joint loosens. Screw down it

Leaky exhaust pipe
The exhaust pipe or the muffler is damaged. Repair or replace it.
The muffler loosens. Replace it.
The rubber pad falls off. Replace it.

Abnormal noise The exhaust pipe or the muffler connects with Correct them
the vehicle body.
The exhaust pipe or the muffler is damaged. Repair or replace it.
59
Mechanical Part of
XV. Maintenance Parameters
1. List for Technical Parameters of Engine
List for Technical Parameters of Engine
Item Standard Value Limit

Camshaft
Intake 37.298 36.8
Height of camshaft (mm)
Exhaust 37.161 36.66
Diameter of camshaft journal (mm) 44.925~44.94 -
Cylinder head and valve
Planeness of cylinder pad surface (mm) ＜0.03 0.1
Total height of cylinder pad (mm) 119.9~120.1 -
Intake valve 1.35 0.85
Thickness of valve edge (mm)
Exhaust valve 1.85 1.35
Diameter of valve stem (mm) φ5.5 -
Gap between valve stem and valve Intake valve 0.020~0.036 0.10
conduit (mm) Exhaust valve 0.030~0.045 0.15
Conical angle of valve 45°~45.5° -
Protrusion of valve stem (mm)
Total length of valve (mm)
Free height of valve spring (mm) 50.87 50.37
216/44.2 -
Load / mounting height of valve spring (N)/(mm)
588/34.7 -
Perpendicularity of valve spring ＜2° 4°
Contact width of valve seat (mm) 0.9~1.3 -
Inner diameter of valve conduit (mm) φ5.5 -
Protrusion of valve conduit (mm) 23.0 -
Extended by
φ10.605~10.615 -
0.05mm
Diameter of size-extended valve conduit on Extended by
φ10.805~10.815 -
cylinder head (mm) 0.25mm
Extended by
φ11.055~11.065 -
0.50mm
Extended by
φ28.425~28.445 -
0.3mm
Intake
Diameter of Extended by
φ28.725~28.745 -
size-extended 0.6mm
4G13S1
valve seat ring Extended by
hole (mm) φ26.425~26.445 -
0.3mm
Exhaust
Extended by
φ26.725~26.745 -
0.6mm
60
Mechanical Part of
Item Standard Value Limit Limit

Engine oil pump and oil pan
Addendum gap of engine oil pump 0.06~0.18 -
Side gap of engine oil pump(mm) 0.04~0.11 -
Gap of engine oil pump housing 0.10~0.18 0.35
Piston and connecting rod
Reference outer diameter of piston
4G13S1 71.0 -
(mm)
1st piston ring 0.03~0.07 0.1
Side gap of piston ring mm) nd
2 piston ring 0.02~0.06 0.1
st
1 piston ring 0.20~0.35 0.8
nd
Gap of piston ring opening (mm) 2 piston ring 0.35~0.50 0.8
Oil ring 4G13S1 0.20~0.50 1.0
Outer diameter of piston pin (mm) 18.0 -
Pressing load on piston pin (under room temperature) (N) 4900~14700 -
Oil gap of crankshaft pin (Gap of connecting rod journal) (IIⅡ11) 0.02~0.04 0.1
Side gap of big end of connecting rod (mm) 0.10~0.25 0.4
Crankshaft and cylinder body
Axial gap of crankshaft (mm) 0.05~0.18 0.25
Diameter of main journal of crankshaft (mm) 48.0 -
Diameter of connecting rod journal (mm) 42.0 -
Gap of main journal of crankshaft (mm) 0.02~0.04 0.1
Planeness of surface of cylinder body gasket (mm) 0.03 以下 0.1
Total height of cylinder body (mm) 256 -
Cylindricality of cylinder body (mm) 0.01 -
Reference inner diameter of
4G13S1-D2\4G13S1-DL 71.0 -
cylinder body (mm)
Gap between piston and cylinder (mm) 0.02~0.04 -
2. Tightening Torques
List of Tightening Torques
Item N·m
Engine and ignition system
Bolts for water pump belt pulley 7~11
Bolt for generator supporting bar (at the side face of
20~25
generator)
Bolt for generator kingpin 34~54
Oil rule bolt 19~28
165 (for homemade crankshaft) (with bolt head forging mark YM);
Crankshaft bolt M14×1.5
181(for KD crankshaft)
Spark plug 20~29
61
Mechanical Part of
Generator nut 34~54

Ignition coil 8~12
Bolt for camshaft position sensor 7.8~9.8
Bolt for camshaft position sensor support 12~15
Bolt for toothed plate of camshaft position sensor 17~26
Timing belt
Mounting bolt for timing belt housing 10~12
Mounting bolt for camshaft 78~98
Mounting bolt for tension pulley of timing belt 20~27
Mounting bolt for crankshaft rotation angle sensor (rotation
6~10
speed sensor)
Mounting nut and bolt (M10) for right support of engine 30~42
Mounting bolt (M8) for right support of engine 17~25
Fuel injection system
Mounting bolt for throttle valve body assembly 15~22
Mounting bolt for oil rail assembly 10~13
Water pump and inlet pipe
Water temperature alarm switch 10~12
Water inlet joint bolt 17~26
Water temperature sensor 20~40
Thermostat housing bolt 19~28
Water inlet pipe bolt 10~15
Water pump bolt 12~15
Mounting bolt for carbon canister solenoid valve support 8~10
Mounting bolt for knock sensor 15~25
Mounting bolt for other sensors 4~6
Supporting bolt (M8) for intake manifold 15~20
Supporting bolt (M10) for intake manifold 27~34
Intake manifold bolt 15~20
Exhaust manifold bolt (M8) 15~20
Exhaust manifold bolt (M10) 27~33
Bolt for adiabatic pad of exhaust manifold 8~12
Bolt for engine lifting lug 15~20
Rocker arm, rocker arm shaft and camshaft
Bolt for rocker arm chamber housing 3~4
Bolt for rock arm shaft assembly 28~34
Adjusting screw 8~10
Cylinder cap and valve
① Screw down the bolt to 49N·m; ② Loosen the bolt ;
Cylinder head bolt
③20±2Nm; ④ 90°~94°; ⑤ 90°~94°
62
Mechanical Part of
Engine oil pump and oil pan

Oil drain bolt 34~44
Oil pan bolt (M6) 6~8
Oil pan bolt (M8) 22~25
Bolt for engine oil filter 12~16
Mounting bolt for engine oil pump 12~15
Connecting rod
Connecting rod nut 16.7±2.0+90°~94°
Crankshaft and cylinder body
Flywheel bolt 127~137
Bolt for upper division plate 8~12
Bolt for rear oil seal housing of crankshaft 10~12
Bearing cap bolt 34±2+30°~34°
Mounting nut for knock sensor 15~25
Interface between engine and complete vehicle
Mounting bolts for exhaust manifold and front exhaust pipe 50±5
Mounting nuts for right support of engine and support of
57±5
complete vehicle
63
Mechanical Part of
Section II Engine Lubrication System

I. Precautions
Application Steps of Sealant:
1. Clear the used sealant attached on the application surface and matching surface of pad with scraper.
Fig. 1.2.001
Scraper
Attention:
■ Thoroughly clear the used sealant from grooves, fixed bolts and bolt holes on sealant application
surface.
2. Clean the application surface and matching surface of sealant with unleaded petrol, and clear the
attached water, lubricant and foreign substances.
3. Set the complete sealant with specified dimension on appointed position.
1) Mount the connecting element with properly applied sealant within 5min.
2) If there is any dirt on sealant, please clear it as soon as possible.
3) Do not retighten the bolt and nut after installation.
4) Fill engine oil and engine coolant 30min after the installation.
64
Mechanical Part of
II. Preparation
1. Repair Tools
List of repair tools
No. Tool Outline Drawing Illustration
1 Oil pressure gauge Measure oil pressure
Connect oil pressure

2 Hose gauge to cylinder
body
Oil pressure switch Dismount and mount

3
sleeve oil pressure switch
65
Mechanical Part of
III. Engine Oil
1. Check
1) Engine oil level
Note: Before starting the engine, park the vehicle levelly and stably and check the engine oil level. If the
engine has been started, stop the engine and check it after waiting for 10min.
① Pull out the oil rule and clean it .
② Insert the oil rule and make sure the engine oil Fig. 1.2.002
level is within the range shown in the figure.
③ Please adjust the oil level if it is out of range.
2) Appearance of engine oil
① Check the engine oil for white turbidity and Make sure the oil level is
severe pollution. between “L” and “H”.
② If the oil is turbid or polluted, it may be caused by pollution of engine coolant. Please repair or
replace the damaged spare parts.
3) Leakage of engine oil
Check the following areas for engine oil leakage.
■ Oil pan
■ Oil drain bolt for oil pan
■ Oil pressure switch
■ Oil filter
■ Matching surface of cylinder body and cylinder cover
■ Front and rear oil seals of crankshaft
■ Matching surface of oil pump and cylinder body
■ Matching surface of valve chamber cover and cylinder cover
■ Front oil seal of camshaft
4) Check of oil pressure
Attention:
■ As the temperature of engine oil is high, please prevent yourself from being hurt.
■ Check oil pressure after parking the vehicle.
66
Mechanical Part of
① Check oil level. Please refer to “Engine oil level”.
② Lift the vehicle, cut off the harness connector Fig. 1.2.003
at oil pressure switch and dismount the oil
pressure switch.
③ Mount the oil pressure gauge and hose.

Fig. 1.2.004
④ Start the engine and warm it to normal working temperature.
⑤ Check oil pressure when engine operates with no load.
Note: The engine pressure will increase when the temperature of engine oil is low.
■ If there is obvious difference, please check the oil piping and oil pump for leakage.
⑥ Mount the pressure switch in accordance with the following steps after check:
a. Remove the used sealant attached on pressure switch and engine.
b. Apply the sealant according to instructions and tighten the pressure switch.
■ Please apply the specified sealant: LT5699 or equivalent.
c. After the engine is warmed, make sure there is no oil leakage during normal operation of engine.
2. Replace Engine Oil
Attention:
■ As the temperature of engine oil is high, please prevent yourself from being hurt.
■ Please avoid direct contact of your skin with waste oil for a long time. If contact has taken place,
please wash your skin thoroughly with soap or detergent as soon as possible.
① Warm the engine and check the engine compartment for oil leakage. Please refer to “Leakage of
engine oil”.
67
Mechanical Part of
② Stop the engine and wait for 10min.
③ Loosen the engine oil filler cap and dismount the oil drain bolt.
④ Discharge the engine oil.
⑤ Mount the oil drain bolt equipped with new gasket.
Attention:
■ Be sure to clean the oil drain bolt and mount new gasket.
■ Tightening torque of oil drain bolt: 34~44N·m
⑥ Fill new oil.
Please refer to “Maintenance” for specification and viscosity of oil.
■ Oil volume: 2.5~3.5L
Attention:
■ Do not pull out oil rule when filling oil.
■ The oil filling volume varies with oil temperature and oil drainage time, thus the above data are only
for reference.
■ Always use an oil rule to check if the oil filling volume is proper.
⑦ Warm the engine and check the oil drain bolt and oil filter for oil leakage.
⑧ Stop the engine and wait for 10min.
⑨ Check the oil level. Please refer to “Engine Oil Level”.
IV. Oil Filter
1) Dismantlement
Dismount the oil filter with an oil filter spanner.
Attention:
■ Use original oil filter provided by JAC or equivalent.
■ As the temperatures of engine and engine oil are high, please prevent yourself from being hurt.
■ During dismantlement, prepare a cleaning cloth for absorption of leaked or splashed engine oil.
■ Do not make the engine oil stick o drive belt.
■ Thoroughly wipe and dry the engine oil splashed on the engine and vehicle.
68
Mechanical Part of
2) Installation
① Remove the foreign substances attached on

Fig. 1.2.005
mounting surface of oil filter.
② Apply one coating of a suitable of amount of

engine oil on oil seal surface of new oil filter.
③ Tighten the oil filter until the O-ring engages with the mounting surface. Tighten the oil filter for
another circle with a tightening torque of12~20N·m.
Attention:
■ The oil filter must be tightened with filter spanner.
■ If the filter is tightened by hand, oil leakage may occur due to inadequate tightening torque.
1) Check oil level. Please refer to “Engine Oil”.
2) Start the engine and check if there is oil leakage.
3) Stop the engine and wait for 10min.
4) Check oil level and fill engine oil. Please refer to “Engine Oil”.
69
Mechanical Part of
V. Oil Pan and Engine Oil Pump
1. Element
Breakdown drawing of oil pan and oil pump
1-Oil filter 2-Oil drain bolt 3-Oil drain bolt gasket 4-Oil pan 5-Oil pickup 6-Oil pickup gasket
7-Relief valve 8-Relief valve spring 9-Relief valve piston 10-Front oil seal 11-Oil pump casing
12-O-ring 13-Oil pump cover 14-Outer rotor of oil pump 15-Inner rotor of oil pump
2. Dismantlement
Caution:
■ Do not discharge engine oil when engine is hot, so as to avoid being hurt.
1) Discharge engine oil. Please refer to “Replace engine oil”.
70
Mechanical Part of
2) Dismount oil pan. Fig. 1.2.006

a. Loosen the fixed bolts according to following
sequence: center-both sides.
■ Tightening torque: (M6) 6~8N·m
(M8) 22~25 N·m
b. Knock the special tool into the space between Fig. 1.2.007
oil pan and cylinder body as it is shown in Fig.
1.2.007.
c. Slightly knock the side of special tool, make

the tool move along the sealing surface of oil
pan/cylinder body, and then dismount the oil
pan.
Attention:
■ Do not damage the matching surface.
3) Dismount oil pickup.

Fig. 1.2.008
Attention:
■ Do not drop the gasket.
4) Dismount oil pump casing.

Fig. 1.2.009
71
Mechanical Part of
5) Dismount the fixed bolt for oil pump casing and take off oil pump cover and oil pump gear.
6) Dismount the front seal of camshaft, relief valve and oil filter from oil pump casing.
3. Check after Dismantlement
1) Oil pickup
■ Clear the oil pickup of attached substances.
2) Oil pump casing
■ Check the oil hole of oil pump casing for blockage, and clean it when necessary.
■ Check the oil pump casing for crack and other damage. If there is any, please replace it.
3) Oil pump
Attention:
■ Check each clearance of oil pump. Replace the oil pump if the clearance is out of specified range.
■ Mount the rotor into front cover before check.
① Check the clearance of tooth crest.

Fig. 1.2.010
② Check the side clearance. Fig. 1.2.011

72
Mechanical Part of
③ Check the casing clearance.

Fig. 1.2.012
Limit value: 0.35mm
4. Installation Fig. 1.2.012

1) Mount oil pump casing
■ Wash the application surface of sealant and

front oil seal housing on cylinder body.
■ Apply 3mm of curling sealant on the whole

outside of oil pan flange.
■ Specified sealant: LT5699 or equivalent.
2) Mount front oil seal of camshaft

Fig. 1.2.014
■ Put the special tool on forehead of camshaft,
JAC-T3F003
and coat engine oil on its outside.
■ Coat the engine oil on sealing lip, and then Fig. 1.2.015
manually push the oil seal along guide sleeve
JAC-
until contacting with front oil seal housing.
Knock the oil seal to proper position with special

tool.
3) Mount relief valve assembly.
4) Mount oil filter.
■ Clean the mounting surface of oil filter on oil pump casing.
73
Mechanical Part of
■ Apply engine oil on O-ring of oil filter.
■ Tighten the oil filter until the O-ring engages with the mounting surface. Then tighten the oil filter for
another circle with a tightening torque of 12~20N.m.
Attention:
■ The oil filter must be tightened with filter spanner. If the filter is tightened by hand, oil leakage may
occur due to inadequate tightening torque.
5) Mount oil pan.
■ Clean the matching surface of cylinder body and oil pan.
■ Apply 4mm of curling beaded sealant on the Fig. 1.2.016

whole outside of oil pan flange.
6) Mount oil drain bolt of oil pan

Fig. 1.2.017
■ Mount the oil drain bolt gasket of oil pan as it is
shown in the figure.
Oil pan
Attention: side
■ After installation of oil pan, wait for at least

30min before filling engine oil .
1) Check the oil level and fill engine oil. Please refer to “Engine Oil”.
2) Start the engine and make sure there is no oil leakage.
3) Stop the engine and wait for 10min.
4) Recheck the oil level. Please refer to “Engine Oil”.
74
Mechanical Part of
Section III Cooling System of Engine
Fig. 1.3.001
I. Precautions
Precautions on sealant:
1. Removal of Sealant
After dismounting the fixed nut and bolt, separate

the matching surface with scraper and remove the
used sealant.
Attention:
■ Be careful not to damage the matching surface.
■ Insert the scraper and knock its side to make it slip, as shown in the figure..
■ Please slightly knock the spare parts with a plastic hammer for dismantlement in places where the
scraper is difficult to be used.
Attention:
■ Please be careful not to damage the matching surface when tools such as right-angled screwdriver
have to be used.
2. Application Steps of Sealant Fig. 1.3.002

Scraper
1) Clear the used sealant attached on the
application surface and matching surface of
pad with scraper.
■ Thoroughly clear the used sealant from Fig. 1.3.003

grooves, fixed bolts and bolt holes on sealant
application surface.
75
Mechanical Part of
2) Clean the application surface and matching surface of sealant with unleaded petrol, and clear the
attached water, lubricant and foreign substances.
3) Set the complete sealant with specified dimension on appointed position.
■ If there is a groove for sealant to be placed, put the sealant into the groove.
■ For a bolt hole, the sealant is generally put into Inner

Fig. 1.3.004 side
the hole and occasionally it is put outside.
Groove Bolt hole
Inner side
Please read this manual to confirm the operations.
■ Mount connecting element within 5min after sealant application.
■ If there is any dirt on sealant, please remove it as soon as possible.
■ Please do not retighten the bolt or nut after installation.
■ Fill engine oil and engine coolant 30min after the installation.
Attention:
■ The special illustration (if any) described in this manual should be complied with.
76
Mechanical Part of
II. Cooling Circuit
1. Cooling Circuit Diagram

Outlet pipe of radiator
Thermostat
Water
pump This circuit is closed during
major cycle
Engine water jacket

Radiator
Warm air
device: heat
Fan
exchanger
The water temperature

thermostat at this position will be
turned on at 82℃ to actuate
major circle and turned off below
82℃ to actuate minor cycle
Minor cycle
Coolant
Rubber
hose
Expansion
tank
Inlet pipe of radiator
Cooling circuit diagram

2. Basic Diagram of Cooling
Radiator
Expansion
tank
Thermostat
Thermostat
casing
Air throttle body
Warm air heat
exchanger
Water pump
Cylinder
Thermostat on body
Thermostat off
Cylinder
cover
Basic diagram of cooling
77
Mechanical Part of
III. Engine Coolant
1. Check
1) Level check
After the engine has cooled, check if the level of engine coolant in stock solution tank is within the range
between MIN and Max.
■ Adjust the engine coolant level when necessary.

Fig. 1.3.005
2) Leakage check
Apply pressure to cooling system with leak

Fig. 1.3.006
detector for radiator cover to check if there is any
leakage.
3) Test pressure
Caution:
■ Please do not dismount radiator cover when engine is very hot, or else, the high-pressure engine
coolant overflowing from radiator will cause severe burns.
Attention:
■ Test pressure over specified value may cause damage to radiator.
■ When it is detected that the engine coolant is decreasing, fill engine coolant into radiator. If any
spare parts are damaged, please repair or replace them.
78
Mechanical Part of
2. Replace Engine Coolant
Caution:
■ To avoid being burned, please do not replace coolant when engine temperature is extremely high.
■ Wrap up the radiator cover with thick cloth, and turn and open it carefully. Release the pressure in
radiator first, and then fully open the cover.
■ Be careful not to splash engine coolant onto the drive belt.
1) Discharge engine coolant
① Dismount the deflector on the right side of the engine. Please refer to “Engine Deflector”.
② Open the water drain plug at the bottom of radiator, and then open the radiator cover.
③ When necessary, please dismount the stock solution tank, discharge engine coolant and clean the
tank before reinstallation.
④ Check the discharged engine coolant for rust and other impurities or discoloration.
■ If it is polluted, please wash the engine cooling system. Please refer to “Wash Cooling System”.
2) Refill engine coolant
① Mount the dismounted stock solution tank and water drain plug of radiator.
Attention:
■ Be sure to clean the water drain plug and mount the new O-ring.
② Make sure all the hose clamps have been tightened firmly.
③ Dismount the air cleaner upper cover and air intake hose. Please refer to “Air Cleaner Assembly”.
④ Cut off the outlet pipe of warm water pipe. Please lift the hose as high as possible.
⑤ Fill coolant into radiator and stock solution tank until specified level is achieved and slowly fill engine
coolant, so as to exhaust the air in system gradually.
Attention:
■ Apply the original engine coolant provided by JAC. Please refer to “Recommended Oil and
Lubricant”.
■ Cut off the connection when engine coolant overflows from warm water pipe, and then carry out
reconnection and continue to fill engine coolant.
⑥ Mount the air cleaner upper cover and air intake hose. Please refer to “Air Cleaner Assembly”.
⑦ Mount the radiator cover.
⑧ Warm the engine until the thermostat is turned on.
Touch the lower water pipe of radiator to detect if any warm water flows out, so as to check if the
thermostat has been turned on.
79
Mechanical Part of
Attention:
■ Check the engine water temperature indicator to avoid overheating of engine.
⑨ Stop the engine to lower the temperature.
■ The cooling time can be reduced by using fan.
■ Fill the engine coolant in radiator to the filler when necessary.
⑩ Fill the engine coolant in stock solution tank to the MAX position.
○
11 Mount the radiator cover and repeat steps ③~⑨ more than twice until the engine coolant level does
not lower any more.
○
12 Run the engine to check the cooling system for leakage.
3) Wash cooling system
① Mount the dismounted radiator water drain plug and stock solution tank.
Attention:
■ Be sure to clean the water drain plug and mount the new O-ring.
② Dismount the air cleaner upper cover and air intake hose. Please refer to “Air Cleaner Assembly”.
③ Cut off the outlet pipe of warm water pipe. Please lift the hose as high as possible.
④ Fill the engine coolant into radiator and stock solution tank, and mount radiator cover.
Cut off the connection when engine coolant overflows from warm water pipe, and then carry out
reconnection and continue to fill engine coolant.
⑤ Mount the air cleaner upper cover and air intake hose. Please refer to “Air Cleaner Assembly”.
⑥ Run the engine to warm it up to normal working temperature.
⑦ Increase the engine speed for several times when no load is applied to the engine.
⑧ Stop the engine and wait for it to cool.
⑨ Discharge the water in system. Please refer to “Discharge engine coolant”.
⑩ Repeat steps ①~⑨ until the radiator begins to discharge the cleared water.
80
Mechanical Part of
IV. Radiator
Caution:
■ Please do not dismount radiator cover when engine is very hot, or else, the high-pressure engine
coolant will cause severe burns. Wrap up the radiator cover with thick cloth and slowly turn it to
discharge the air pressure inside. Turn and open the radiator cover and take it off carefully after the
pressure is fully released.
1) Dismantlement
① Dismount the engine deflector. Please refer to “Deflector”.
② Discharge the engine coolant in radiator. Please refer to “Replace Engine Coolant”.
Attention:
■ Operate after engine is cooled.
■ Please do not make the engine coolant splash onto the drive belt.
③ Dismount the air intake pipe and take it off.

Fig. 1.3.007
④ Disconnect the harness connector of radiator fan motor and move it aside.
⑤ Dismount the inlet and outlet hoses of radiator and return hose of stock solution tank.
⑥ Dismount the mounting support of radiator and take off the radiator and radiator cooling fan
subassembly.
Attention:
■ Please do not damage or scratch the radiator core during dismantlement.
⑦ Dismount the radiator cooling fan sub-assembly from the radiator.
2) Installation
Install in the reverse order with dismantlement.
3) Check after Installation
■ Check if there is any engine coolant leakage with leak detector for radiator cover. Please refer to
“Leakage Check”.
81
Mechanical Part of
■ Start and warm up the engine. Visually inspect if there is any engine coolant leakage.
2. Check of Radiator Cover
1) Pull out the negative pressure valve and open it. Check if it can be fully closed after the pressure
release.
■ Make sure there is no dirt on or damage to negative pressure valve seat of radiator cover.
■ Make sure the opening and closing operations

of negative pressure valve are normal. Fig. 1.3.008
2) Check the relief pressure of radiator cover.
Standard value: 78~98KPa，

Fig. 1.3.009
Limit value: 59KPa
Connect the radiator cover to the leak detector for
radiator and apply engine coolant to sealing face of
the cover.
Replace the radiator cover when the operation of
negative pressure valve is abnormal or the relief
pressure decreases below limit value.
3. Check of Radiator
■ Check the radiator for slurry or blockage. If necessary, wash the radiator surface according to
following methods.
■ Be careful not to bend or damage the radiating fin.
■ When washing the radiator without dismantling it, please dismount all accessories such as cooling
fan, wind collection cover and horn. Then wrap up the harness connectors with adhesive tape to
prevent water from flowing in.
1) Wash the back of radiator core from top to bottom with the water hose pointing to the radiator
vertically.
2) Wash each surface of radiator core every 1min.
3) If no dirt is washed off radiator, washing must be stopped.
4) Vertically blow the back of radiator downwards with compressed air. Apply the compressed air with
pressure lower than 490KPa and keep the distance above 30cm.
5) Blow each surface of radiator core with compressed air every 1min until no water is blown out.
82
Mechanical Part of
V. Radiator Cooling Fan
1) Dismantlement
① Dismount the air intake pipe and take it off.
② Disconnect the harness connector of radiator Fig. 1.3.010

fan motor and move it aside.
③ Dismount the radiator cooling fan

sub-assembly.
Attention:
■ Do not damage or scratch radiator core during

dismantlement.
2) Installation
1) Disassembly
① Dismount the cooling fan from fan motor.
② Dismount the fan motor from wind collection cover.
2) Check after disassembly
① Cooling fan
Check the cooling fan for cracks or abnormal bend. If any, please replace the cooling fan.
② Fan motor
Check the motor for jamming.
3) Assembly
Assemble in the reverse order with disassembly.
83
Mechanical Part of
VI. Water Pump
Attention:
■ Be careful not to splash the engine coolant onto the drive belt while dismantling the water pump.
■ As the water pump can not be disassembled, it should be replaced as a whole.
■ After the installation of water pump, connect the hose, fix it with clamping band, and then check if
there is any leakage with leak detector for radiator cover.
1) Dismantlement
① Discharge the engine coolant in radiator.
Please refer to “Replace Engine Coolant”.
② Loosen the fixed bolt for belt pulley of water

Fig. 1.3.011
pump.
③ Dismount the drive belt. Please refer to “Drive

Belt”.
④ Carry out the dismantlement steps 3~9

described in “Timing Belt Mechanism”. Fig. 1.3.012
⑤ Dismount the fixed bolt for water pump.
Attention:
■ Please differentiate the positions for fixed

bolts properly.
■ Check the water pump body assembly for severe corrosion, leakage of water-seal and erosion.
■ Check for improper running due to too large end clearance.
■ Check the water pump bearing for jamming and other damages. Replace the bearing when
necessary.
84
Mechanical Part of
3) Installation
① Clear the sealant on mounting seat of water pump and inlet pipe at water pump side.
② Mount the new O-ring on groove of inlet pipe at water pump side.
Note: Apply engine coolant to O-ring.
③ Apply 3mm of curling sealant to mounting Fig. 1.3.013

surface of water pump.
④ Mount the water pump.
Attention:
■ Please do not drop the gasket during

installation.
■ Alternately tighten each fixed bolt evenly and insert them into water pump.
a. In this step, operate according to the installation steps described in “Timing Belt Mechanism”.
b. Mount the drive belt and adjust it in accordance with specified tension. Please refer to “Drive Belt”.
c. Mount the belt pulley of water pump.
d. Fill engine coolant. Please refer to “Refill engine coolant”.
VII. Thermostat Sub-assembly
1) Dismantlement
① Discharge the engine coolant through water

drain plug of radiator. Please refer to “Replace Fig. 1.3.014
Engine Coolant”.
Attention:
■ Operate after the engine has cooled.
■ Please do not splash the engine coolant

onto the drive belt.
85
Mechanical Part of
② Disconnect the inlet pipe, outlet pipe and minor

cycle pipe of radiator at thermostat casing side. Fig. 1.3.015
③ Disconnect the harness connectors of coolant
temperature sensor and water temperature alarm
switch and fixed bolts for support racks of harness
connectors of front and rear oxygen sensors, and
then remove them.
④ Dismount the fixed bolt for thermostat casing and

take off the thermostat casing. Fig. 1.3.016
⑤ Dismount the fixed bolt for thermostat upper cover

and take out the thermostat. Fig. 1.3.017

Fig. 1.3.018
① Thermostat
■ Check the opening of thermostat valve at normal
room temperature.
Temperature of thermostat (ON): 82℃ (initially open)
95℃ (fully open)
Maximum lift of valve stem: ≥8mm
Temperature of thermostat (OFF): >77℃
Please replace the thermostat when the measured
value exceeds the specified range.
② Thermostat upper cover and thermostat casing
86
Mechanical Part of
Check them for cracks and other damages.
3) Installation
Please pay attention to the following precautions and install in the reverse order with dismantlement.
① Be careful not to splash engine coolant onto the engine and wipe and dry the engine coolant with
cleaning cloth.
② Replace the O-ring of inlet pipe with a new one and apply coolant to the O-ring, so that it can be
inserted into the thermostat casing of water pump easily.
Attention:
■ Do not apply engine oil or other oils to O-ring.
■ The water pipe behind thermostat casing must be mounted stably.
③ When mounting thermostat, its poppet valve

Fig. 1.3.019
must be set at the highest position.
④ If the water temperature alarm switch needs to Fig. 1.3.020

be reused, apply specified sealant to its
thread.
⑤ If the engine coolant temperature sensor

Fig. 1.3.021
needs to be reused, apply specified sealant to
its thread.
87
Mechanical Part of
VIII. Water Piping Sub-assembly
1. Dismantlement
① Discharge the engine coolant through water drain plug at the bottom of radiator. Please refer to
“Replace Engine Coolant”.
Attention:
Fig. 1.3.022
■ Operate after the engine has cooled.
Rear end of cylinder cover
② Dismount the air cleaner assembly. Please
refer to “Air Cleaner Assembly”.
③ Dismount the upper and lower water hoses of

radiator.
④ Dismount the warm water hose and minor cycle

water piping.
⑤ Dismount the fixed bolt for intake manifold

support and take off the support. Fig. 1.3.023
⑥ Dismount the fixed bolt for inlet pipe, and then Air intake manifold
dismount the inlet pipes from rear ends of water

pump and thermostat casing.
Attention:
■ Please dismount the negative terminal of

storage battery before dismantlement.
2. Installation
Please pay attention to following precautions and install in the reverse order with dismantlement.
1) Firmly insert each hose. Mount the clamping band properly so that it will not clamp the raised
position of water piping.
2) Replace the O-ring of inlet pipe with a new one and apply coolant to the O-ring, so that it can be
inserted into the water pump and thermostat casing easily.
Attention:
■ Do not apply engine oil or other oils to O-ring.
88
Mechanical Part of
■ The water piping behind thermostat casing and water pump must be mounted firmly.
1) Check if there is any engine coolant leakage with leak detector for radiator cover. Please refer to
2) Start and warm up the engine. Visually inspect if there is any engine coolant.
IX. Trouble Analysis
Table for Overheating Cause Analysis
Symptom Check Item

Water pump Abrasion or excessive
malfunction looseness of drive belt
Jamming of thermostat
at close position
Blockage due to dust or
Improper heat radiation paper scraps —
Radiator is damaged
Mechanical damage
Excessive foreign
The radiator cooling is
substances (corrosion,
blocked
pollutants, sand, etc.)
The cooling fan fails to
work
Trouble of Spare Parts of Cooling System
The resistance for fan

Insufficient air flow rotation is too large Fan assembly —
The fan blade is
damaged
Damage of wind collection
— — —
cover
Incorrect mixture ratio of
— — —
coolant
Poor quality of engine Viscous engine coolant
—
coolant
Loose clamping band
Coolant hose
Broken hose
Water pump Improper sealing
Looseness
Radiator cover
Improper sealing
Damage, aging or incorrect
Engine coolant leaks installation of O-ring
Radiator Broken radiator water tank
Insufficient engine coolant
Broken radiator core
Breakage of stock solution
Stock solution tank
tank
Aging of cylinder cover
The stock solution tank Tail gas leakage to
is overflowing cooling system Aging of cylinder cover
gasket
Excessively high engine
speed in the case of
The engine is no-load
— Abnormal driving
overloaded
Long-term traveling
Driving at ultra high-speed
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Mechanical Part of
Drivetrain malfunction
Wheel and tyre with

Trouble of Spare Parts of Other Systems
incorrect specifications
—
mounted
Braking drag
Incorrect ignition timing
The vent of bumper is
—
blocked
Mounting cover
The radiator grill is
Blockage of slurry and
blocked
Poor ventilation paper scraps —
The radiator is
—
blocked
The condenser is Poor ventilation
blocked
X. Maintenance Parameters
Technical specification for cooling system
Temperature of thermostat (ON) 82℃ (Initially open) 95℃ (Fully open)

Temperature of thermostat (OFF) ≥77℃
Maximum lift of thermostat valve stem >8mm
90
Mechanical Part of
Section IV Fuel Supply System of Engine

I. General Precautions
Caution:
The following rules should be complied with during the replacement of spare parts of fuel pipeline.
■ Set the mark “Attention: combustive” in workshop.
■ Be sure to operate in the well-ventilated area, and prepare C02 fire extinguisher in the operation
workshop.
■ Do not smoke during the fuel system servicing. No fire in working area.
■ Hold the discharged fuel in the container and cover it. Put the container in safe area.
Attention:
■ Comply with the following steps when dismounting spare parts of fuel pipeline.
- Release the fuel pressure in fuel pipeline. Please refer to “Release Fuel Pressure”.
- Cut off the negative pole of storage battery.
■ Replace new circlip all the time.
■ Do not distort the fuel pipe during installation.
■ Please operate on level ground.
■ Connect the fuel pipe joint and make sure the joint has been fixed. Make sure the joint and resin
pipe don’t contact with any adjacent spare parts.
■ Do not excessively tighten the hose circlip to prevent damage of hose.
■ Check each connection for fuel leakage according to following steps after installation of fuel pipe.
- Set the ignition switch at “ON” position to apply fuel pressure on fuel pipeline (do not start the
engine). Then check each connection for fuel leakage.
- Start the engine, increase its speed and check each connection for fuel leakage.
■ Only the original fuel filler cap provided by JAC can be adopted.
■ Please refer to “Fuel Evaporative Emission System” for maintenance of spare parts of the system.
91
Mechanical Part of
II. Preparation
The special tools are listed in the table below:
List of Special Tools
S.N. Tool Outline Diagram No. Illustration
Fuel pressure Measure fuel

1 JAC－T1F018
gauge pressure
III. Fuel System
1. Check Fuel Pipe
Check the fuel pipeline, fuel filler cap and fuel tank for proper installation, leakage, crack, damage, loose
connection, abrasion and aging.
2. Release Fuel Pressure
1) Dismount the fuel pump fuse in fuse box.
2) Start the engine.
3) After the engine stops, restart and actuate the engine to idle for 2~3 times to thoroughly release the
fuel pressure.
4) Set the ignition switch at OFF position.
5) Remount the fuel pump fuse after fuel system servicing.
3. Check Fuel Pressure
Attention:
■ Before cutting off the fuel pipeline, release the fuel pressure in fuel pipeline to avoid danger.
■ Always keep the joints of fuel hose sealed with O-ring.
■ Do not operate electrical system during check.
Note: prepare a container under the fuel pipe to be cut off to avoid fuel splash.
1) Fully release the fuel pressure. Please refer to “Release Fuel Pressure”.
2) Dismount the nut for fuel pressure inspection door on fuel injector guide rail.
3) Connect fuel pressure gauge.
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Mechanical Part of
4) Set the ignition switch at “ON” position and check if there is fuel leakage.
5) Start the engine and check if there is fuel leakage.
6) Obtain the reading shown in fuel pressure gauge.
■ Fuel pressure: 350KPa
Attention:
■ Do not check fuel pressure during system operation.
■ During the check of fuel pressure, please always check the fuel connecting piping for fuel leakage.
7) If the check result is not good, turn to the next step.
8) Check for the following matters.
- Blockage of fuel hose and fuel pipe.
- Blockage of fuel filter.
- Water pump and its control circuit.
IV. Fuel Injector and Guide Rail
1. Dismantlement
Caution:
■ Read the “General Precautions” before dealing with fuel system. Please refer to “General
Precautions”.
1) Release the fuel pressure in fuel pipeline. Please refer to “Release Fuel Pressure”.
2) Cut off the PCV hose joint at intake manifold

Fig. 1.4.001
side.
3) Cut off the harness connector of manifold absolute pressure sensor and fuel injector.
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Mechanical Part of
4) Cut off the air throttle wiredrawing and the

fixed support of wiredrawing at air throttle Fig. 1.4.002
body side.
5) Disconnect the joint of fuel hose on fuel guide

rail. Fig. 1.4.003
Attention:
■ Please prepare the container and cleaning
cloth in advance as fuel leakage may take
place.
■ Avoid the naked flame and spark.
■ Please keep the spare parts away from heat
source. Special attention must be paid when
welding around them.
■ Do not expose the spare parts to the
electrolyte of storage battery or other fluid.
■ Keep the connection clean and prevent damage and foreign substance, and properly cover the
connection with plastic bag or equivalent.
6) Dismount the fixed bolt for fuel guide rail.
7) Take out the fuel guide rail with injector from Fig. 1.4.004
intake manifold.
Attention:
■ Avoid interference with fuel injector during
removal.
■ Absorb the fuel leaked from fuel pipe with
cleaning cloth.
8) Dismount the fuel injector from fuel guide rail
according to following steps:
a. Prize up and dismount the snap-in.
b. Straightly pull out the fuel injector from fuel
pipe.
Attention:
■ Pay attention to the leakage of residual fuel in
fuel pipe.
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Mechanical Part of
■ Do not damage the nozzle of fuel injector.

■ Do not make it fall off or knock it.
■ Do not disassemble it.
1) Fuel Injector
■ Check the upper and lower seal rings of fuel injector for crack, aging and breakage. If any, please
replace them.
■ Check the injection hole of fuel injector for blockage. If any, please wash or replace it with special
instrument.
2) Fuel Guide Rail
■ Check the fuel inspection hole for damage and jamming. If any, please replace the guide rail.
■ Check if there is residuum in guide rail. If any, please replace the guide rail.
3. Installation
1) Please pay attention to the following precautions when mounting new O-ring on fuel injector.
Attention:
■ As the upper and lower O-rings are different, do not confound them.
Fuel pipe side: thick one
Nozzle side: thin one
■ Please mount the O-ring manually.
■ Lubricate the O-ring with petrol.
■ Do not wash O-ring with solvent.
■ Please make sure there is no foreign substance on O-ring and its accessories.
■ Make sure the O-ring will not be scraped by tool or fingernail, distorted or stretched during its
installation.
■ Insert new O-ring into fuel injector straightly. Fig. 1.4.005

Do not deflect or distort it.
2) Mount fuel injector ④ on fuel pipe ① in

accordance with following steps.
③ : thick one
⑤ : thin one
a. Insert the snap-in ② into the fixing groove for

snap-in on fuel injector. Insert the snap-in slice
D into raised position F of fuel injector.
95
Mechanical Part of
Attention:
■ Replace with the new snap-in every time.
■ Make sure there is no interference between the snap-in and O-ring.
b. Insert the fuel injector into fuel pipe where snap-in has been mounted.
Attention:
■ Make sure the direction of insertion aligns with the axis.
■ Insert the snap-in slice C into the raised position B of fuel pipe.
■ Make sure the flange A of fuel pipe is properly mounted in the fixing groove on snap-in flange.
c. Make sure the fuel injector will not move or fall off to complete the installation.
3) Mount fuel pipe guide rail and fuel injector assembly inside of intake manifold.
Attention:
■ Be careful not to make fuel injector nozzle contact with other spare parts.
4) For the following steps, install in the reverse order with dismantlement.
Check if there is fuel leakage according to following steps.
1) Set the ignition switch at “ON” position (when the engine stops), and then check the connection of
fuel pipe for leakage.
2) Start the engine, increase its speed and recheck the connection of fuel pipe for leakage.
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Mechanical Part of
V. Fuel Filter
1. Dismantlement
Caution:
Precautions”.
Attention:
■ The fuel filter should be periodically replaced in accordance with the maintenance instruction
specified in “User’s Manual”.
1) Release the fuel pressure in fuel pipeline. Please refer to “Release Fuel Pressure”.
6) Cut off the fuel pipe joint 1 (at fuel pump side),
joint 2 (at fuel filter side) and grounding end 3 Fig. 1.4.007
of fuel filter.
Attention:
The fuel filter should be wrapped up with towel or

equivalent, so as to avoid injection of residual fuel
pressure.
Cut off the joint according to following methods:
2) Open the fuel filler cap. Fig. 1.4.006

3) Release the pressure in fuel tank.
4) Dismount the rear seat cushion. Please refer

to “Rear Seat”.
5) Dismount the service lid for fuel tank.
■ Directly prize it up with right-angled

screwdriver.
■ Hold the side edge of joint and press the

raised position of joint to pull out the fuel pipe. Fig. 1.4.008
■ If the joint attaches to the resin pipe, push and

pull the joint for several times until it moves,
and then pull out the joint.
Attention:
■ The joint can not be cut off until the raised

position is fully pressed down. Do not
excessively distort the joint.
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Mechanical Part of
■ Do not cut off the joint with any tool.
■ Prevent the resin pipe from being heated. Special attention must be paid when welding around the
resin pipe.
■ Prevent the resin pipe from contacting with acidic fluid such as electrolyte of storage battery.
■ Do not bend or distort the resin pipe during installation and dismantlement.
■ To keep the connection clean and prevent from damage and foreign substance, please fully cover
them with plastic bag or equivalent.
7) Take off the fuel filter and fuel pipe.

Fig. 1.4.009
2. Installation
Pay attention to the following precautions and
install in the reverse order with dismantlement.
1) Fuel filter
■ Pay attention to the installation direction of

Fig. 1.4.010
fuel filter.
Face to the fuel inlet pipe side
2) Connector
Connect the connector of fuel supply hose according to following methods:
① Check the connection for foreign substance and damage.
② Make the connector align with the resin pipe and insert the connector straightly until “click” is heard.
③ Check if the connector is properly connected in accordance with following methods after connection.
■ Visually check if the 2 raised positions have been connected to the connectors.
98
Mechanical Part of
■ Stretch the resin pipe and its connector hard

Fig. 1.4.011
and make sure they have been firmly
connected.
1) Set ignition switch at “ON” position (when engine stops), and then check the connection of fuel pipe
for leakage.
VI. Fuel Pump Assembly
Figure of fuel pump assembly
99
Mechanical Part of
1. Dismantlement
Caution:
Precautions”.
1) Check the fuel level indicated by fuel oil meter. If the meter indicates “full” or “to be full”, discharge
the fuel in fuel tank until the meter indicates that the fuel level is lower than position “E”.
Note:
As the fuel level exceeds the mounting surface of fuel level sensor, the fuel may overflow during the
dismantlement of fuel level sensor.
2) Release the fuel pressure in fuel pipe. Please refer to “Release Fuel Pressure”.
3) Open the fuel filler cap.
4) Release the pressure in fuel tank.
5) Dismount the rear seat cushion. Please refer to “Rear Seat”.
6) Dismount the service lid for fuel tank. Fig. 1.4.012

■ Directly prize it up with right-angled
screwdriver.
7) Cut off the harness connector of fuel pump

and fuel pipe joint. Fig. 1.4.013
① Fuel pipe joint of fuel pump
② Harness connector of fuel harness
Cut off the joint according to following methods:
■ Hold the side edge of joint and press the raised position of joint to pull out the fuel pipe.
■ If the joint attaches to the resin pipe, push and pull the joint for several times until it moves, and then
pull out the joint.
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Mechanical Part of
Attention:
■ The joint can not be cut off until the raised position is fully pressed down. Do not excessively distort
the joint.
■ Do not cut off the joint with any tool.
■ Prevent the resin pipe from being heated. Special attention must be paid when welding around the
resin pipe.
■ Prevent the resin pipe from contacting with acidic fluid such as electrolyte of storage battery.
■ Do not bend or distort the resin pipe during installation and dismantlement.
■ To keep the connection clean and prevent damage and foreign substance, please fully cover them
with plastic bag or equivalent.
8) Loose and take off the locknut with special tool. Fig. 1.4.014
Note: to facilitate dismantlement, the fuel tank has

been dismounted.
9) Take off the Y-ring. Fig. 1.4.015
Attention:
■ Tilt the fuel pump when it is taking out, so as to

avoid breakage of fuel level sensor.
■ Prevent the residual fuel from being polluted

and wrap the Y-ring with cloth to pull it out
straightly.
10) Take off the fuel pump.
Fig. 1.4.016
1) Fuel pump
① Visual Inspection
■ Check if there is breakage or fuel impurity. If

any, please replace or wash it.
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Mechanical Part of
② Check of Fuel Pump Operation
■ Actuate the fuel pump with 12V regulated power supply directly and check if the operation is normal.
Attention:
■ Do not make the fuel pump operation for a long time, so as to avoid damage of pump core.
2) Y-ring
■ Check it for material loss and breakage.
3) Locknut
■ Check it for deformation, crack, material loss, breakage and damage at mounting thread.
4) Fuel Level Sensor
■ Check the fuel float for interference and oxidation of its surface.
3. Installation
Pay attention to following precautions and install in the reverse order with dismantlement.
1) Fuel pump assembly
■ The Y-ring must fully engage with fuel tank during installation.
■ Tilt the fuel pump to facilitate its installation and pay attention to its assemblage direction.
■ There should be no turnup on Y-ring during the installation.
■ Pre-tighten the locknut during its installation, and then tighten it horizontally.
2) Connector
Connect the connector of fuel supply hose according to following methods:
① Check the connection for foreign substance and damage.
② Make the connector align with the resin pipe and insert the connector straightly until “click” is heard.
③ Check if the connector is properly connected in accordance with following methods after connection.
■ Visually check if the 2 raised positions have been connected to the connectors.
■ Stretch the resin pipe and its connector hard and make sure they have been firmly connected.
1) Set ignition switch at “ON” position (when engine stops), and then check the connection of fuel pipe
for leakage.
102
Mechanical Part of
VII. Fuel Tank Assembly
Breakdown diagram of fuel tank assembly

1-Filler cap 2-Filler port 3-Fuel tank 4-Fastening band of fuel tank 5-Service lid 6-Locknut 7-Y-ring
8-Fuel pump 9-Fuel filter 10-Thermal baffle
1） Dismantlement
Caution:
Precautions”.
■ Discharge the fuel in fuel tank when necessary. Please refer to “Fuel Pump”.
■ Please operate on level ground.
① Carry out the dismantlement steps 1~7 of fuel pump. Please refer to “Fuel Pump”.
② Disconnect the fuel supply hose and vent hose.
③ Disconnect the EVAP hose.
④ Support the fuel tank bottom with special jack.
Attention:
■ The fastening band of fuel tank can not be blocked by supporting position.
103
Mechanical Part of
⑤ Dismount the clamping bands of filler port and fuel tank, and then disconnect the filler port and fuel
tank.
⑥ Dismount the fastening band of fuel tank.
■ Tightening torque: 30~40N·m Fig. 1.4.017

⑦ Manually support the tank and carefully lower
the jack to dismount fuel tank.
Attention:
■ Make sure all connections have been

disconnected.
■ Make sure there is no interference to the

vehicle.
2) Check after dismantlement
① Fuel tank
■ Check if there is impurity in fuel. If any, clean it with hot water.
② EVAP hose and circlip
■ Check the hose for blockage, corrugation, deformation and breakage.
■ Check the circlip for damage and breakage.
③ Reinforced plate and its backing pad
■ Check the surface of reinforced plate for scratch and deformation.
■ Check the backing pad of reinforced plate for crack, material loss, deformation and breakage.
3) Installation
Pay attention to following precautions and install in the reverse order with dismantlement.
■ Firmly clamp and insert the fuel supply hose.
■ Do not set the hose clamp in expansion area of fuel pipe.
■ Please refer to “Fuel Pipe Joint” for precautions of fuel pipe joint connection.
① Set ignition switch at “ON” position (when engine stops), and then check the connection of fuel
pipeline for leakage.
② Start the engine, increase its speed and recheck the connection between piping and fuel pipe of fuel
system for leakage.
104
Mechanical Part of
VIII. Acceleration Control Device
1. Element
Breakdown diagram of acceleration control device

1-Accelerator pedal 2-Support rack of accelerated wiredrawing 3-Throttle control mechanism 4-Accelerated
wiredrawing
1) Dismantlement
① Lift the accelerator pedal and disconnect the connection of pedal and wiredrawing.
② Dismount the fixed bolt for accelerator pedal Fig. 1.4.018

and take off accelerator pedal from the
internal of vehicle.
105
Mechanical Part of
③ Disconnect the connection of throttle

Fig. 1.4.019
wiredrawing and air throttle body and loose
the wiredrawing to adjust the locknut.
④ Dismount the fixed bolt for wiredrawing and

disconnect the fixation of wiredrawing. Fig. 1.4.020
⑤ Take off the throttle wiredrawing.
① Accelerator pedal
Check the pedal for crack and flexibility of movable

knot.
② Throttle wiredrawing
Check if the wiredrawing operates smoothly. If not,

please fill enough lubricating oil.
3) Installation
Pay attention to following precautions and install in Fig.
the reverse order with dismantlement.
■ Please check if the movement is smooth
during installation of throttle wiredrawing.

■ Check the adjusting nut of wiredrawing during idling and set 1~2mm of idle stroke for the pedal.
■ Check if the operation of accelerator pedal is smooth.
IX. Maintenance Parameters
Table of Maintenance Specification
Capacity of fuel tank 45L
106
Mechanical Part of
Section V Emission Control System of Engine

I. Fuel Evaporation System
1. System Illustration
Intake manifold
Air cleaner
EVAP carbon canister

solenoid valve
Fuel-burning steam
EVAP carbon Air
canister
Fuel tank
Schematic diagram of fuel evaporation system
To decrease the emission of hydrocarbon from fuel system, the fuel evaporation system is applied. The
specific method is using charcoal in EVAP carbon canister. When the engine stops or fuel is filling into
the fuel tank, the fuel-burning steam evaporated from the sealed fuel tank will be induced and stored in
the EVAP carbon canister with charcoal. During the operation of engine, the fuel-burning steam in EVAP
carbon canister will be introduced into intake manifold through clean pipeline. EVAP carbon canister is
controlled by ECM. When the engine operates, the adjustment of steam volume controlled by EVAP
carbon canister solenoid valve will be directly proportional to the increase of air flow. During deceleration
and idling, EVAP carbon canister will cut off the steam cleaning pipeline.
107
Mechanical Part of
2. Diagram of Fuel Evaporative Emission Pipeline
Diagram of fuel evaporative emission pipeline
1-Carbon canister assembly 2-Fuel inlet hose of engine 3-Pipe connecting carbon canister with solenoid valve
4-Hose connecting carbon canister with solenoid valve 5-Fuel inlet pipe of engine 6-Fuel filter
Note:
Fig. 1.5.001
Do not use soap water or any other detergent
when installing vacuum pipe or cleaning pipeline.
3. Check of Element
1) EVAP carbon canister
① Check EVAP carbon canister in accordance

with following methods:
a. Block up port 1, blow at port 3 and make sure

the air flows out from port 2 freely.
b. Block up port 3, blow at port 1 and make sure

the air flows out from port 2 freely.
② Dismount the vacuum hose
Loose the clamping band locating from carbon canister to fuel tank and carbon canister solenoid valve
and pull out the vacuum hose with slip-joint pliers.
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Mechanical Part of
③ Dismount the carbon canister
Lift the carbon canister and dismount it from the

Fig. 1.5.002
retainer of inner lining of left fender. Left front frame
2) EVAP carbon canister solenoid valve
The air flow rate is controlled by the opening variation of steam by-pass pipeline in EVAP carbon canister
solenoid valve. The solenoid valve will repeat the operations of “ON” and “OFF” according to the signal
sent by ECM to actuate the variation of valve opening, so as to optimize engine control. The optimum
value saved in ECM lies on the condition of engine. When the engine operates, the airflow rate of
fuel-burning steam coming from EVAP carbon canister will adjust along with the variation of airflow.
① Element illustration
The EVAP carbon canister controls the flow rate of fuel-burning steam flowing out from EVAP carbon
canister by duty cycle of ON/OFF. The EVAP carbon canister solenoid valve is actuated by signal of
ON/OFF duty cycle sent from ECM. The wider the pulse width in “ON” condition is, the more fuel-burning
steam will flow through the valve.
② Dismantlement
Fig. 1.5.003
a. Disconnect the vacuum hose of EVAP carbon
canister solenoid valve.
109
Mechanical Part of
b. Disconnect the harness connector of EVAP

Fig. 1.5.004
carbon canister solenoid valve.
c. Take down EVAP carbon canister solenoid

Fig. 1.5.005
valve from the retainer.
3) Filler cap
Vacuum relief valve is mounted at the filler cap. When the pressure in fuel tank is high (with much
fuel-burning steam), the vacuum relief will be closed, so as to avoid emission of fuel-burning steam to
ambient environment. When the pressure in fuel tank is low (negative pressure), the vacuum relief valve
will be opened, so as to enable the outside air to get into fuel tank.
110
Mechanical Part of
II. Forced Ventilating System of Crankcase
Diagram of forced ventilating system of crankcase
1-Air cleaner 2-Air intake hose 3-Throttle valve casing 4-Purification can 5-PCV valve 6-Vent hose 7-Air intake
manifold 8-Fuel injector
The forced ventilating system of crankcase is used to bring the cylinder blow-by gas in crankcase back
to intake manifold.
It is the forced ventilating valve (PCV) which brings the cylinder blow-by gas in crankcase back to intake
manifold. When the air throttle of engine is partially open, the intake manifold sucks blow-by gas of
crankcase through PCV valve. In normal condition, the ventilation volume of PCV valve is enough for
suction of all blow-by gas of crankcase and a little of vent air. The vent air is brought into crankshaft
through air intake pipe. During this course, the air flows through the hose connecting air intake pipe and
rocker arm chamber cover. When the air throttle is fully open, the vacuum degree can not meet the
requirement of opening of PCV valve and suction of blow-by gas of crankcase. The airflow will flow
through connecting hose in reverse direction. The PCV valve can not meet the requirements when
severe blow-by takes place in the vehicle, as part of air will get into the air intake pipe all the time.
111
Mechanical Part of
2. Check of Element
Check the PCV (forced ventilation of crankcase) valve as it is shown below:
1) Operating principle
Table for operating principle of PAV valve
No High
Valve chamber cover side Valve chamber cover side

Operating condition of Operating condition of
Out of work Idling or deceleration
engine engine
PCV valve Out of work PCV valve Fully open
Variation of vacuum degree Limited Variation of vacuum degree Slight
Moderate No
Valve chamber cover side Valve chamber cover side

Operating condition of Operating condition of Improper acceleration and
Normal operation
engine engine high speed
PCV valve Normal operation PCV valve Retardant operation
Variation of vacuum degree Large Variation of vacuum degree Extremely large
112
Mechanical Part of
2) Dismantlement and Installation
① Dismantlement
a. Disconnect the connection of PCV valve hose

Fig. 1.5.006
and valve chamber cover.
b. Dismount PCV valve from valve chamber cover.

Fig. 1.5.007
① PCV valve
Fig. 1.5.008
Fizzy noise will arise from the valve in normal
operating condition when the airflow flows by.
Strong vacuum pressure will be detected when
putting a finger at the valve inlet.
② Vent hose of PCV valve
a. Check the hose and its joint for leakage.
b. Disconnect all hoses and clean them with compressed air. If the blockage in hose can not be
cleared, replace it.
113
Maintenance Manual of Tojoy Sedan Electrical Part of Engine
Chapter 2 Electrical Part of Engine
Section 1 Ignition System

I. Ignition coil
1. Element
Fig. of Ignition coil
2. Dismantlement & Installation
1) Dismantlement
Attention:
Fig. 2.1.001
■ Confirm that the ignition switch is in the “OFF”
position.
① Dismount the trimming cover of engine. Refer

to the “Intake Manifold” section.
114
② Disconnect the harness connector from the

Fig. 2.1.002
ignition coil and the connection with the high
voltage wire.
③ Dismount the ignition coil stop bolt, and take

Fig. 2.1.003
off the ignition coil.
■ Tightening torque: 8-12 N·m
④ Dismount the high voltage wire.

Fig. 2.1.004
Attention:
■ Please do not pull the lead wire of high voltage

wire.
⑤ Dismount the ignition plug with Ignition plug

Fig. 2.1.005
sleeve.
Attention:
■ Please do not drop or shake it.
115
① Ignition coil
■ Check the primary coil resistance between the terminals.
Primary coil resistance: 0.77-0.95 Ω
■ Check the secondary coil resistances at the high voltage ends between the No.1 cylinder and No.4
cylinder, and between No.2 cylinder and No.3 cylinder.
Secondary coil resistance: 7.75-10.23 KΩ
Attention:
■ The ignition coil harness connector must be taken off when the secondary coil resistance is being
measured.
② Ignition plug
Check the ignition plug:
■ Check whether the insulator of ignition plug is damaged or fractured.
■ Check whether the ignition plug has carbon deposit. See the following table for the reasons for
carbon deposit.
Phenomenon Black charcoal Hard charcoal

Reason There are impurities in the fuel or the Impurities in the fuel; wrong ignition
mixed air content in the fuel is too high. timing, or; untight ignition plug.
■ Check whether the ignition plug electrodes are damaged.
■ Check the clearance of ignition plug.
Check the clearance of ignition plug with a clearance gauge.
Standard clearance: 1.0-1.1 mm
If the clearance is beyond the standard value, please change it.
■ Check the sparking ability of ignition plug.
a. Connect the ignition plug with the high voltage wire.
b. Keep the clearance between the edge of ignition plug and the ground metal at about 14 mm.
c. Start the engine for about 3 s, and check whether there are sparks produced between the edge of
ignition plug and the ground metal.
Attention:
■ During check, be careful not to get an electric shock.
■ If the clearance is less than 14 mm, the sparks may also be produced even though the high voltage
wire has trouble.
116
■ If there are no sparks, please change the ignition

plug. Fig. 2.1.006
③ High voltage wire
■ Check whether the high voltage wire is damaged or

cracked.
■ Check the resistance of high voltage wire.
No.1 cylinder: 5.8 KΩ
No.3 cylinder: 2.9 KΩ
If the resistance is out of the specified range, please

change it.
3) Installation
II. Diagnosis of Common Troubles

Table for Diagnosis of Common Troubles
Trouble phenomena Possible causes Solution measures

The engine can’t or is difficult Trouble of ignition coil or ignition Check or change the ignition coil or the
to start. locking switch ignition locking switch
Trouble of ignition plug Check or change the ignition plug
Unconnected high voltage wire Check the high voltage wire
Unstable idle speed Trouble of high voltage wire or Check the high voltage wire or check or
ignition plug change the ignition plug
Trouble of ignition coil Check or change the ignition coil
Engine surge or poor Trouble of high voltage wire. Check the high voltage wire
acceleration Trouble of ignition plug Check or change the ignition coil
Poor economical efficiency of Trouble of ignition plug Check or change the ignition coil
fuel.
III. Maintenance Parameters

Maintenance Specification Table for Ignition System
Ignition coil Primary coil resistance 0.77- 0.95 Ω

Secondary coil resistance 7.75-10.23 KΩ
Ignition plug Ignition plug clearance 1.0-1.1 mm
Resistance of high voltage wire 16±3.2 KΩ/m
117
Section 2 Starting and Charging System

I. Basic Diagram of Starting and Charging System
Central electric box

120 A fuse
30 A fuse link
Storage battery
link
Ignition switch
Charging
alarm light
Combined
device
Anti-theft relay
Electric generator
ETACS－low level Rectifier

Magnetic
effective field
winding
Starter
Stator
winding
Solenoid
Electric switch
motor
One-way clutch
Basic Diagram of Starting and Charging System
II. Storage Battery
1. How to use storage battery
Attention:
■ If it is necessary to use auxiliary storage battery and jumper wire to start the engine, please use a 12
V auxiliary storage battery.
■ After the connection of the jumper wires of storage battery, confirm that the jumper wires are
clamped to the terminals of storage battery and have good contact.
2. Methods of preventing excessive discharging of storage battery
The following precautions shall be particularly emphasized to prevent excessive discharging of storage
battery.
■ Always keep the surface of storage battery (esp. the top) clean and dry.
■ The connecting part of the terminals shall be clean and tightened.
118
■ If the vehicle is not used for a long time, the cathode terminal of storage battery shall be
disconnected.
■ Check the charging condition of storage battery.
3. Check
1) Visual check
■ Check whether the terminals of storage battery are damaged, and whether the electrolyte leaks. If it
is the case, please change it.
2) Voltage check (U)
① If U>13.2V, please check the electrical system.
② If 12.5V<U<12.9V, the system is normal.
③ If 11V<U<12.4V, please check the charging system.
④ If U<11V, the storage battery is damaged or the charging system has trouble. Please check the
charging system and storage battery.
3) Dismantlement and installation
Attention:
■ The ignition switch shall be turned to the “OFF”

Fig. 2.2.001
position.
① Disconnect the cathode terminal.
② Dismount the anode terminal of storage

Fig. 2.2.002
battery and the fixed bolts of storage battery
pressure plate, and then take off the pressure
plate.
③ Take off the storage battery.
④ Take off the pallet of storage battery.
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① Pallet of storage battery
■ Check whether there is erosion. If there is, clean it with warm clean water.
② Storage battery harness
■ Check whether it is eroded or damaged. If it is, please change it.
7) Installation
Attention:
■ During connection, the anode terminal of storage battery shall be connected first.
■ After installation, each terminal may be smeared with mineral oil.
120
III. Starting System
The close of solenoid switch of starter provides a closed circuit between the storage battery and starter.
The starter is connected to the engine body for grounding. After the power supply and ground are
provided, the starter turns the crankshaft, and the engine starts.
2. Dismantlement and installation
Figure of Element of Starter
1-M port 2-S port 3-B port
1) Dismantlement Fig. 2.2.003

① Disconnect the cathode terminal of storage
battery.
Note: Before disconnecting the cathode terminal of

storage battery, pull off the vehicle key first.
121
② Lift the vehicle, and dismount the support rack

Fig. 2.2.004
of intake manifold. Please refer to the “Intake
Manifold” section.
③ Disconnect the harness connector of starter.

Fig. 2.2.005
④ Dismount the stop bolts of starter, and take off
the starter.
2) Installation
Attention:
■ Ensure to tighten the nut of “B” port.
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3. Disassembly and Assemblage
1) Disassembly
Exploded View of Starter
1-Screw 2-Front support 3-Stop ring 4-Snap ring 5-Pinion 6-Gear ring 7-Solenoid switch 8-Sun gear
9-Planetary gear 10-Ball 11-Pad 12-Stator 13-Armature 14-Electric brush retainer 15-Rear support
16-Fastening bolt
123
2) Check
① Solenoid switch check
■ Before check, disconnect the cathode terminal of storage battery.
■ Disconnect the “M” port of starter.
a. Test whether electricity is conducted between Connecting from

Fig. 2.2.006 the power
“S” port and switch body. supply
“M”
■ If not, please change the solenoid switch.
b. Test whether electricity is conducted between Fig. 2.2.007

Connecting from
the power supply
“S” port and “M” port.
“M”
■ If not, please change the solenoid switch.
② Pinion check
a. Check the teeth of meshing gear
■ If the teeth are abraded or damaged, please change the meshing gear (check the teeth of fly wheel
at the same time).
b. Check the teeth of pinion
■ If the teeth are abraded or damaged, please change the pinion (check the teeth of armature shaft
gear at the same time).
c. Check whether the pinion locks in one direction while turns smoothly in the other direction.
■ If it is able to lock or turn in both the directions, or if there is abnormal resistance, please change it.
124
③ Electric brush check

Fig. 2.2.008
■ Check the abrasion condition of electric brush.
If it is excessively abraded, please change it.
Vernier caliper
Electric brush
④ Electric brush spring check

Fig. 2.2.009
■ Remove the spring from the electric brush and
check the spring tension.
Electric brush
spring
Electric brush
⑤ Electric brush retainer

Fig. 2.2.010
a. Conduct insulation test between the electric
brush retainer (the anode side) and the support
(the cathode side). If electricity is conducted
between them, please change the electric
brush retainer.
b. Check whether the electric brush can move

smoothly.
■ If the support of electric brush bends, please

change it. If the sliding surface is dirty, please
clean it.
⑥ Stator check
Fig. 2.2.011 Magnet
■ Check whether the magnet is firmly fixed on the
stator, and check whether there are cracks.
If the spare parts have trouble, change the

assembly.
Attention:
■ Please do not clamp the stator with a bench

clamp, nor hammer it.
125
⑦ Armature check Fig. 2.2.012

a. Check whether electricity is conducted
between the adjacent rectifier cells.
■ If it is not conducted, please change it.
b. Check whether electricity is conducted

between the copper plate and the shaft of
each commutator.
■ If it is conducted, please change it.
c. Check the surface of commutator. Fig. 2.2.013

■ If it is rough, please slightly sand it with # 500
sand papers.
Sand paper
d. Check the diameter of commutator. Fig. 2.2.014

■ If it is below the standard value, please
change the commutator.
Vernier
caliper
Commutator
126
3) Assemblage
When assembling the starter, the bearing, the gear and the friction surface shall be lubricated by adding
high temperature lubricating grease. And then conduct the following operations.
① Gear clearance adjustment Fig. 2.2.015

■ Push the pinion out with the magnetic switch
powered on, and check the clearance between
the pinion and the stop block with a clearance
gauge.
Stop block
Gear clearance 0.5~1 mm
Pinion
■ If the clearance is out of the specified range,

Fig. 2.2.016
please adjust it with adjusting gaskets.
Adjusting gasket
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4. Flow of Diagnosis of Common Troubles (if there is any abnormal situation, please disconnect the
cathode of storage battery at once.)
Check Flow Chart of Common Troubles of Starting System

The engine fails to stop. Change the solenoid switch.
The engine fails to start.
Yes
Does the electric generator Does the electric generator run Yes
run after the rotation of
crankshaft? normally? Check the ignition/fuel system.
Yes
No
Check the following aspects of
Abnormal
the storage battery: 1. Charging
A Normal
situation 2. Connection of Repair the starter.
terminal 3. Erosion of terminal.
Yes Yes
Does the gear shaft run? Check the pinion clutch.
Does the starter run?
No No
Check the reduction gear, the armature and the gear shaft.
Abnormal
Check the fuse and the fusible Change.
fuse.
Normal
Check the following aspects of
the storage battery: 1. Abnormal
Charging situation 2. 1. Charge the storage battery.
Connection of terminal 3. 2. Repair the poor connection and A
Erosion of terminal. the eroded terminal of storage
battery.
Normal
Abnormal
Check the circuitry of starting
system. Repair.
Normal
Does the solenoid switch No
Repair the starter.
make noises during running?
Yes
Check the mesh condition of
If the starter is wired as follows with no
pinion and gear ring. Yes
load, does it run? Change the solenoid switch.
Abnormal
1. Adjust the displacement of
pinion. 2. Check the motion
mechanism of pinion. 3. Check
No
the gear ring. Repair the starter.
128
IV. Charging System
The electric generator provides DC voltage for the vehicle electric system, and keeps the charging
condition of storage battery. The voltage output is controlled by IC adjuster.
The “B” port supplies electricity for vehicle electric system, and provides charge power supply for the
storage battery. The IC adjuster checks the input voltage at the No.4 port (“S” port) and thereby controls
the output voltage.
After the power-on and grounding, the charging alarm light will be on. When the electric generator can
provide high enough voltage, the ground circuit will be opened, and the charging alarm light will be off. If
the charging alarm light is still on when the engine is running, it has troubles.
2. Charging alarm light
If the following situations occur when the electric generator is working, the warming function of IC
adjuster will be actuated, and the charging alarm light will be turned on.
■ No or too high voltage is produced.
3. Dismantlement and installation
Exploded View of Charging System
1-Engine belt 2-Belt pulley of water pump 3-Electric generator 4-Belt pulley of crankshaft
129
1) Dismantlement
Fig. 2.2.017
① Disconnect the cathode terminal of storage
battery.
② Disconnect the harness connectors of electric

generator. Fig. 2.2.018
③ Dismount the outrigger set bolts of electric

generator and the kingpin bolts of electric Fig. 2.2.019
generator.
■ Tightening torque: set bolt: 20-25 N·m
kingpin bolt: 34-54 N·m
Fig. 2.2.020
④ Dismount the belt of electric generator. Please refer to the “Drive Belt” section.
⑤ Take off the electric generator from the vehicle.
130
2) Installation
■ Install it in the reversed order of dismantlement.
■ Before installing the electric generator, please check the belt tension of electric generator. Please
refer to the “Drive Belt” section.
Attention:
■ Tighten the nut of “B” port. Tightening torque: 10-12 N·m
4. Disassembly and Assemblage
Exploded View of Engine
1-Lock nut 2-Belt pulley 3-Spacer 4-Front end cover 5-Front bearing 6- Bearing cap 7-Bolt 8-Armature
9-Rear bearing 10-Stator 11-Seal gasket 12-Rectifier 13-Electric brush retainer
14-Guide sleeve of slip ring 15-Rear cover

131
1) Disassembly
Disassemble in accordance with the following order.
① Belt pulley
② Rear cover
③ Rectifier assembly
④ Separate front end cover assembly and rear cover assembly.
Attention:
■ Be careful not to damage the stator assembly.
2) Check after disassembly
① Armature check
Fig. 2.2.021
a. Resistance test
Resistance: about 2.0-2.5 Ω
■ If it is beyond the standard range, please

change the armature.
Slip ring
b. Insulator test
■ If electricity is conducted in the insulator, please change it.
c. Check the abrasion situation of slip ring.
■ If it is beyond the standard range, please change the slip ring.
② Carbon brush
a. Check whether the carbon brush can move The mark line of abrasion limit of
Fig. 2.2.022 electric brush
smoothly.
■ If not, please check and clean the carbon brush

support.
b. Check the abrasion situation of carbon brush.
■ If it exceeds the limit value, please change the carbon brush.

132
② Stator check
Check whether electricity is conducted between Lead

Fig. 2.2.023
the terminals.
■ If it is not conducted, please change the stator.
Ground test
Fig. 2.2.024 Lead
■ If electricity is conducted, please change the
stator.
Stator
core
3) Assemblage
① Rear bearing
Attention:
■ The rear bearing can not be reused again after being taken off. Please change it for a new one.
■ It is not allowed to lubricate the outer ring of rear bearing.
② Installation of rear cover

Fig. 2.2.025
a. Mount the carbon brushes assembly, the
adjuster assembly and the stator.
b. Push the carbon brushes with fingers, and install them on the stator.
Attention:
■ Be careful not to damage the slip surface of slip ring.
133
5. Trouble Diagnosis for Charging System
Before the electric generator test, confirm that the storage battery has been sufficiently charged. For the
test, a 30 V volt meter and a proper test probe are needed. Refer to the check table to check the electric
generator.
■ Before startup, check the fusible fuse.
■ Use a storage battery with full capacity.
Check Flow Chart of Charging System

Disconnect the Conduct the following
The ignition The alarm connector, and The alarm
check: 1. Bulb of
switch is on. light is off. ground the L-side light is off.
alarm light 2. Fuse of
harness. alarm light .
The alarm light is Conduct the following
on. check: 1. Armature 2.
The alarm light is Change the
Slip ring of armature
on. damaged IC
3. Electric brush.
regulator.
Conduct the
The engine starts
The alarm light is following check: The engine The alarm light
with a rev of 1500
on. 1. Armature runs at idle is off.
rpm.
2. Slip ring of speed.
armature 3. Normal.
Electric brush
The alarm light is
The alarm light is Normal.
on.
off.
The engine rev is Change the

More than 16.0 V.
2500 rpm. damaged IC
Measure the regulator.
voltage of B port. Less than 13.0 V.
Change the
Conduct the following
damaged IC
check: 1. Armature 2. Slip
regulator or
ring of armature 3. Electric
diode assembly.
brush 4. Stator.
Alarm light: the “charging” alarm light in the combined device.

Note:
■ If the charging system has trouble but the test results suggest normal, check the connection of “B”
port (check the tightening torque and voltage drop).
■ Check the conditions of armature coil, armature slip ring, electric brush and stator coil. If necessary,
change the spare parts out of order.
134
Electronic Control
Maintenance Manual of Tojoy Sedan System of Engine
Chapter III Electronic Control System of Engine

Section I Precautions
I. Precautions of Supplement Restraint System (SRS)

Using the SRSs like airbag and pretensioner of safety belt together with the front seat safety belt can
contribute to the reduction of the risk of injury or the hazard severity of driver and front passenger during
the crash. About the information of proper maintenance of the system, please refer to the “airbag” part of
the manual.
Caution:
■ All of the maintenance should be carried out by the franchised stores authorized by JAC in order to
avoid increasing the risk of the personal injury and death due to the SRS system failure.
■ Improper maintenances, including incorrect dismantlement and installation of SRS system, are
likely to cause the wrong action of the system resulting in the personal injury and death.
About the dismantlement methods of clock spring (hair spring) and airbag controller, please refer to the
airbag part.
■ Except for the operations illustrated in the manual, please don’t use the electrically testing
equipment to test any circuit of the airbag system. The air bag circuit harness can be identified by
the yellow or orange harness or harness connectors.
II. General Precautions
1. Only the digital electric meter is permitted to be used to check the electronic control system.
2. JAC genuine components should be used during the maintenance, otherwise it is impossible to
guarantee the normal operation of the system.
3. Only the unleaded petrol can be used during the maintenance and usage.
4. The standardized maintenance and diagnosis flow should be complied with to carry out the
maintenance.
5. The disassembly and dismantlement for the system components are prohibited during the
maintenance.
6. During the maintenance process, the electronic elements (electronic control module and sensor)
should be fetched and placed very carefully to avoid the fall of it.
7. Foster the awareness of environmental protection to effectively deal with waste of the maintenance
process.
III. Precautions in Maintenance
1. During the simulation of hot working conditions of trouble and other maintenance operations
possibly resulting in the temperature rise, never make the temperature of electronic control module
exceed 80℃.
2. The fuel pipe should not be dismantled casually during the course of maintenance. In case of the
need for maintaining the fuel system, it is necessary to carry out the pressure release for the fuel
135
Electronic Control
system before the dismantlement of fuel pipe.

3. The dismantlement of fuel pipe and the replacement of fuel filter should be carried out in the
well-ventilated place by the professional maintenance personnel.
4. The fuel injection pump is not permitted to run in dry state or water, otherwise its service life may be
shortened. In addition the positive and negative poles of the fuel injection pump can not be
reversed.
5. During the check for the ignition system, the sparking should be detected only when it is necessary
and the time should be as short as possible. The air throttle can not be opened during the check,
otherwise the copious unburned petrol may flow into the exhaust pipe, accordingly leading to the
damage of three-way catalyst.
6. The manual adjustment is unnecessary, because the idling regulation is completed solely by the
electronic fuel injection system. The throttle stop screw of air throttle body has been adjusted well by
the manufacturer before leaving the factory, and it is not permitted for the users to change its initial
position arbitrarily.
7. Do not test the input and output electric signal of components by puncturing the skin of lead wire.
IV. Precautions of On-board Diagnosis (OBD) System

The electronic control module (ECM) has an OBD system. The malfunction indicator lamp (MIL) would
light up when the OBD system is warning the driver of the malfunction caused by the aging of the
emission system.
Notes:
■ Be sure to turn the ignition switch to OFF position and disconnect the connecting wire of storage
battery cathode before carrying out the repair and check. The open circuit or short circuit of relative
switch, sensor and solenoid valve may make the MIL brighter.
■ After the operation, be sure to connect and firmly lock the connectors. Loose (unlocked) connector
may lead to the open circuit, accordingly making the MIL brighter. (confirming that there is no water,
lubricating grease and filth on the joint and port is not bent).
■ After the operation, be sure to arrange and fix the harness correctly. The interference between the
support and harness etc. may lead to the short circuit, accordingly making the MIL brighter.
■ After the operation, be sure to connect the rubber pipe well. The failed connection of the rubber pipe
may lead to the brightness of the MIL caused by the troubles of the EVAP system and fuel injection
system etc.
■ The unwanted trouble information in the ECM should be erased before delivering the vehicle to the
user (the repair is done).
■ Be sure to use the 12V storage battery as the power supply.
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Electronic Control
■ Don’t disconnect the connecting wire of storage battery when he engine is running.
■ Turn the ignition switch to OFF position and disconnect the connecting wire of storage battery
cathode before connecting or disconnecting ECM harness connectors. Otherwise the ECM may be
damaged, because even if the ignition switch is turned to OFF position, the ECM still has 12V
voltage.
■ Turn the ignition switch to OFF position and

Fig 3.1.001
disconnect the connecting wire of storage
battery cathode before dismounting the
components.
Storage
battery
■ Don’t disassemble the ECM.

■ If some storage battery cable is disconnected, the memorizer will return to the initial value of ECM.
The ECM will begin to control by itself according to the initial value. When the port of storage battery
is disconnected, the engine will operate a little differently, which doesn’t mean any trouble. Don’t
replace the components because of a little change.
■ When connecting the ECM harness
connectors, push the button pole (1) to the Fig 3.1.002
end to lock the (B) as shown in the Fig.
- ECM(2)
- Release (A)
■ Insert the contact pin connector into the ECM

Fig 3.1.003
or pull it out of the ECM and pay attention to Bent
avoid damaging the contact pin port (bent or
broken). When connecting the contact pin
connector, guarantee that the contact pin port
of ECM is not bent or broken.
■ Connect the harness connectors of ECM Broken

firmly. The poor connection will cause the
extremely high (fluctuation) voltage on the coil
and capacitor, accordingly leading to the
damage of IC.
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Electronic Control
■ The harness of the electronic control system of engine should be remained for a length of at least
10cm from the joint to avoid the trouble of the electronic control system of engine caused by
receiving the exterior noise signal and decreasing the operation of IC etc.
■ Keep the spare parts and harness of the electronic control system of engine dry.
■ Check with the ECM port and reference value to assure the normal function of ECM before
replacing the ECM.
■ Even the very little leakage in the intake system may lead to the severe trouble.
■ Don’t swing or vibrate the camshaft position sensor (phase) and the crankshaft position sensor
(position).
■ Operate the DTC validation procedures or the whole function check after running the trouble
diagnosis. If the repair process is finished, DTC should be shown in the validation procedures of
DTC. If the maintenance is finished, the whole function check should obtain a good result.
■ When measuring the ECM with the circuit tester, the contact between the two measuring devices is
not permitted. If the probes touch, the short circuit may occur and the power transistor of ECM may
be damaged.
■ When measuring the input/output voltages, don’t use the grounding port. Otherwise the transistor of
ECM may be damaged. Please use the port other than the ECM to ground.
■ When there is no fuel in the fuel pipe, don’t use the fuel pump.
■ Screw down the clamping collar of fuel hose to
the specified torque. Fig 3.1.004
■ Don’t press down the accelerator pedal when
starting the vehicle.
■ Don’t increase the rotating speed of engine
immediately after starting the vehicle.
■ Don’t speed up before shutting down the
engine.
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Electronic Control
Section II Structural Principle and Overhaul of Engine Control System

I. System Illustration
Engine Control System
1-Carbon canister 2-Carbon canister solenoid valve 3-Air throttle body assembly 4-Air throttle position
sensor 5-Stepper motor 6-Intake pressure and temperature sensor 7-Fuel injector 8-Camshaft position
sensor 9-Ignition coil 10-Front oxygen sensor 11-Three-way catalyst 12-Rear oxygen sensor 13-Engine
coolant temperature sensor 14-Crankshaft position sensor 15-Fuel filter 16-Electric fuel injection pump
17-Fuel tank 18-Diagnosis joint 19-Engine control module
II. Multiple-point Fuel Injection System
Multiple-point fuel injection (MPI) system comprises of the sensor detecting the operating conditions of
engine and the electronic control module (ECM) of engine.
The system is controlled based on the signals sent by these sensors and all of the actuators are
operating under the control of the ECM. ECM has the functions like fuel injection control, idle control and
ignition timing control etc. and some trouble diagnosis methods for simplifying the troubleshooting when
the trouble occurs.
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Electronic Control
2. Input/Output Signal
Input/Output Signal Table
Sensor Input Signal to ECM ECM Function Actuator
Crankshaft position sensor Rotation speed of
(position) engine
Camshaft position sensor (phase) Piston position
Intake pressure sensor
Intake quantity
Intake temperature sensor
Oxygen
Oxygen sensor concentration in the
Control of fuel
wasted air
injection and mix Fuel injector
Air throttle position sensor Air throttle position
proportion
Knock conditions of
Knock sensor
engine
Air conditioner
Air conditioner switch
pressure
Rotation speed sensor Vehicle speed
Engine coolant
Engine coolant temperature sensor
temperature
3. Starting Control
During the starting process, it is necessary to take the special calculation methods to control the air
quantity, fuel injection and ignition timing. In the beginning stage of the process, the air inside the intake
manifold is stagnant and the inner pressure of the air intake manifold is the atmospheric pressure. When
the air throttle is closed, the idle adjuster (idle stepper motor) is designated a fixed parameter depending
on the starting temperature. During the similar process, the specific "fuel injection timing" is designated
as the initial fuel injection pulse. Fuel injection quantity changes depending on the engine temperature to
promote the formation of the fuel film in the intake manifold and on the cylinder wall, therefore, before the
engine reaches a certain rotation speed, it is necessary to increase the concentration of the gas mixture.
Once the engine runs, the system immediately begins to reduce the starting concentration increase and
completely end the starting concentration increase when the starting operation conditions is finished
(600~700rpm). The ignition advance angle has been adjusted under the starting operation conditions
depending to the engine temperature, intake temperature and the rotation speed of engine.
4. Warm-up and Heating Control of Three-way Catalyst
After the engine is started at the low temperature, intake quantity of cylinder, fuel injection and electronic
ignition are all adjusted to compensate the higher requirement of the engine for the torque; this process
continues until the temperature is proper. During this process, the most important is the quick heating of
the three-way catalyst, because the fast transition to the three-way catalyst can markedly reduce the
emission. Under this operation condition, the “heat of the three-way catalyst” is carried out by postpone
the ignition advance angle properly and take advantage of the wasted gas.
5. Acceleration/Deceleration and Back-tow Fuel Cut Control
A part of the fuel injected into the intake manifold may fail to timely arrive in the burning process involving
the cylinder. Instead, it forms a layer of fuel film on the intake manifold wall. The fuel stored in the fuel
film may dramatically increase as the rise of load and the time extension of fuel injection. When the
opening of air throttle is increasing, part of the injected fuel is absorbed by the fuel film. Therefore, it is
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Electronic Control
necessary to inject the corresponding quantity of fuel for the complement and prevent the gas mixture
from getting thinner during the acceleration. Once the index of coincidence reduces, the additional fuel
contained in the fuel film on the intake manifold wall will re-release, and then it is necessary to reduce
the injection time accordingly during the acceleration. Back-tow or towing operation condition refers to
the situation that the power supplied by the engine at the fly wheel is negative value. At this time, the
engine friction and pumping gas loss can be used to make vehicles slow down. When the engine is in
the back-tow or towing operation condition, the fuel injection is cut off in order to reduce the fuel
consumption and the emission, but the more important is to protect the three-way catalyst. Once the
rotation speed decreases to the specific fuel supply recovery speed above the idle speed, the fuel
injection system will re-supply. In fact, ECM program has a rotation speed recovery range which
depends on the changes of such parameters as engine temperature, dynamic change of engine rotation
speed and can prevent the rotation speed from dropping to the specified minimum rotation speed by
calculation. Once the fuel injection system re-supplies the fuel, the system starts using the initial injection
pulse as the supply of fuel and re-builds the fuel film on the intake manifold wall. After the resumption of
fuel injection, torque-based control system makes the increase of engine torque slow and steady (slow
transition).
6. Idle Control
At the idle speed, the engine does not provide the torque to the fly wheel. To ensure the engine running
stably at the lowest possible idle speed, the closed-loop idle speed control system should keep the
balance between the generated torque and the "power consumption" of engine. The necessary power
should be generated during the idle time to meet the load requirements of all aspects, including the
internal friction from the engine crankshaft and valve mechanism, as well as the auxiliary components,
such as water pump. The system is based on the torque-based control strategy, that is, determining the
required output torque of engine to maintain the required idle rotation speed under any operating
conditions according to the closed-loop idle speed control. The output torque increases as the reduction
of the rotation speed of engine and decreases as the rise of the rotation speed of engine. The system
request the greater torque in response to the new "disturbance factors", such as the switching of the
air-conditioning compressor. When the engine temperature is decreasing, it is necessary to increase the
torque to compensate the greater internal friction loss and/or maintain the higher idle rotation speed. The
sum of all these required output torque is delivered to the torque coordinator to carry out the calculation
to get the corresponding intake density, gas mixture composition and ignition timing.
7. λClosed-loop Control
The post treatment of exhaust in the three-way catalyst is an effective way to decrease the concentration
of hazardous substance in the wasted gas. The three-way catalyst can decrease the HC, CO and NOX
by 98% or more and transform them into H2O, CO2 and N2. But this high efficiency can be achieved
only in a very narrow range near the excessive air factor of engine λ=1. The objective of the λ
closed-loop control is to ensure the gas mixture concentration at this range. λ closed-loop control system
functions only when equipped with the oxygen sensor. Oxygen sensor detects the oxygen content of the
wasted gas at the side of three-way catalyst. Rarefied gas mixture (λ> 1) produces a sensor voltage of
about 100mV and the concentrated gas mixture (λ <1) produces a sensor voltage of about 900mV. In
case of λ=1, the sensor voltage has a jump. λ closed-loop control responds to the input signal (λ>1= too
rarefied gas mixture, λ<1= too concentrated gas mixture) to revise the control variable and produce the
correction factor as a multiplier to correct the fuel injection duration.
8. Evaporation Exhaust Control
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Because of the transfer of the external radiation heat and oil return heat, the fuel inside the fuel tank is
heated to form the fuel vapor. Due to the limit of evaporative emission regulation, it is not permitted to
exhaust the vapor containing large quantity of HC composition directly into the atmosphere. The fuel
vapor in the system is collected in the active carbon canister through the conduit and flushed into the
engine at appropriate time to participate in the combustion process. Flushing air flow is controlled by the
control valve of control carbon canister of ECM. The control functions only when the λ closed-loop
control system is running under the closed-loop condition.
9. Fuel Injection Control
The fuel injection timing and impulse width should be controlled to provide the best mix proportion of
air/fuel to the engine corresponding to the everchanging operation condition of engine. The fuel injector
is installed at the inlet of every cylinder. The fuel is extruded from the fuel tank by the fuel pump and
delivered to each fuel injector. Normally, each cylinder injects fuel once when the crankshaft turns two
circles. The operating sequence of each cylinder is 1-3-4-2.
10. Ignition Timing Control
The primary current to the ignition coil is controlled by connecting and disconnecting the power transistor
of primary ignition circuit to regulate the ignition timing so that the best ignition timing can be provided
according to the operating conditions of engine. Ignition timing is determined by the ECM according to
the rotation speed of engine, intake quantity, engine coolant temperature and atmospheric pressure.
11. Self-diagnosis Function
When abnormal situation is detected by the sensor or actuator related to the exhaust control, the alarm
lamp of engine (inspection lamp of engine) lights up to inform the driver. The abnormal situation detected
by the sensor or actuator equals to the output of trouble diagnosis code of this kind of abnormal situation.
The RAM data inside the ECM related to the sensor and actuator can be read with the diagnosis
apparatus, and the actuator may be driven forcibly in some cases.
12. Other Control Functions
1) Fuel Injection Pump
Connect the relay of fuel injection pump to electrify the fuel injection pump when the crankshaft of engine
is beginning to rotate or rotating.
2) Fan Relay Control
The rotation speeds of the radiator fan and condenser fan is controlled according to the engine coolant
temperature, vehicle speed and air conditioner switch signal (AC).
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III. On-board Diagnosis System
1. Illustration
On-board diagnosis system (hereinafter referred to as OBD system) refers to the diagnosis system,
integrated in the engine control system, monitoring the trouble components affecting the emission as
well as the main function state of the engine. It is capable of identifying, storing and showing the trouble
information through the self-diagnosis malfunction indicator lamp (MIL).
2. Trouble Information Record
Electronic control module constantly monitors the sensor, actuator, associated circuit, malfunction
indicator lamp (MIL) and storage battery voltage etc. as well as even the electronic control module itself,
and carries out the credibility detection for the output signal of sensor, the drive signal of actuator and the
internal signal (such as λ closed-loop control, coolant temperature, idle rotation speed control and
storage battery voltage control etc.). Once a trouble is found in some link or a signal value is incredible,
the electronic control module immediately sets the trouble information record in the trouble memorizer of
the RAM. Trouble information record is stored according to the trouble code and shown based on the
order in which the troubles occurred.
The troubles can be divided into “steady-state trouble" and "sporadic trouble" according to their
occurrence frequencies (for example, because of short open circuit of harness or the poor contact of
connector).
3. Malfunction Indicator Lamp (MIL) Illustration and Its Control Strategy
1) Malfunction indicator lamp (MIL): the indicator required by the regulation for the emission-related
components or system failure. Generally, MIL is an indicator lamp can display on the console with
shape in line with the requirements of regulation and standard.
2) MIL should be activated following the principles below:
① In case of ignition switch in "ON" position (non-starting), MIL is continuously bright.
② Within the 3s after starting the engine, if there is no requirement in the trouble memory to light up the
MIL, MIL would extinguish.
③ When there is requirement to light up the MIL both in the trouble memory and the outside of the
ECM, MIL is lit.
④ When there is the requirement outside the ECM or in the trouble memory or due to the fire to blink
the MIL, MIL would blink under the frequency of 1Hz.
4. Overhaul steps
1) For the vehicles with OBD function, the overhaul in general should be carried out following the steps
below:
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OBD Overhaul Step Table
1. Connect the diagnosis test equipment to the

diagnosis connector to put through the
diagnosis test equipment.
2. Connect the “ignition switch”.
3. Read the trouble information (trouble code,

freeze frame): inquire in the maintenance
manual to confirm the trouble component and
type: draw up the maintenance plan according
to the trouble information and experiences.
4. Remove the trouble.
5. Eliminate the trouble memorizer: run the

vehicle properly following the corresponding
trouble diagnosis conditions: read the trouble
information and confirm the clearing of the
trouble.
2) Connection of Diagnosis apparatus:
The “K” line protocol and ISO9141-2 standard diagnosis joint are adopted for the system as shown in the
figure.
Standard Diagnosis Connector
This standard diagnosis joint is connected on the harness of engine steadily. The pins No 4, 7 and 16 of
the standard diagnosis joint are used for the electronic control system of engine. The pin No 4 of the
standard diagnosis joint is connected to the grounding wire: pin No 7 is connected to the pin No 15 of
ECM, that is, the data “K” line of the electronic control system of engine; pin No 16 is connected to the
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anode of the storage battery.
5. DTC Index
DTC Index Table of Trouble Diagnosis Code
Trouble Code Illustration (UAES)

P0030 Open circuit of heat control circuit of upstream oxygen sensor
P0031 Short circuit to ground of heat control circuit of upstream oxygen sensor
P0032 Short circuit to power supply of heat control circuit of upstream oxygen sensor
P0036 Open circuit of heat control circuit of downstream oxygen sensor
P0037 Short circuit to ground of heat control circuit of downstream oxygen sensor
P0038 Short circuit to power supply of heat control circuit of downstream oxygen sensor
P0053 Unreasonable heat internal resistance of upstream oxygen sensor
P0054 Unreasonable heat internal resistance of downstream oxygen sensor
P0105 Unchangeable signal of intake pressure sensor
P0106 Unreasonable signal of intake pressure sensor
P0107 Short circuit to ground of intake pressure sensor
P0108 Short circuit to power supply of intake pressure sensor
P0112 Too low signal voltage of intake temperature sensor
P0 13 Too high signal voltage of intake temperature sensor
P0 16 Unreasonable signal of engine coolant temperature sensor
P0117 Too low circuit voltage of engine coolant temperature sensor
P0118 Too high circuit voltage of engine coolant temperature sensor
P0122 Air throttle position sensor circuit voltage below minimum limit
P0123 Air throttle position sensor circuit voltage above maximum limit
P0130 Unreasonable signal of upstream oxygen sensor
P0131 Too low signal circuit voltage of upstream oxygen sensor
P0132 Too high signal circuit voltage of upstream oxygen sensor
P0133 Aging of upstream oxygen sensor
P0134 Signal trouble of upstream oxygen sensor circuit
P0136 Unreasonable signal of downstream oxygen sensor
P0137 Too low voltage of signal circuit of downstream oxygen sensor
P0138 Too high voltage of signal circuit of downstream oxygen sensor
P0140 Signal trouble of downstream oxygen sensor circuit
P0170 Unreasonable self-learning of closed-loop control of off-line detection air-fuel ratio
P0171 Too diluted self-learning of closed-loop control of off-line detection air-fuel ratio
P0172 Too concentrated self-learning of closed-loop control of off-line detection air-fuel ratio
P0201 Open circuit of fuel injector control circuit of cylinder No. 1
P0261 Short circuit to ground of fuel injector control circuit of cylinder No. 1
P0262 Short circuit to power supply fuel injector control circuit of cylinder No. 1
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P0265 Short circuit to power supply of fuel injector control circuit of cylinder No. 2
P0300 Accidental fire of multiple cylinders
P0301 Accidental fire of cylinder No. 1
P0317 Trouble of ABS signal for detecting damaged circuit
P0318 Trouble of sensor signal for detecting damaged circuit
P0321 Trouble of reference point of rotation speed
P0322 No crankshaft position sensor pulse signal (open circuit or short circuit)
P0327 Too low voltage of knock sensor signal circuit
P0328 Too high voltage of knock sensor signal circuit
P0340 Improper mounting position of camshaft position sensor
P0341 Poor contact of camshaft position sensor
P0342 Short circuit to ground of camshaft position sensor
P0343 Short circuit to power supply of camshaft position sensor
P0420 Aging of oxygen storage capability of three-way catalyst (emission exceeding limit)
P0444 Open circuit of control circuit of carbon canister solenoid valve
P0458 Too low voltage of control circuit of carbon canister solenoid valve
P0459 Too high voltage of control circuit of carbon canister solenoid valve
P0480 Open circuit of control circuit of cooling fan relay (low speed)
P0481 Open circuit of control circuit of cooling fan relay (high speed)
P0501 Unreasonable signal of speed sensor
P0506 Controlled rotation speed of idle below target idle
P0507 Controlled rotation speed of idle above target idle
P0508 Short circuit to ground of drive pin of stepper motor
P0509 Short circuit to power supply of drive pin of stepper motor
P0511 Open circuit of drive pin of stepper motor
P0532 Too low voltage of air conditioner pressure sensor circuit
P0533 Too high voltage of air conditioner pressure sensor circuit
P0537 Too low voltage of temperature sensor circuit of air conditioner evaporator
P0538 Too high voltage of temperature sensor circuit of air conditioner evaporator
P0560 Unreasonable voltage signal of system storage battery
P0562 Too low voltage of system storage battery
P0563 Too high voltage of system storage battery
P0602 Coding trouble of electronic control module
P0627 Open circuit of control circuit of fuel injection pump relay
P0628 Short circuit to ground of control circuit of fuel injection pump relay
P0629 Short circuit to power supply of control circuit of fuel injection pump relay
P0645 Open circuit of control circuit of A／C compressor relay
P0646 Short circuit to ground of control circuit of A／C compressor relay
P0647 Short circuit to power supply of control circuit of fuel injection pump relay
P0650 Trouble of drive circuit of MIL
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P0691 Short circuit to ground of control circuit of cooling fan relay

P0692 Short circuit to power supply of control circuit of cooling fan relay
P0693 Short circuit to ground of control circuit of cooling fan relay (high speed)
P0694 Short circuit to power supply of control circuit of cooling fan relay (high speed)
P 1651 Trouble of drive circuit of SVS lamp
P2177 Self-learning value of closed-loop control of air-fuel ratio above upper limit
P2178 Self-learning value of closed-loop control of air-fuel ratio below lower limit
P2195 Aging of upstream oxygen sensor (diluted)
P2196 Aging of upstream oxygen sensor (concentrated)
P2270 Aging of downstream oxygen sensor (diluted)
P2271 Aging of downstream oxygen sensor (concentrated)
IV. Engine Trouble Diagnosis

1. Trouble Overhaul General of Control System of Engine
The discontinue of fuel supply or the failure to provide the correct fuel quantity for the different operating
conditions due to the failure of sub-assemblies of electronic control system of engine (sensor, ECM and
fuel injector etc.) will lead to the following situations:
a. Starting hardship or failure of engine
b. Unstable idle
c. Poor driving performance
If any of these situations occurs, first of all, carry out the conventional detections including the basic
check of engine (ignition system trouble and correct adjustment of engine etc.). Then use the trouble
diagnosis apparatus to check the sub-assemblies of the electronic control system of engine.
Attention:
■ Before dismantling and installing any component, first of all, read the trouble code, and then
disconnect the terminal of the storage battery cathode.
■ Before disconnecting the harness from the storage battery terminal, first turn off the ignition switch.
When the engine is running or the ignition switch is turning on, disconnecting the harness of storage
battery would lead to the damage of ECM.
■ The harness between the ECM and sensor should be shielded by the grounding wire connected to
the vehicle body in order to prevent the interference from the ignition system and radio. If the
shielded harness fails, the harness should be replaced.
■ When checking the charging state of engine, don’t disconnect the anode of the storage battery to
prevent the damage of ECM.
■ When using the outside charger to charge the storage battery, it is necessary to disconnect the
connecting wire of storage battery to prevent the damage of ECM.
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2. Trouble Diagnosis Flow Chart
The check starts
1. Acquire the symptom information

Ask the user for more information associated with symptom
1. Check the DTC

Check DTC and print DTC and freeze frame User described the
User described the
data, and check the related maintenance record symptom and
symptom and the
apparatus did not
apparatus displayed the
User did not show the DTC
DTC
describe the
2. Recognize the symptom symptom, but 4. Recognize the symptom
Attempt to diagnose the apparatus Attempt to diagnose the symptom
symptom described by the user. displayed the described by the user.
DTC.
5. Implement the confirmation steps of DTC. 6. Implement the basic check.
Do not use the trouble diagnosis apparatus Use the trouble

diagnosis apparatus
Within the scope
of technical 7. Run the trouble diagnosis &
9. Use the trouble parameters
check mode
symptom table to check
the troubled system Beyond the scope of
the technical
No troubled parameters
component found
8. Check the troubled
10. Check the troubled component through the component
diagnosis steps
Troubled component
found
Abnormal (DTC detected)
11. Repair or replace the troubled components
12. Final check Abnormal (symptom

Confirm no symptom found still exists)
Implement the “DTC confirmation steps” again,
and be sure to maintain the trouble properly.
Normal
The check ends
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3. Trouble Symptom Check Table
Trouble Symptom Check Table
Trouble Symptom Check Order No.

Unable to communicate with Unable to communicate with all the systems 1
diagnosis apparatus Only unable to communicate with ECM 2
Engine alarm lamp failed to light up immediately after the
Engine alarm lamp and 3
ignition switch is turned to ON.
corresponding element
Engine alarm lamp keeps bright 4
No initial ignition (unable to start) 5
There is initial ignition but it burns incompletely (unable to
Start 6
start)
Too long starting duration (unable to start normally) 7
Unstable idle (fluctuant idle speed and hunting) 8
Idling Stability (abnormal idle speed) High idle speed (abnormal idle speed) 9
Low idle speed (abnormal idle speed) 10
The engine extinguishes at the idle when it is cold.
11
(extinguishing at the deceleration)
The engine extinguishes at the idle when it is hot.
Idle Stability (extinguishment of 12
(extinguishing at the deceleration)
engine)
The engine extinguishes at the start. (extinguishing at the
13
acceleration)
The engine extinguishes during the deceleration 14
Vehicle surge, drop or instability of vehicle speed 15
Shock or vibration during the acceleration 16
Shock or vibration during the deceleration 17
Drive
Poor acceleration 18
Surge 19
Knock 20
Failure of extinguishment 21
Too high concentration of CO and HC at the idle operation 22
Low voltage of AC generator 23
Abnormal idle when starting the air conditioner 24
Abnormal operation of fan 25
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4. Trouble Symptom Table
Trouble Symptom Table
Items Symptom
Starter drags the engine, but there is no combustion inside the cylinder and the
Failure of starting
engine does not start.
Start Extinguishment after
There is combustion inside the cylinder, but the engine extinguishes immediately.
combustion
Hardship of starting Engine starts after the crankshaft rotates a while.
Engine does not maintain a constant speed and the speed changes within the
Hunting
range of idle speed.
Usually, it can be determined with the swing of tachometer pointer and the
Fluctuation of idle
vibration passed to the steering wheel, selector rod and body etc.
Stability Incorrect idle Engine is running idly at the incorrect rotation speed.
of idle Extinguishment of engine
When releasing the accelerator pedal, no matter whether the vehicle is moving,
speed (extinguishment during
the engine extinguishes.
deceleration)
Extinguishment of engine
When the accelerator pedal is depressed or being depressed, the engine
(extinguishment during
extinguishes.
acceleration)
The phenomenon of “vehicle breath” refers to that the vehicle speed (rotation
Vehicle surge, drop of speed of engine) is corresponding slow when there is a need to accelerate and
vehicle speed depress down the accelerator pedal at the current vehicle speed or the temporary
decline of vehicle speed (rotation speed of engine) during the acceleration.
Poor acceleration refers to that the vehicle is unable to acquire the acceleration
capability changing with the opening of air throttle, even if it remains a stable
Poor acceleration
acceleration, it is still the trouble; or refers to the disability to reach the maximum
Driving
vehicle speed.
When firstly depressing down the accelerator pedal to speed up, the rotation
Instability
speed of engine increases slowly.
Shock There is huge shock or vibration when the engine is accelerating or decelerating.
Surge There is repeatedly forward surge when traveling at a constant or variable speed.
There is a strong voice like the hammer against the cylinder wall during the driving
Knock
which is harmful to the moving.
Keep running(failure of
Parking
extinguishment)
5. Basic Trouble Check
When checking the engine trouble, first of all, it should begin from the basic system. If the starting failure
of engine, unstable idle or insufficient fuel supply occurs, it is necessary to start checking the following
basic systems:
a. power supply: storage battery, fusible link and fuse wire
b. Grounding wire
c. Fuel supply: fuel pipe, fuel filter and fuel pump
d. Ignition system: ignition plug, high tension line and ignition coil.
e. Emission control system: PCV system and vacuum leakage.
f. Others: ignition timing and idle.

The trouble of electronic control system of engine is generally caused by the poor contact of the harness
connector. All the harness connectors should be checked to verify whether they are connected correctly.
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6. Check of Idling Rotation Speed
1) Check Conditions
Attention:
■ Check the conventional items like ignition plug, fuel injector and compression pressure of the
cylinder before carrying out the check.
① The engine coolant temperature is 80~95℃.
② Lamps, electronic fan and all the accessories are turned off.
③ Gearbox is at neutral position.
④ The steering wheel is at the medial position (equipped with power steering system).
2) Connect the diagnosis apparatus.
3) Start the engine and run it at the lowest idle speed.
4) Run the engine for over 5s when the rotation speed is 2000~3000r/min and then make the engine
operate for 2min at the idle speed.
5) Read the idle rotation speed (1.3L:750±50r/min; 1.5L: 750±100r/min).
7. Fuel Pressure Test
Attention:
■ Before disconnecting the fuel pipeline, it is necessary to release the fuel pressure inside the fuel
pipeline to eliminate the danger.
■ It is necessary to consistently use the O-ring to keep the seal of the connecting joint of fuel hose.
■ Don’t operate the electrical system when carrying out the check.
Note: Prepare a container under the fuel pipe which is about to be disconnected to avoid the fuel
spillage.
1) Release the fuel pressure to zero. Please refer to “Release of Fuel Pressure”.
2) Dismount the nut at fuel pressure inspection port on the guide rail of fuel injector.
3) Connect the fuel pressure gauge.
4) Turn the ignition switch to the “ON” position to check for the fuel leakage.
5) Start the engine and make it run at the idle speed to check for the fuel leakage.
6) Read the value on the fuel pressure gauge.
■ Fuel pressure: 350KPa
Attention:
■ Don’t check the fuel pressure when the system is operating.
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■ When checking the fuel pressure, it is necessary to confirm whether there is fuel leakage in the fuel
pipeline.
7) If the measured fuel pressure is more than the standard value, analyze the possible reasons based
on the following table and carry out the necessary repairs.
Fuel System Trouble Diagnosis Table 1
Phenomenon Possible Cause Troubleshooting

Blockage of fuel filter Replace the fuel filter
Too low fuel pressure Poor seal of fuel pressure adjuster leading to the fuel Replace the fuel
leakage at the fuel return side injection pump
Replace the fuel
Cementation of fuel pressure
injection pump
Too high fuel pressure
Repair or replace the
Blockage or bend of fuel return pipe
fuel pipe
8) Shut down the engine and check the changes of fuel pressure gauge reading for 5min. If the reading
of fuel pressure gauge drops, observe the reduction rate. Press down the gauge to analyze and
eliminate the trouble.
Fuel System Trouble Diagnosis Table 2
Phenomenon Possible Cause Troubleshooting

Slow drop of fuel pressure after the
Leakage of fuel injector Replace the fuel injector
extinguishment of engine
Complete drop of fuel pressure after the Replace the fuel injection
Trouble of fuel injection pump
extinguishment of engine pump
9) Reduce the pressure inside the fuel pipeline.
10) Disconnect the fuel pressure gauge and install the inspection port nut.
11) Check for the leakage of fuel through the following steps.
① Turn the ignition switch to the "ON" position (extinguishment of engine), and then check for leakage
at the joint of the fuel pipeline.
② Start the engine and increase the rotation speed, and confirm whether there is the leakage at the
joint of fuel system.
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Section III Structural Principle and Overhaul of Engine Electronic Elements

I. Intake Manifold Absolute Pressure (MAP) Sensor
1. Element Illustration
1) The sensor is composed of the intake manifold absolute pressure and intake temperature sensors.
2) The intake manifold absolute pressure (MAP) sensor is a voltage-dependent variable resistance
which measures the pressure change in the intake manifold leading to the changes of engine load
and speed, and transforms it into a voltage output. MAP sensor is also used to measure the
atmospheric pressure when starting the vehicle, and under certain conditions, permit the ECM to
adjust automatically at different altitudes. ECM provides the voltage of 5V to the MAP sensor and
receives the voltage through the signal wire. The sensor provides a grounding wire through its
variable resistance. The input signal of MAP sensor affects the control of fuel output and ignition
timing by the ECM.
3) The intake temperature sensor is a thermal resistance with the negative temperature coefficient
(NTC), and the resistance value decreases with the rise of intake temperature. The sensor conveys
to the controller a voltage representing the changes of intake temperature.
2. Installation Position of Element

Fig. 3.3.001
It is installed on the intake manifold
3. Circuit Diagram of Element

Fig. 3.3.002
Pin 1: grounding
Pin 2: output the temperature signal
Pin 3: power supply 5V
Pin 4: output the pressure signal
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4. Element Check
1) Disconnect the connector of wire harness to check the resistances of pin 1 and pin 2 of element.
■ Rated resistance at 20 ℃: 2.5kΩ±5%
2) Check the voltage of pin 4 of element.
■ Voltage is about 1.3V at idle speed.
■ In case of no load, there is a little change in voltage after slowly opening the air throttle; voltage
instantaneously climbs up to about 4.0V after quickly opening the air throttle and drops down to
around 0.8V after quickly closing the air throttle and finally maintains at about 1.3V.
■ If the voltage is not within the range, please check whether the system leaks or is blocked; replace
the sensor if necessary.
1) Dismantlement
① Disconnect the wire harness connectors of intake

Fig. 3.3.003
manifold pressure & temperature sensors.
Attention:
■ confirm the ignition switch is at the “Off” position.
② Dismantle the fastening bolts of intake manifold

Fig. 3.3.004
pressure & temperature sensors and take off the
intake pressure & temperature sensors.
■ Tightening torque: 4～6N·m
Attention:
■ Pay attention to the position of seal ring during

the dismantlement, and don’t damage or miss the
seal ring.
2) Installation
Pay attention to the following items and install in the reverse order with dismantlement.
■ Apply a small amount of engine oil to the seal ring of sensor in order to facilitate the installation.
■ Confirm the complete joint of sensor and intake manifold.
■ Confirm the reliable installation of wire harness connector.
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II. Engine Coolant Temperature (ECT) Sensor
The engine coolant temperature sensor is used to detect the engine coolant temperature and send the
signal to the ECM. The engine coolant temperature sensor uses a thermal resistance with the negative
temperature coefficient, the resistance value of which decreases with the rise of temperature. ECM
determines the coolant temperature through the output voltage of sensor and provides the gas mixture
with the best air-fuel ratio to the engine.

Fig. 3.3.005
It is installed on the casing of the thermostat.
Pin 1: Grounding
Fig. 3.3.006
Pin 2: Output the temperature signal
4. Element Check
Make the temperature induction part of the engine coolant temperature sensor immersed into the hot
water and check the resistance value between pin 1 and pin 2.
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Resistance Value Specification Table of Coolant Temperature Sensor
Resistance Value (kΩ)

Temperature
No. Temperature Tolerance ±1℃ Temperature Tolerance ±0℃
(℃)
Minimum Maximum Minimum Maximum
1 8.16 10.74 8.62 10.28 -10
2 2.27 2.73 2.37 2.63 +20
3 0.290 0.354 0.299 0.345 +80
■ If the resistance value is not within the range, please replace the sensor.
1) Dismantlement
Fig. 3.3.007
① Discharge the engine coolant in the radiator. Please
refer to "Replacement of Engine Coolant".
② Disconnect the wire harness connector of the engine

coolant temperature sensor.
③ Dismantle the engine coolant temperature sensor. Fig. 3.3.008

2) Installation
Pay attention to the following steps and install in the reverse order with dismantlement.
■ Apply LT648 or equivalent product to the thread part of sensor and screw it down according to the
specified torque.
■ Start the engine and make it run at idle speed and check for the leakage of engine coolant visually.
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III. Air Throttle Position Sensor (TPS)
The air throttle position sensor is a rotationally variable resistance which rotates with the air throttle shaft
to sense the angle of air throttle. When the shaft of air throttle rotates, the angle of air throttle of TPS is
changing. ECM detects the opening of air throttle according to the output signal of TPS.

Fig. 3.3.009
It is installed on the air throttle body

Fig. 3.3.010
Pin 1: grounding
Pin 2: 5V power supply
Pin 3: output signal
4. Element Check
Note: when checking the resistance value, it is necessary to disconnect the wire harness connector of
sensor.
1) Check the resistance value between pin 1 and pin 2.
■ Resistance value: 2kΩ~20％ (at room temperature)
2) Check the resistance value between pin 1 and pin 3. When rotating the air throttle, the resistance
value should vary linearly with the opening of the air throttle.
3) Check the resistance value between the pin 2 and pin 3. The resistance value is the opposite.
Note: when observing the changes of resistance value, notice whether there is a huge jump of resistance
value.
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4) Check the voltage of pin 2.
Note: At this point, ignition switch is turned to the "ON" position but the engine is not started.
■ Reference voltage is 5.0V.
5) Check the voltage of pin 3.
Note: At this point, ignition switch is turned to the "ON" position but the engine is not started.
① when the air throttle is fully closed, its voltage is about 0.4V.
② when the air throttle is fully opened, its voltage is about 4.0V.
1) Dismantlement
① Disconnect the wire harness connector of air throttle position sensor.
Note: Make sure that the ignition switch is at the “Off” position.
② Dismantle the air throttle body assembly.

Fig. 3.3.011
③ Dismantle the fastening bolts of the air throttle

position sensor to take off the sensor.
2) Installation
■ Tightening torque: 1.5～2.5N·m
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IV. Camshaft Position Sensor (CMP)
The camshaft position (phase) sensor is Hall type, which is used to sense the stop point position of first
cylinder at the compression stroke. ECM determines the sequence of fuel injection according to the CMP
signal.
2. Installation Position of Element Fig. 3.3.013

It is installed at the rear end of the cylinder cover
and on the end cap of camshaft.
3. Circuit Diagram of Element Fig. 3.3.014

Pin 1: grounding
Pin 2: signal output
Pin 3: 5V reference voltage
4. Element Check
1) Check the output voltage of camshaft position

sensor.
Output Signal Table of Camshaft Position Sensor
Operating Conditions of Engine Idle Speed 3000r/min

Output Signal 0~B+(5~8Hz) 0~B+(24~26Hz)
2) Use the voltage range of multimeter to check the voltage between the pin 3 and pin 1.
Note: At this point, ignition switch is turned to the “ON” position but the engine is not started.
■ The reference voltage is 12V or 5V (depending on the vehicle model).
3) Use the vehicle oscilloscope to check whether the signal of pin 2 is normal, which should be the
square-wave signal.
Note: Start the engine to check.
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Electronic Control

Fig. 3.3.015
1) Dismantlement
① Disconnect the PCV pipe and CMP wire

harness connector.
② Dismantle the fastening bolt of CMP sensor to

take off the CMP sensor.
2) Installation
■ Pay attention to the Installation gap.
Standard value: 0.8～1.2mm
■ Tightening torque:7.8～9.8N·m
V. Crankshaft Position Sensor (CKP)
Crankshaft position (rotating speed of engine) sensor is magnetic-electric type and composed of the
magnet and coil. The voltage signal of the crankshaft position sensor is sent to ECM and used to
determine the rotating speed of engine and the location of crankshaft.
It is installed on the plane of the fly wheel at the

Fig. 3.3.016
rear of engine.
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Electronic Control
Fig. 3.3.017
Pin 1: Signal wire A
Pin 2:Signal wire B
Pin 3: Shielded wire
4. Element Check
1) Disconnect the wire harness connector to

check the resistance value between pin 2 and
pin 3.
Resistance value:731～989Ω
2) Check the gap between the crankshaft position sensor and the tooth tip of signal disk.
Standard gap: 0.8～1.2mm
3) Check the signal of crankshaft position sensor.
Note: use the vehicle oscilloscope to check when the engine is starting.
Test waveform (AC signal) figure is as follows:
Waveform Figure of Crankshaft Position Sensor

Fig. 3.3.018
1) Dismantlement
① Disconnect the CKP sensor wire harness

connector.
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② Dismantle the fastening bolts of CKP sensor Fig. 3.3.019

to take off the CKP sensor.
2) Installation
■ Pay attention to the installation gap of CKP sensor.
■ It is necessary to first press in the CKP sensor, and then screw it down according to the specified
torque.
VI. Heated Oxygen Sensor (HO2S)
Heated oxygen sensor oxygen senses the oxygen 图 3.3.020
Fig. 3.3.020
concentration in the exhaust and then transforms it into
the voltage signal and sends such signal to the ECM.
When the air-fuel ratio is higher than the theoretical
value, the output voltage of heated oxygen sensor is
about 900mV; when the air-fuel ratio is lower than the
theoretical value (the oxygen concentration in the
exhaust is too high), the output voltage of oxygen
sensor is approximately 100mV. ECM controls the fuel
injection based on these signals in order to maintain an
appropriate air-fuel ratio.

Fig. 3.3.021
The front (upstream) oxygen sensor is installed on the
exhaust manifold before the three-way catalyst and the
rear (downstream) oxygen sensor installed behind the
three-way catalyst.
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Pin 1: anode of heated power supply
Pin 2: cathode of heated power supply
Pin 3: signal grounding
Pin 4: signal
Downstream oxygen sensor and upstream oxygen

sensor
4. Element Check
1) Check the voltage between the pin 3 and pin 4.
At the idle speed, when the oxygen sensor reaches its normal operating temperature of 350 ℃, carry out
the check. At this time, the voltage should be fluctuating quickly within 0.1~0.9V.
2) Check the resistance value of pin 1 and pin 2.
Note: it is necessary to disconnect the wire harness connector of the sensor when carrying out the
check.
■ Resistance value: 2.5～4.5Ω

Fig. 3.3.023
1) Dismantlement
① Disconnect the oxygen sensor wire harness
connector.
② Dismantle the oxygen sensor with the special socket.

Attention:
■ Use the hairless cotton to block the mounting hole of the oxygen sensor to keep the debris or oil &
water away from the exhaust manifold.
■ Check the appearance of oxygen sensor.
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Reddish brown: lead poisoning
Off-white: normal
Black: carbon deposition
2) Installation
■ Pay attention to the trend of wire harness of oxygen sensor.
VII. Fuel Injector (INJ)
The fuel injector injects the fuel according to the signal sent by the ECM and determines the fuel
injection volume through the opening time of the fuel injector solenoid valve.

Fig. 3.3.024
It is installed on the fuel guide rail.
Fig. 3.3.025
Pin 1: power supply (anode)
Pin 2: control (cathode)
1st cylinder 2nd cylinder 3rd cylinder 4th cylinder
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4. Element Check
Attention:
■ Please use the special cleaning and analysis instruments for fuel injector under a certain cycle to
clean and analyze the fuel injector.
1) Check the resistance.
Note: check after disconnecting the wire harness connector.
■ Standard resistance value: 11-16Ω
2) Use the trouble diagnosis apparatus to check the operating time of the fuel injector.
■ Standard operation time: 2.O～3.0ms at the idle speed and more during the acceleration.
3) Check the operating sound of fuel injector.
Note: Use a stethoscope to check the click sound of the fuel injector at the idle speed or use the fingers
to check the vibration situation of the fuel injector.
If the vibration can not be felt, check the wire harness connector, fuel injector or the control signal about
fuel injector by ECM.
Please refer to the “Fuel System”.
VIII. Stepper Motor (IAC)
ECM controls the number of moving steps of stepper motor by controlling the times of changing the coil
current direction in order, so as to adjust the cross-sectional area of bypass channel and the air flow.

Fig. 3.3.026
It is installed on the air throttle body
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Pin A:ECM pin 22
Pin B:ECM pin 21
Pin C:ECM pin 35
Pin D:ECM pin 36
4. Element Check
1) Resistance Check
Note: disconnect the wire harness connector to carry out the check.
■ Rated resistance: 53±5.3Ω
■ Self-learning method: turn on the ignition switch, but don’t start the engine immediately, wait for 5s
to start the engine.
If it is found at this time that the idle of engine is poor, it is necessary to repeat the above steps.

Fig. 3.3.028
1) Dismantlement
① Disconnect the wire harness connector and dismantle
the fastening bolts of stepper motor.
② Take off the stepper motor
Attention:
■ It is not permitted to impose any form of the axial force
for trying to push in or pull out the shaft.
2) Installation
■ Before installing the idle adjuster of the stepper motor into the air throttle body, the shaft should be in
the fully retracted position.
■ Pay attention to the cleaning and maintenance of the by-pass air passage.
■ After dismantling the storage battery or ECM, pay attention to the self-learning of the stepper motor.
■ Tightening torque: 4.0±0.4Nm
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IX. Knock Sensor (KS)
The knock sensor is installed on the side surface of cylinder body to sense the deflagration of engine.
The deflagration is provided to the piezoelectric element in the form of vibration and pressure. And then
the vibration and pressure are transformed into the voltage signals and sent to the ECM. If the engine
deflagration occurs, it is necessary to prevent the deflagration by delaying the ignition time.

Fig. 3.3.029
It is installed on the side surface of cylinder body.
3. Element Check
1) Circuit Diagram of Element。
Pin 1: signal A terminal
Pin 2: signal B terminal
Pin 3: shielded wire
2) Check the resistance.

Fig 3.3.030
resistance value: 5MΩ
4.Dismantlement and Installation
1) Dismantlement
① Disconnect the wire harness connector of knock

sensor.
② Dismantle the fastening nuts of knock sensor to

take off the knock sensor, as shown in Fig. 3.3.029. Fig. 3.3.031
Attention:
■ Don’t drop or damage the sensor.
2) Installation
■ Tightening torque: 20N·m
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X. Air Conditioner Switch and Relay
When the air conditioner is turned on, the switch of air conditioner delivers the voltage signal of storage
battery to the ECM. When the signal representing that the air conditioner is turned on is input, ECM
drives the stepper motor to enhance the idle speed of engine and correct the advance angle of ignition.
ECM simultaneously controls the action of the relay of air conditioner so that the electromagnetic clutch
of compressor is operating.
2. Element Check
When the engine is running at the idle speed, the trouble diagnosis apparatus should be used to check
whether the switch of air conditioner is normal.
Check Table of Air Conditioner Switch
Check Items Switch of Air Conditioner Normal Indications

Off Off
Switch of Air Conditioner
On On
Compressor of Air Off Off (Compressor clutch doesn’t operate)
Conditioner On On (Compressor clutch operates)
XI. Carbon Canister Solenoid Valve
The carbon canister solenoid valve is used to control the flow of fuel steam in the carbon canister.
Operating principle: refer to “Fuel Evaporation System”.

It is installed at the side of intake manifold.
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Fig. 3.3.033
Pin 1: output end of main relay
Pin 2: control signal of ECM
4. Element Check
Fig. 3.3.034
1) Check the resistance between pin 1 and pin 2.
■ Rated resistance: 22～30Ω
1) Dismantlement
① Disconnect the hose at the side of carbon canister

solenoid valve.
② Disconnect the wire harness connector of carbon

canister solenoid valve. Fig. 3.3.035
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③ Disconnect the hose at the side of carbon

Fig. 3.3.036
canister.
④ Take off the carbon canister solenoid valve

Fig. 3.3.037
from the retainer.
2) Installation
■ The airflow direction should meet the requirement during the installation.
■ It is necessary to try to keep the water and oil away from the valve during the dismantlement and
installation.
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XII. Ignition Coil
When the ignition power transistor is turned on through the signal from the ECM, ECM delivers the signal
to the ignition coil, and then the current of the primary coil is cut off and a high voltage is generated in the
secondary coil.

It is installed at the upper end of valve chamber
cover.

Fig. 3.3.039
1) Ignition coil No. 1 (cylinders 1 to 4)
Primary winding pin +: main relay
Primary winding pin -:
Pin No.3 of ECM
2) Ignition coil No. 2 (cylinders 2 to 3)
Primary winding pin +: main relay
Primary winding pin -:
Pin No.7 of ECM
4. Element Check
1) Check the resistance value of winding with the

ammeter.
Note: Check after disconnecting the wire harness connector of element.
■ Resistance value of primary winding: 0.77～0.95Ω
■ Resistance value of secondary winding: 7.57～10.23kΩ。
Dismantlement and Installation: refer to “Ignition System”.
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XIII. Electric Fuel Pump
It is used to deliver the fuel to the main fuel supply pipe from the fuel tank at a certain fuel pressure and
flow, and maintain the stable fuel pressure (through the fuel pressure adjuster).
It is installed inside the fuel tank
Pin illustration: the electric fuel pump has two pins, and the fuel pump casings next to the two pins are
marked with "+" and "-" signs, which represent respectively the connections to the anode (fuel pump
relay) and ground.
Fig. 3.3.040
4. Element Check
1) Check the internal resistance of fuel pump.
Its internal resistance is not zero or infinity.
2) Check the fuel pressure
Refer to “Fuel System”.
Refer to “Fuel Pump Assembly”.
Attention:
■ In order to prevent the accidental damage of fuel pump, please do not run the fuel pump at the
fuel-free state.
■ When there is a need to replace the fuel pump, please pay attention to the cleaning of fuel tank and
pipeline, and the replacement of fuel filter.
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XIV. Electronic Control Module (ECM) of Engine
1) Function
■ Multi-point fuel sequence injection control
■ Ignition control
■ Idle control
■ Provide the power supply of sensor: 5V/100mA
■ λ closed-loop control with self-adaptation
■ Carbon canister solenoid valve control
■ Switch of air conditioner
■ Malfunction indicator lamp of engine
■ Fuel ration correction
■ Output of rotating speed signal of engine (TN signal)
■ Input of speed signal
■ Self-diagnosis of trouble
■ Receipt of load signal of engine,
And so on.
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2) Definitions of ECM Pins:
Definition Table of ECM Pins
Pin Function Code Pin Function Code

1 Reserved Q1 33 Reserved D2
2 Heating of upstream oxygen sensor P1 34 Reserved C2
3 Ignition coil 1 Q2 35 Terminal C of stepper motor B2
4 Heating of downstream oxygen sensor P2 36 Terminal D of stepper motor A2
5 Ignition grounding Q3 37 Carbon canister solenoid valve O3
6 Reserved P3 38 Reserved N3
7 Ignition coil 2 Q4 39 Sensor grounding 1 M3
8 Non-durative power supply P4 40 Sensor grounding 2 L3
9 Output of rotating speed of engine O1 41 Engine coolant temperature K3
10 Pressure switch of air conditioner N1 42 Camshaft position (phase) sensor J3
11 Reserved M1 43 Electronic grounding 1 H3
12 Switch of headlight L1 44 Switch of air conditioner G3
13 Reserved K1 45 Upstream oxygen sensor F3
Terminal B of engine rotating speed
14 Reserved J1 46 E3
(crankshaft position) sensor
Terminal A of engine rotating speed
15 Diagnosis wire K H1 47 D3
(crankshaft position) sensor
16 Durative power supply G1 48 Power grounding 1 C3
17 Ignition switch F1 49 Fuel injector - cylinder 3 B3
18 5V power supply 2 E1 50 Fuel injector - cylinder 1 A3
19 5V power supply 1 D1 51 Non-durative power supply 04
20 Malfunction indicator lamp (MIL) C1 52 Relay of high-speed fan N4
21 Terminal B of stepper motor B1 53 Reserved M4
22 Terminal A of stepper motor A1 54 Reserved L4
23 Services indicator lamp (SVS) O2 55 Reserved K4
24 Switch of blower N2 56 Reserved J4
25 Intake temperature sensor M2 57 Speed signal sensor H4
26 Air throttle position sensor L2 58 Reserved G4
27 Reserved K2 59 Intake pressure sensor F4
28 Reserved J2 60 Fuel pump relay E4
29 Downstream oxygen sensor H2 61 Relay of A/C compressor D4
30 Terminal A of knock sensor G2 62 Relay of low-speed fan C4
31 Terminal B of knock sensor F2 63 Fuel injector - cylinder 2 B4
32 Main relay E2 64 Fuel injector - cylinder 4 A4
* The specific pin numbers are subject to the wire harness principle diagram (the reserved mean the
empty pins).
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3) Electrical Principle Diagram
Power supply
Ignition Fuel injector 1
5V output 1 Fuel injector 2
5V output 1 Fuel injector 3
Main relay Fuel injector 4
Self-diagnosis wire K Trouble indication signal
CAN 1H
CAN 1L Fuel pump relay
Crankshaft sensor + Air conditioner relay
Crankshaft sensor - Fan 1
Knock sensor A Stepper motor A

Knock sensor B Stepper motor B
Stepper motor C
Stepper motor D
Intake pressure sensor
Upstream oxygen sensor
Air throttle position Heating of oxygen sensor
Coolant temperature sensor Heating of oxygen sensor
Intake temperature sensor Carbon canister control valve
Downstream oxygen sensor Wasted gas recycle control valve
Pressure and temperature of air
conditioner
Acceleration sensor
Recycle position of wasted gas
Reserved input Output of fuel consumption

Reserved input Output of rotating speed
Battery
Fan 2
Camshaft signal Reserved
Speed Reserved
Electronic load 1 Reserved
Switch of air conditioner Reserved
ABS
Electronic load 2
Anti-theft password Ignition control 1
Ignition control 2
Heating of oxygen sensor
Heating of oxygen sensor
Electrical Principle Diagram
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It is installed at the side of “A pillar”
3. Element Check
1) Read the engine trouble record with the data wire K.
2) Check whether the connecting wire of ECM is intact and put the focus on the ECM power supply
and grounding line.
3) Check whether the external sensor is normal, whether the output signal is credible and whether its
line is intact.
4) Check whether the actuator is normal and whether its line is intact.
5) Finally, replace the ECM to carry out the test.
1) Dismantlement
① Turn the ignition switch to “OFF” position to dismantle the negative terminal of storage battery.
② Dismantle the lower part of the console referring to “console”.
③ Disconnect the wire harness connector of ECM port. Refer to “Precautions”.
④ Dismantle the fastening bolts of ECM to take off the ECM.
2) Installation
■ Install in the reverse order with dismantlement.
■ For the precautions about the installation, please refer to “Precautions”.
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Section IV Trouble Diagnosis Procedures for Engine Control System

I. Diagnosis by Trouble Code
1. Illustration
1) The following overhaul can be carried out only after the current stable trouble has been identified,
otherwise the diagnosis will be wrong.
2) The "multimeter" referred to hereinafter means the digital multimeter and it is not permitted to use
the analog multimeter to check the electric control system lines.
3) When carrying out the overhaul for the vehicle with the anti-theft system, if the requirement of
replacing the ECM is included in the "Next Steps" column, it is necessary to program the ECM after
the replacement.
4) If the trouble code points to a low voltage of a specific circuit, it indicates that the circuit is likely to
have short circuit to ground or open circuit; if the trouble code points to a high voltage of a specific
circuit, it indicates that the circuit is likely to have short circuit to the power supply; if the trouble code
points to a circuit trouble, it indicates that the circuit is likely to have broken circuit or a variety of line
troubles.
2. Diagnosis Help
1) If the trouble code can not be erased, it means the trouble is stable; in case of the sporadic trouble,
it is necessary to check whether the connector of wire harness is loosened.
2) The check has been accomplished according to the above steps and nothing unusual has been
found.
3) It is not permitted to neglect the effects of the maintenance of vehicle, cylinder pressure and
mechanical ignition timing etc. on the system during the overhaul process.
4) Replace the ECM to carry out the test.
■ If the trouble code can be cleared at this time, it means the trouble site is at ECM; if the trouble code
still can not be erased at this point, then remount the original ECM and repeat the procedures again
to carry out the overhaul.
3. Illustration of Scan Tool or Diagnosis Apparatus Mode
OBD system can provide a great deal of the information related with the trouble diagnosis, which is the
useful reference for the overhaul of the electronic control system of engine. According to the definition in
the automotive industry international standard ISO/DIS15031-5, the information about the OBD system
based on 9 different services/modes can be obtained through the diagnosis instrument in line with the
requirements of ISO/DIS15031-4. The primary functions of each mode are as follows:
- 01 Read the current data of the diagnosis about power system;
- 02 Read the data of freeze frame;
- 03 Read the diagnosis trouble code of the system about the emission;
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- 04 Clear and reset the diagnosis information about the emission;
- 05 Read the monitoring test results of oxygen sensor;
- 06 Read the OBD test results of the specific monitoring system;
- 07 Read the monitoring trouble code of OBD system about the current or last driving cycle;
- 08 Component test, where no mandatory requirement is specified;
- 09 Read the identification numbers of vehicle and software
It is worth while to point that the various scan tools or diagnosis apparatus may be different in the design
and use, but the read content must belong to one of the above-mentioned modes. The trouble code will
be displayed and output at mode 3 after the confirmation of the trouble; the trouble codes in the current
drive cycle or in the last drive cycle will be displayed and output at mode 7.
4. Trouble Code Diagnosis
■ Various ECM pins referred to below should be subject to the actual wire harness diagrams.
1) Trouble code: P0030 open circuit in the heating control circuit of upstream oxygen sensor
Step 1: Use the diagnosis apparatus to read the “ mode 3” and “ mode 7”
Read Result 1 Read Result 2
Mode 3 Mode 7 Mode 3 Mode 7
With trouble information No trouble information No trouble information With trouble information
P0030 P0030
Maintenance hints: Maintenance hints:

The trouble has been identified and there may be the The trouble has not been finally identified and may be the
following problems: intermittent one, and the following items should be
1) Open circuit between the circuit connected to ECM checked:
pin and the pin 2 of upstream oxygen sensor 1) Measure the resistance between the pin of ECM
2) Open circuit between the pin 1 of upstream oxygen connector and the pin 2 of upstream oxygen sensor
sensor and the main relay and determine whether it is normal.
3) Open circuit between the pin 1 and pin 2 of upstream 2) Measure the resistance of pin 1 of upstream oxygen
oxygen sensor sensor and the main relay and determine whether it is
normal.
3) Measure the resistance between the pin 1 and pin 2 of
upstream oxygen sensor and determine whether it is
normal.
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2) Trouble code: P0031 short circuit to ground in the heating circuit of upstream oxygen sensor
Step 1: Use the diagnosis apparatus to read “mode 3” and “mode 7”
P0031 P0031

1) Short circuit to ground in the circuit connected to the checked:
ECM pin 1) Measure whether the resistance to ground of ECM pin
is normal.
3) Trouble code: P0032 short circuit to power supply in the heating circuit of upstream oxygen sensor
P0032 P0032

1) Short circuit between the circuit connected to ECM pin checked:
and the circuit of pin1 of upstream oxygen sensor 1) Measure whether the ECM voltage is normal.
2) Short circuit between the circuit connected to ECM pin 2) Measure the resistance between the ECM pin and the
and other power supply circuits pin 1 of upstream oxygen sensor.
4) Trouble code: P0036 open circuit in the heating circuit of downstream oxygen sensor
P0036 P0036

1) Open circuit between the circuit connected to ECM checked:
pin and the pin 2 of downstream oxygen sensor 1) Measure the resistance between the ECM connector
2) Open circuit in the circuit from the pin 1 of and pin 2 of downstream oxygen sensor.
downstream oxygen sensor to the main relay 2) Measure the resistance between the pin 1 of
3) Open circuit between the pin 1 and pin 2 of downstream oxygen sensor and the main relay.
downstream oxygen sensor 3) Measure the resistance between the pin 1 and pin 2 of
downstream oxygen sensor.
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5) Trouble code: P0037 short circuit to ground in the heating circuit of downstream oxygen sensor
P0037 P0037

1) Short circuit to ground in the circuit connected to ECM checked:
pin 1) Measure whether the resistance to ground of ECM pin
is normal.
6) Trouble code: P0038 short circuit to power supply in the heating circuit of downstream oxygen
sensor
P0038 P0038

and the circuit of pin 1 of downstream oxygen sensor 1) Measure whether the resistance of ECM pin is normal.
2) Short circuit between the circuit connected to ECM pin 2) Measure the resistance between ECM pin and the
and other power supply circuits circuit of pin 1 of downstream oxygen sensor.
7) Trouble code: P0053 unreasonable heating internal resistance of upstream oxygen sensor
Diagnosis illustration of oxygen sensor heater: The system identifies whether the heating output is
correct by measuring the heating resistance of sensor. The oxygen sensor will be damaged by the
condensate under some certain adverse conditions, especially at cold start-up stage.
Upstream oxygen sensor is heated directly after the engine is started. The downstream oxygen sensor
will be heated only when the theoretic temperature inside the catalytic converter device is higher than
308 ℃.
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P0053 P0053

The trouble has been identified and there may be the Trouble has not been finally identified and it is necessary to
following problems: wait for the system to finish the diagnosis.
1) The heating function of upstream oxygen sensor fails
and it is necessary to replace the oxygen sensor.
8) Trouble code: P0054 unreasonable heating internal resistance of downstream oxygen sensor
Diagnosis illustration of oxygen sensor heater: The system identifies whether the heating output is
correct by measuring the heating resistance value of sensor. The oxygen sensor will be damaged by the
condensate under some certain adverse conditions, especially at cold start-up stage.
Upstream oxygen sensor is heated directly after the engine is started. The downstream oxygen sensor
will be heated only when the theoretic temperature inside the catalytic converter device is higher than
308 ℃.
P0054 P0054

1) The heating function of downstream oxygen sensor
fails and it is necessary to replace the oxygen sensor.
9) Trouble code: P0105 No change of intake pressure sensor signal
P0105 P0105

following problems: check the following items:
1) Vacuum leakage or blockage of intake pressure 1) Check or clean the vacuum pipe of sensor and then
sensor reinstall it. Use the “mode 1” of diagnosis apparatus to
2) Seriously aging of intake pressure sensor read the pressure after the start-up.
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10) Trouble code: P0106 unreasonable signal of intake pressure sensor
P0106 P0106

1) Air leakage of induction element inside the pressure checked:
sensor 1) The pressure sensor is a free voltage sensor, so it can
2) Damage of pressure sensor not carry out the diagnosis by reading the pressure
3) Air leakage at the installation position of pressure parameters in the diagnosis apparatus. Therefore it is
sensor necessary to wait for the system to give the final
4) Excursion of pressure sensor characteristics diagnosis result.
11) Trouble code: P0107 too low voltage in the intake pressure sensor circuit
P0107 P0107

1) Short circuit to ground in the sensor signal circuit checked:
detected by ECM 1) Resistance between the ECM pin and ground
12) Trouble code: P0108 too high voltage in the intake pressure sensor circuit
P0108 P0108

1) Short circuit to power supply of sensor signal circuit checked:
detected by ECM 1) Voltage of ECM pin
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13) Trouble code: P0112 too low signal voltage in the intake temperature sensor
P0112 P0112

1) Short circuit to ground in the sensor signal circuit checked:
connected to ECM pin 1) Measure the resistance between the sensor signal
circuit of ECM pin and ground.
14) Trouble code: P0113 too high signal voltage in the intake temperature sensor
P0113 P0113

1) Short circuit to power supply in the sensor signal checked:
circuit connected to ECM pin 1) Measure whether the voltage of sensor signal circuit
of ECM pin is normal.
15) Trouble code: P0116 unreasonable indicating temperature of engine coolant temperature sensor
P0116 P0116

1) The coolant temperature sensor is damaged and
needs replacing.
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16) Trouble code: P0117 too low voltage of engine coolant temperature sensor circuit
P0117 P0117

and the ground 1) Measure the resistance between the ECM pin and the
ground.
17) Trouble code: P0118 too high voltage of engine coolant temperature sensor circuit
P0118 P0118

and other power supply circuits 1) Measure whether the voltage of ECM pin is normal.
18) Trouble code: P0122 the voltage of air throttle position sensor circuit less than the minimum limit
P0122 P0122

1) Short circuit to ground of ECM pin checked:
1) Measure the resistance between the ECM pin and the
ground.
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19) Trouble code: P0123 the voltage of air throttle position sensor circuit more than the maximum limit
P0123 P0123

and other power supply circuits 1) Measure whether the voltage of ECM pin is normal.
20) Trouble code: P0130 unreasonable signal of upstream oxygen sensor

Introduction of trouble causes: when the signal of upstream oxygen sensor is of the following conditions,
the system will determine that the signal of upstream oxygen sensor is unreasonable.
a. Upstream oxygen sensor signal maintains within the lower voltage range (0.1～0. 4V) for a long
time, but the downstream oxygen sensor signal constantly keeps above 0.5V.
b. Upstream oxygen sensor signal maintains within the higher voltage range (0.6～1.5V), but the
downstream oxygen sensor signal constantly keeps 0.1V below.
c. Upstream oxygen sensor signal circuit couples with the heating circuit.
P0130 P0130

following problems: wait for the ECM to finish the final detection.
1) Check whether the connector of oxygen sensor is
correct and normal.
2) Check whether the upstream oxygen sensor signal
circuit couples with the heating circuit.
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21) Trouble code: P0131 too low voltage of upstream oxygen sensor circuit
P0131 P0131

1) Short circuit to ground in the signal circuit connected checked:
to ECM pin 1) Measure the resistance between the signal circuit
connected to ECM pin and the ground.
22) Trouble code: P0132 too high voltage of upstream oxygen sensor circuit
Introduction of trouble causes: ECM will measure the voltage of upstream oxygen sensor circuit after the
engine is started, and if the signal voltage is more than 1.5V for a long time, such situation will be
determined as the short circuit to power supply in the upstream oxygen sensor signal circuit.
P0132 P0132

1) Short circuit between the signal circuit connected to checked:
ECM pin and the circuit of pin 1 of oxygen sensor 1) Measure the resistance between the signal circuit
2) Short circuit between the signal circuit connected to connected to ECM pin and the pin 1 of oxygen sensor
ECM pin and other power supply circuits 2) Measure the voltage of signal circuit connected to
ECM pin.
23) Trouble code: P0133 aging of upstream oxygen sensor
Introduction of trouble causes: Under the normal circumstances, the air-fuel ratio of gas mixture is
switched between the diluted and the concentrated, and the corresponding oxygen sensor signal will be
reflected in the continuous jump of signal amplitude. When the oxygen sensor is aged, its perceptual
sensitivity to gas mixture will drop, which will be reflected in the lengthening of cycle of signal fluctuation.
ECM will calculate the average signal cycle in accordance with the corresponding algorithm. If the
calculated cycle is slower than the pre-set critical value, the sensor will be determined as aged.
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P0133 P0133

The trouble has been identified and there may be the The trouble has not been finally identified and it is
following problems: necessary to wait for the ECM to finish the detection.
1) The sensor is aged and should be replaced.
24) Trouble code: P0134 trouble of signal of upstream oxygen sensor

Introduction of trouble causes: ECM will measure the voltage of the upstream oxygen sensor circuit after
starting the engine. When the signal voltage is always changing within 0.4~0.6V, system determines that
the trouble is the open circuit of the upstream oxygen sensor signal circuit.
P0134 P0134

1) Open circuit in the circuit from the oxygen sensor to checked:
the ECM pin 1) Measure the resistance between the ECM connector
2) Poor connector of oxygen sensor (oxidation of pin) and the pin 4 of oxygen sensor.
25) Trouble code: P0136 unreasonable signal of downstream oxygen sensor

Introduction of trouble causes: the upstream oxygen sensor signal circuit couples with the heating circuit.
P0136 P0136

1) Check whether the connector of oxygen sensor is
correct and normal.
2) Check whether the upstream oxygen sensor signal
circuit couples with the heating circuit.
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26) Trouble code: P0137 too low voltage of downstream oxygen sensor signal circuit
P0137 P0137

1) Short circuit to ground in the signal circuit connected checked:
to ECM pin 1) Measure the resistance between the signal circuit
connected to ECM pin and the ground.
27) Trouble code: P0138 too high voltage of downstream oxygen sensor signal circuit
Introduction of trouble causes: ECM will measure the voltage of the downstream oxygen sensor circuit
after starting the engine. When the signal voltage is above 1.5V for a long time, such situation is
determined as the short circuit to power supply in the downstream oxygen sensor signal circuit.
P0138 P0138

1) Short circuit between the signal circuit connected to checked:
ECM pin and the pin 1 of oxygen sensor 1) Measure the resistance between the signal circuit
2) Short circuit between the signal circuit connected to connected to ECM pin and the pin 1 of oxygen sensor
ECM pin and other power supply circuits 2) Measure the voltage of signal circuit connected to
ECM pin.
28) Trouble code: P0140 signal trouble of downstream oxygen sensor circuit
Introduction of trouble causes: ECM will measure the voltage of the downstream oxygen sensor circuit
after starting the engine. When the signal voltage is constantly changing within 0.4～0.6V, the system
determine that the trouble is the open circuit in downstream oxygen sensor signal circuit.
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Electronic Control
P0140 P0140

1) Open circuit in the circuit from the oxygen sensor to checked:
the ECM pin 1) Measure the resistance between the ECM connector
2) Poor connector of oxygen sensor (oxidation of pin) and the pin 4 of oxygen sensor.
29) Trouble code: P0170 unreasonable self-learning of closed-loop control of air-fuel ratio in the off-line
detection
30) Trouble code: P0171 too diluted self-learning of closed-loop control of air-fuel ratio in the off-line
detection
31) Trouble code: P0172 too concentrated self-learning of closed-loop control of air-fuel ratio in the
off-line detection
Note: Overhaul procedure is applicable to such situation where trouble codes of intake pressure sensor,
carbon canister solenoid valve and oxygen sensor etc. do not appear at the same time. If the related
trouble codes coexist at the same time, deal with other troubles first and then overhaul the fuel pipeline.
32) Trouble code: P0201 open circuit of control circuit of fuel injector of cylinder 1
P0201 P0201

1) Whether there is the open circuit in the coil of fuel checked:
injector. 1) Whether there is the open circuit in the coil of fuel
2) Whether the pin of fuel injector connector is injector
connected well to the ECM pin. 2) Whether the pin of fuel injector connector is
3) Whether the pin of fuel injector connector is connected well to the ECM pin
connected well to the main relay. 3) Whether the pin of fuel injector connector is
connected well to the main relay
36) Trouble code: P0261 short circuit to ground in the control circuit of fuel injector of cylinder 1
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Electronic Control
P0261 P0261

1) Short circuit to ground in every drive circuit connected checked:
to ECM pin 1) Measure the resistance to ground in the circuit
connected to ECM pin.
40) Trouble code: P0262 short circuit to power supply of control circuit of fuel injector of cylinder 1
P0262 P0262

and other power supply circuits 2) Measure the voltage of circuit connected to ECM pin.
44) Trouble code: P0300 miss-fire in multiple cylinders

45) Trouble code: P0301 miss-fire in cylinder 1
Introduction of trouble causes: The miss-fire means that because of the failure of engine ignition system
to effectively release the ignition energy (ignition failure), the deviation of fuel injection volume (deviation
of the concentration of the gas mixture), too low cylinder compression pressure or any other cause, the
combustion process inside a cylinder is interrupted or failed, which will result in the excessive emissions
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or the damage of the catalytic converter due to the overheating. As for the OBD system, it refers to the
trouble where the times of miss-fire are more than the set value.
P030x P030x

following problems: necessary to wait for the system to determine.
1) Fuel injector should be cleaned.
2) Intake passage should be cleaned.
3) Air leakage of valve
4) Trouble of ignition system (check and replace the
ignition plug and high-voltage wire).
5) Serious abrasion of cylinder
49) Trouble code: P0317 trouble of ABS poor road detection signal
Introduction of trouble causes: The signal from the ABS wheel speed sensor is abnormal, which makes
the signal can not be used to detect the road bumps.
P0317 P0317

1) Check the ABS wheel speed signal. checked.
50) Trouble code: P0318 trouble of poor road detection sensor signal
Introduction of trouble causes: When the acceleration measured by the acceleration sensor is beyond
the set reasonable range, such situation will be determined as the trouble of sensor. A period of time, for
example 10s after the vehicle stops, the acceleration sensor should not detect the bumpy road. If there is
bumping road detected at this time, the system will determine that the trouble of acceleration sensor
occurs.
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Electronic Control
P0318 P0318

pin 1) Check the resistance to ground in the circuit
2) Short circuit to power supply or open circuit in the connected to ECM pin.
circuit connected to ECM pin 2) Check the voltage of circuit connected to ECM pin.
3) Looseness at the installation position or support of the 3) Check whether the installation position and support
acceleration sensor are normal.
4) Damaged acceleration sensor
51) Trouble code: P0321 trouble of reference point of crankshaft position sensor
Introduction of trouble causes: The 60-2 teeth speed measurement system is adopted for the System.
The 60-2 induction ring gear is installed on the fly wheel and will generate the magnetic changes in the
sensor with the rotation of fly wheel (rotating speed in line with the crankshaft), which will result in the
induced AC voltage the frequency of which depends on the rotating speed. ECM signal circuit converts
the input sine wave to the square wave. When the ECM detects that the distance between two falling
edges of two square waves is greater than two times of tooth space, the reference location is found.
Physically, the reference pitch corresponds to the specific location of cylinder 1, and the second falling
edge in the system after the reference pitch is defined as the signal of software reference point (BM) and
the distance from the software reference point signal to the crankshaft corner at the upper stop point of
cylinder 1 is the fixed value of 108° CA. Therefore, crankshaft rotates a circle each and the system will
receive a software reference point signal and the signal system will maintain “synchronized" with the
crankshaft position in accordance with the software reference point signal to ensure the correct control of
fuel injection, intake and ignition timing.
If one of the following circumstances is found, then the crankshaft software reference point signal (BM)
trouble is determined:
① It is frequently found that the crankshaft software reference point signal (BM) precedes or lags the
expected position;
② The rotating speed signal can be detected but the crankshaft software reference point signal (BM)
can not be detected;
③ The crankshaft software reference point signal (BM) is lost frequently;
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P0321 P0321

The trouble has been identified and there may be the As the trouble is caused by the intermittent short circuit or
following problems: open circuit, it is necessary to wait for the system to confirm
1) Intermittent short circuit or open circuit in the circuit itself before the trouble is finally identified.
connection
2) Deviation of installation position of signal gear of
crankshaft
3) Deviation of installation position of crankshaft position
sensor
52) Trouble code: P0322 no pulse signal of crankshaft position sensor (open circuit or short circuit)
Introduction of trouble causes: After the engine is started, ECM will monitor the signals of crankshaft
position sensor and camshaft position sensor at the same time. If it is able to receive the continuous
camshaft position sensor signal but not the crankshaft position sensor signal, the system will determine
that the signal of crankshaft position sensor signal is lost.
P0322 P0322

1) Open circuit in the circuit from the crankshaft position checked:
sensor to the ECM 1) Circuit resistance from the crankshaft position sensor
1) Short circuit in the circuit from the crankshaft position to the ECM
sensor to the ECM 2) Circuit voltage from the crankshaft position sensor to
3) Open circuit of coil of crankshaft position sensor the ECM
3) Crankshaft position sensor coil resistance
53) Trouble code: P0327 too low voltage of knock sensor signal circuit
Introduction of trouble causes: The knock sensor is installed on the engine body and vibrates according
to different vibration frequencies under various operating conditions of engine to produce voltage signals
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containing a variety of frequencies. Voltage signal is able to reflect not only the occurrence of knock of
engine body but also the value of engine background noise (noise of mechanical component) objectively.
When the engine and knock sensor are operating normally, the background noise value will fluctuate
within the specified range, and once the background noise is lower than the set value, the system will
consider that the trouble exists in the knock sensor signal circuit.
P0327 P0327

following problems: check the following items:
1) Open circuit or short circuit to ground from ECM pin to 1) Check the resistance in the circuit from the ECM to pin
pin 1 of knock sensor 1 of knock sensor.
2) Open circuit or short circuit to ground from ECM pin to 2) Check the resistance in the circuit from the ECM to pin
pin 2 of knock sensor 2 of knock sensor.
54) Trouble code: P0328 too high voltage of knock sensor signal circuit
Introduction of trouble causes: The knock sensor is installed on the engine body and vibrates according
to different vibration frequencies under various operating conditions of engine to produce voltage signals
containing a variety of frequencies. Voltage signal is able to reflect not only the occurrence of knock of
engine body but also the value of engine background noise (noise of mechanical component) objectively.
When the engine and knock sensor are operating normally, the background noise value will fluctuate
within the specified range, and once the background noise is higher than the set value, the system will
consider that the trouble exists in the mechanical component of engine.
P0328 P0328

following problems: wait for the system to finish the diagnosis itself.
1) Some components of engine are worn out seriously
and it is necessary to check the mechanical parts of
engine (piston ring, piston pin, bearing and spare part
gap etc.).
55) Trouble code: P0340 improper installation position of camshaft position sensor
56) Trouble code: P0341 poor contact of camshaft position sensor
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Introduction of trouble causes: The camshaft position sensor works in such a way to monitor the location
of camshaft by using the Hall element to induce a trigger wheel rotating together with the camshaft. The
phase signals received by ECM should change alternatively and regularly between high and low levels.
If the ECM only detects the slow changes between high and low levels or irregular changes, it is
considered that the trouble exists in the phase signal.
P0340 P0340

1) Improper installation position of camshaft position checked:
sensor 1) Installation position of camshaft position sensor
2) Poor connection of connector of camshaft position (angle, gap with phase trigger wheel)
sensor wire harness 2) Connection of connector of camshaft position sensor
wire harness (tightness of pin, oxidation of pin)
57) Trouble code: P0342 short circuit to ground of camshaft position sensor
If the ECM continuously detects the phase signal at the low level, it is considered that the short circuit to
ground exists in the phase signal circuit.
P0342 P0342

1) Short circuit between the circuit connected to ECM checked:
and the circuit of pin 3 of camshaft position sensor 1) Check the resistance to ground of the circuit
2) Short circuit to ground in the circuit connected to ECM connected to ECM pin.
2) Check the resistances of the circuit connected to ECM
pin and the circuit of pin 3 of camshaft position sensor.
58) Trouble code: P0343 short circuit to power supply of camshaft position sensor
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If the ECM continuously detects the phase signal at the high level, it is considered that the short circuit to
power supply exists in the phase signal circuit.
P0343 P0343

and the circuit of pin 1 of camshaft position sensor 1) Check the voltage of ECM pin circuit
2) Short circuit between the circuit connected to ECM 2) Check the resistance between the circuit of ECM pin
and other power supply circuits and the circuit of pin 1 of camshaft position sensor
59) Trouble code: P0420 aging of oxygen storage capability of three-way catalyst (emission exceeding
the limit)
Introduction of trouble causes: There is a corresponding relationship between the three-way catalyst
conversion efficiency and its oxygen storage capacity. The amplitude of downstream oxygen sensor can
indirectly reflect the oxygen storage capacity of catalyst. The greater the amplitude is, the poorer the
oxygen storage capacity of catalyst is and the worse the conversion efficiency of corresponding catalyst
is. The main principle of catalyst diagnosis is to monitor the voltage fluctuation amplitude of downstream
oxygen sensor by the system, and if the measured amplitude is greater than the set limit, the system will
determine the failure of three-way catalyst.
P0402 P0402

following problems. necessary to wait for the system to determine.
1) Too low efficiency of the three-way catalyst will lead to
the excessive emission.
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60) Trouble code: P0444 open circuit in the control circuit of carbon canister solenoid valve
P0444 P0444

1) Open circuit between the circuit connected to the checked:
ECM and the pin 2 of carbon canister solenoid valve 1) Measure the resistance between the ECM connector
2) Open circuit from the pin 1 of canister solenoid valve and pin 2 of carbon canister solenoid valve
to the main relay 2) Resistance between the pin 1 of carbon canister
3) Open circuit in the electromagnetic coil between the solenoid valve and the main relay
pin 1 and pin 2 of carbon canister solenoid valve 3) Resistance between the pin 1 and pin 2 of carbon
canister solenoid valve
61) Trouble code: P0458 too low voltage of control circuit of carbon canister solenoid valve
P0458 P0458

1) Measure whether the resistance to ground of ECM pin
is normal.
62) Trouble code: P0459 too high voltage of control circuit of carbon canister solenoid valve
P0459 P0459

and the pin 1 of carbon canister solenoid valve 1) Measure whether the voltage of ECM pin is normal.
2) Short circuit between the circuit connected to ECM pin 2) Measure the resistance between the ECM pin and pin
and other power supply circuits 1 of carbon canister solenoid valve
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63) Trouble code: P0480 open circuit in control circuit of cooling fan relay (low speed)
64) Trouble code: P0481 open circuit in control circuit of cooling fan relay (high speed)
65) Trouble code: P0691 short circuit to ground in control circuit of cooling fan relay (low speed)
66) Trouble code: P0692 short circuit to power supply in control circuit of cooling fan relay (low speed)
67) Trouble code: P0693 short circuit to ground in control circuit of cooling fan relay (high speed)
68) Trouble code: P0694 short circuit to power supply in control circuit of cooling fan relay (high speed)
Introduction of trouble causes: The circuit control module inside the ECM will detect the fan relay circuit
voltage after the engine is started. When the voltage or current under the trouble mode is met, the
determination is the trouble of relay circuit.
P0480 P0480

1) Open circuit/short circuit to ground/short circuit to checked:
power supply between the circuit connected to ECM 1) Measure the resistance or voltage of the circuit
and fan relay between the ECM connector and relay pin.
2) Open circuit between the relay and main relay 2) Resistance between the relay and main relay
3) Open circuit in the electromagnetic coil of relay 3) Resistance between the two pins of relay
69) Trouble code: P0501 unreasonable signal of vehicle speed sensor
Introduction of trouble causes: When the vehicle is sliding with the released accelerator pedal under a
selected gear, ECM will monitor the rotating speed of engine and the vehicle speed at the same time. If
the engine maintains the high rotating speed but the vehicle speed shown is “zero” or obviously too low,
the system will determine the trouble of vehicle speed signal.
P0501 P0501

1) Short circuit to ground or open circuit in the signal checked:
circuit from ECM to vehicle speed sensor 1) Check the resistance in circuit from ECM connector to
the vehicle speed signal sensor.
2) Check the resistance to ground in the circuit of ECM
pin.
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70) Trouble code: P0506 rotating speed under idle control lower than target idle speed
Introduction of trouble causes: The idle rotating speed of engine is fulfilled through closed-loop control. If
the actual rotating speed of engine is still below the target idle rotating speed after the ECM enters the
idle control for a certain period of time, this trouble is determined.
P0506 P0506

following problems: intermittent one.
1) Stepper motor is blocked in a smaller opening.
2) Check the adjusting screw of air throttle, throttle
wiredrawing and operating conditions of air throttle
and etc.
3) The inside of air throttle body is too dirty.
71) Trouble code: P0507 rotating speed under idle control higher than target idle speed
Introduction of trouble causes: The idle rotating speed of engine is fulfilled through closed-loop control. If
the actual rotating speed of engine is still above the target idle rotating speed after the ECM enters the
idle control for a certain period of time, this trouble is determined.
P0507 P0507
Maintenance hints:
The trouble has been identified and there may be the
following problems:
1) Check the adjusting screw of air throttle, throttle
Maintenance hints:
wiredrawing and operating conditions of air throttle
The trouble has not been finally identified and may be the
and etc.
intermittent one.
2) The inside of air throttle body is too dirty.
3) Stepper motor is blocked in a bigger opening.
4) Check the forced ventilation pipe of crankcase for the
shedding or gas leakage.
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72) Trouble code: P0508 short circuit to ground of drive pin of stepper motor
73) Trouble code: P0509 short circuit to power supply of drive pin of stepper motor
74) Trouble code: P0511 open circuit of drive pin of stepper motor
Introduction of trouble causes: After the engine is started, the circuit control module inside the ECM will
continuously monitor the voltage of drive circuit of idle stepper motor. When the short circuit to
ground/power supply/open circuit occurs in one of four circuits, the system will determine the
corresponding trouble of stepper motor circuit.
P0508 P0508

1) Short circuit to ground/short circuit to power checked:
supply/open circuit in any of drive circuits of stepper 1) Measure the resistance or voltage between the drive
motor connected to ECM circuit of each stepper motor connected to ECM and
the ground
75) Trouble code: P0560 unreasonable voltage signal of system storage battery
76) Trouble code: P0562 too low voltage of system storage battery
77) Trouble code: P0563 too high voltage of system storage battery
P0560 P0560

1) Damaged generator or leakage of storage battery checked:
2) Open circuit in the excitation circuit of generator 1) Check the generating capacity of generator (measure
3) Damaged adjustor of generator leads to the failure of the generator voltage after the start-up).
generated energy control, making too high generated
voltage.
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78) Trouble code: P0627 open circle in control circuit of fuel injection pump relay
79) Trouble code: P0628 short circuit to ground in control circuit of fuel injection pump relay
80) Trouble code: P0629 short circuit to power supply in control circuit of fuel injection pump relay
P0062X P0062X

power supply between the control circuit of fuel 1) Measure the resistance or voltage in the control circuit
injection pump connected to ECM and the fuel of fuel injection pump relay connected to ECM.
injection pump relay 2) Resistance between the relay and main relay
2) Open circuit between the relay and main relay 3) Resistance between the two pins of relay
3) Open circuit in the electromagnetic coil of relay
81) Trouble code: P0645 open circuit in control circuit of A/C compressor relay
82) Trouble code: P0646 short circuit to ground in control circuit of A/C compressor relay
83) Trouble code: P0647 short circuit to power supply in control circuit of A/C compressor relay
P064X P064X

power supply between the control circuit connected to 1) Measure the resistance or voltage in the control circuit
the A/C compressor relay connected to ECM and the of A/C compressor relay connected to ECM.
relay 2) Resistance between the relay and main relay
2) Open circuit between the relay and main relay 3) Resistance between the two pins of relay
3) Open circuit in the electromagnetic coil of relay
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84) Trouble code: P0650 trouble of drive circuit of malfunction indicator lamp (MIL)
P0650 P0650

power supply in the drive circuit of malfunction 1) Measure the resistance or voltage in the drive circuit
indicator lamp (MIL) connected to ECM of MIL connected to ECM.
2) Open circuit between the MIL and main relay
3) Burnout of MIL
85) Trouble code: P1651 trouble of drive circuit of services indicator lamp (SVS)
P0650 P0650

power supply in the drive circuit of SVS connected to 1) Measure the resistance or voltage in the drive circuit
ECM of the SVS connected to ECM.
2) Open circuit between SVS and main relay
3) Burnout of SVS
86) Trouble code: P2177 self-learning value of air-fuel ratio closed-loop control exceeding the upper limit
87) Trouble code: P2178 self-learning value of air-fuel ratio closed-loop control exceeding the lower limit
Principle and introduction of trouble causes: In order to optimize the general conversion efficiency of the
catalytic converters for the HC, CO and NOx, the air-fuel ratio of the gas mixture should be kept at 14.7:1.
In case of the manufacturing deviation of spare part of engine, the deposition of colloid in the petrol at
the back of fuel injector, intake passage or valve and the air leakage of intake and exhaust system, the
air-fuel ratio will deviate from the 14.7:1 (diluted or concentrated), which will lead to the deterioration of
emission and the degradation of engine performance. Engine control system will correct fuel injection
volume and self learn according to the deviation degree of air-fuel ratio and characteristics. When the
value of self-learning reaches the set upper limit of system (if the gas mixture is diluted or concentrated,
the system will continuously correct the fuel injection volume until the maximum value), the system will
determine the trouble that the self-learning value exceeds the upper limit.
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P2177 or P2178 P2177 or P2178
Maintenance hints:
The trouble has been identified and there may be the
following problems:
1) Fuel injector is blocked and needs to be cleaned.
Maintenance hints:
2) Air leakage in the intake and exhaust systems
Trouble has not been finally identified and it is necessary to
3) Too much deposition of colloid at the back of intake
wait for the system to finish the diagnosis.
passage or intake valve should be wiped out.
4) Deviation of spare part of engine
5) Deviation of valve gap
6) Deviation of fuel system pressure
88) Trouble code: P2195 aging of upstream oxygen sensor (diluted)
Introduction of trouble causes: The offset of upstream oxygen sensor signal will lead to the deviation of
air-fuel ratio, and the rear oxygen closed-loop adjustment will rectify this deviation. The system set a
certain range for the correction of rear oxygen closed-loop, and when the correction exceeds the upper
limit of the range set by the system, the system will determine that the characteristics of the upstream
oxygen sensor has deviated.
P2195 P2195

1) The deviation of characteristics of the upstream
oxygen sensor may lead to the excessive emission.
89) Trouble code: P2196 aging of upstream oxygen sensor (concentrated)
Introduction of trouble causes: The offset of upstream oxygen sensor signal will lead to the deviation of
air-fuel ratio and the rear oxygen closed-loop adjustment will rectify this deviation. The system set a
certain range for the correction of rear oxygen closed-loop, and when the correction exceeds the lower
limit of the range set by the system, the system will determine that the characteristics of the upstream
oxygen sensor has deviated.
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Electronic Control
P2196 P2196

1) The deviation of characteristics of the upstream
oxygen sensor may lead to the excessive emission.
90) Trouble code: P2270 aging of downstream oxygen sensor (diluted)
Introduction of trouble causes: Under the normal circumstances, the oxygen sensor signal should
fluctuate around the control target value. If it is found that the sensor voltage is continuously diluted at a
certain period of time, the system will enrich the gas mixture. If the sensor voltage signal is not getting
concentrated in the expected direction, it is determined that the trouble is the diluted aging of oxygen
sensor.
91) Trouble code: P2271 aging of downstream oxygen sensor (concentrated)
Introduction of trouble causes: Under the normal circumstances, the oxygen sensor signal should fluctuate
around the control target value. If it is found that the sensor voltage is continuously concentrated at a certain
period of time, the system will attenuate the gas mixture. If the sensor voltage signal is not getting diluted in the
expected direction, it is determined that the trouble is the concentrated aging of oxygen sensor.
P2270 or P2271 P2270 or P2271

1) Drop of performance of downstream oxygen sensor
may lead to the excessive emission.
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Electronic Control
II. Diagnosis by Trouble Phenomena

1. Illustration
Before carrying out the trouble diagnosis steps in accordance with the engine trouble phenomenon, it is
necessary to first conduct the preliminary check:
1) Confirm that the malfunction indicator lamp of engine is operating normally.
2) Use the trouble diagnosis apparatus to check and confirm there is no record of trouble information.
3) Confirm the existence of the trouble complained about by the owner and the conditions about the
occurrence of the trouble.
And then check the appearance:
1) Check whether there is the fuel leakage in the fuel pipeline.
2) Check whether there is breakage or kink in the vacuum pipeline and whether the connection is
normal.
3) Check whether the intake pipeline is blocked, leaked, flattened or damaged.
4) Check whether the high-voltage wire of ignition system is broken, aged and whether the ignition
sequence is correct.
5) Check whether the grounding position of wire harness is clean and firm.
6) Check the connector of each sensor and actuator for the looseness or poor contact.
Note: If any of the above-mentioned phenomena exists, it is necessary to first take the maintenance
operation against it; otherwise the following trouble diagnosis and maintenance will be affected.
2. Diagnosis Help
1) Confirm there is no trouble record in the engine.
2) Confirm the existence of the trouble complained by the owner.
3) The check has been done according to the above steps, and there is nothing unusual found.
4) It is not permitted to neglect the effects of the maintenance of vehicle, cylinder pressure, mechanical
ignition timing and fuel etc. on the system during the overhaul process.
5) Replace the ECM for the test.
If the trouble phenomenon can be cleared at this time, it means the trouble site is at ECM; if the trouble
phenomenon still exists at this point, remount the original ECM and repeat the procedures again to carry
out the overhaul.
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Electronic Control
Trouble phenomenon 1: during the start-up, the engine does not run or runs slowly
General trouble position:
1. Storage battery; 2. Starter; 3.Wire harness or ignition switch; 4.Mechanical part of engine
General diagnosis procedure:
No. Operating Steps Detection Results Subsequent Steps
Use the multimeter to check the voltage between the two Yes Next step
1 terminals of storage battery to see whether it is about 8-12V
Replace the
during the start-up of engine. No
storage battery
Maintain the ignition switch at the starting position and use the Yes Next step
2 multimeter to check whether there is a voltage above 8V at the
Repair or replace
cathode terminal of starter. No
wire harness
Dismantle the starter to check its operating state. Mainly Repair or replace the
Yes
3 check whether there is a broken circuit in the starter or starter
whether it is blocked due to the poor lubrication.
No Next step
Replace with the

If the trouble only happens in the winter, then check whether
Yes lubricating oil of the
4 too large resistance of starter is caused due to the improper
proper grade
selection of the lubricating oil for engine or the gearbox oil.
No Next step
Overhaul the internal

Check whether the internal mechanical resistance of engine is Yes
resistance of engine
5 too large; if so, the failure of rotation or the slow rotation of
starter may occur. Repeat the above
No
steps
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Electronic Control
Trouble phenomenon 2: Engine can be drive to run but can not be started successfully during the
start-up
1. No fuel in the fuel tank; 2. Fuel injection pump; 3.Crankshaft position sensor; 4.Ignition coil;
5.Mechanical part of engine
Detection
No. Operating Steps Subsequent Steps
Results
Connect the fuel pressure gauge (the access point is at the front Yes Next step
end of the induction manifold of the fuel distribution pipe
1 assembly) to the engine, and start the engine to check whether Overhaul the fuel supply
the reading of fuel pressure gauge at idle condition is at about No
system
350kPa.
Yes Next step

Connect the electric control system diagnosis apparatus to the
2 engine to observe the data of "rotating speed of engine" and start Overhaul the line of
the engine to observe whether there is the speed signal output. No crankshaft position
sensor
Pull out the high-voltage wire of one of the cylinders and connect Yes Next step
the ignition plug to make the ignition plug electrodes around
3
5mm away from the engine body, and start the engine to check Overhaul the ignition
No
whether there is the blue and white high-voltage fire. system
Eliminate the mechanical

Check the pressure states of all the cylinders of engine and Yes
4 trouble of engine
observe whether the pressure of engine cylinder is insufficient.
No Next step
Connect the adapter of electric control system and turn on the Yes Diagnosis help
ignition switch to check whether the power supplies of the pins
5
#16, #17, #8 and #51 are normal; check whether the groundings Overhaul the
No
of pins #5, #43 and #48 are normal. corresponding line
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Electronic Control
Trouble phenomenon 3: Difficulty in warm start

1. Poor quality of fuel; 2.Fuel injection pump; 3.Coolant temperature sensor; 4.Ignition coil
Detection
Results
Connect the fuel pressure gauge (the access point is at the front end Yes Next step
of the induction manifold of the fuel distribution pipe assembly) to the
1
Overhaul the fuel
engine and start the engine to check whether the reading of fuel No
supply system
pressure gauge at idle condition is at about 350kPa.
Pull out the high-voltage wire of one of the cylinders and connect the Yes Next step
ignition plug to make the ignition plug electrodes around 5mm away
2
from the engine body, and start the engine to check whether there is Overhaul the ignition
No
the blue and white high-voltage fire. system
Pull out the connector of coolant temperature sensor and start the Overhaul the line or
Yes
engine to observe whether the engine is successfully started at this replace the sensor
3 time. (Alternatively, connect a 300 ohm resistance in series at the
connector of coolant temperature sensor in place of it to observe No Next step
whether the engine is successfully started at this time.)
Check the vacuum pipe of fuel pressure regulator for the shedding or Yes Overhaul or replace
4
air leakage.
No Next step
Check the fuel state and observe whether the trouble phenomenon Yes Replace the fuel
5
occurs just after adding the fuel.
No Next step
ignition switch to check whether the power supplies of the pins #16,
6
#17, #8 and #51 are normal; check whether the groundings of pins Overhaul the
No
#5, #43 and #48 are normal. corresponding line
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Electronic Control
Trouble phenomenon 4: Difficulty in cold start

1. Poor quality of fuel; 2. Fuel injection pump; 3.Coolant temperature sensor; 4.Fuel injector; 5.Ignition
coil; 6.Air throttle body and idle bypass air passage; 7.Mechanical part of engine

Connect the fuel pressure gauge (the access point is at the Yes Next step
1 front end of the induction manifold of the fuel distribution pipe
assembly) and start the engine to check whether the reading Overhaul the fuel
No
of fuel pressure gauge at idle condition is at about 350kPa. supply system
Pull out the high-voltage wire of one of the cylinders and Yes Next step
2 connect the ignition plug to make the ignition plug electrodes
around 5mm away from the engine body, and start the engine Overhaul the ignition
No
to check whether there is the blue and white high-voltage fire. system
Pull out the connector of coolant temperature sensor and start Overhaul the line or
Yes
the engine to observe whether the engine is successfully replace the sensor
3 started at this time. (Alternatively, connect a 2500 ohm
resistance in series at the connector of coolant temperature
sensor in place of it to observe whether the engine is No Next step
successfully started at this time.)
Wash the air throttle
Gently step down the accelerator pedal to observe whether it Yes
4 and idle air passage
is easy to start.
No Next step
Dismantle the fuel injector and use the cleaning analyzer Replacement of
Yes
5 special for fuel injector to check whether there is leakage or trouble
blockage in the fuel injector.
No Next step
Check the fuel state and observe whether the trouble Yes Replace the fuel
6
phenomenon occurs just after adding the fuel.
No Next step
Eliminate the
Check the pressure states of all the cylinders of engine and Yes mechanical trouble of
7 observe whether the pressure of engine cylinder is engine
insufficient.
No Next step
8 ignition switch to check whether the power supplies of the
pins #16, #17, #8 and #51 are normal; check whether the Overhaul the
No
groundings of pins #5, #43 and #48 are normal. corresponding line
209
Electronic Control
Trouble phenomenon 5: Difficulty in starting at any time but with normal rotating speed
1. Poor quality of fuel; 2. Fuel injection pump; 3.Coolant temperature sensor; 4.Fuel injector; 5.Ignition
coil; 6.Air throttle body and idle bypass air passage; 7.Intake passage; 8.Ignition timing; 9.Ignition
plug; 10.Mechanical part of engine
Overhaul the intake

Check whether the air filter is blocked and whether the intake Yes
1 system
passage is leaked.
No Next step
Connect the fuel pressure gauge (the access point is at the front Yes Next step
2 end of the induction manifold of the fuel distribution pipe assembly)
and start the engine to check whether the reading of fuel pressure Overhaul the fuel
No
gauge at idle condition is at about 350kPa. supply system
Pull out the high-voltage wire of one of the cylinders and connect Yes Next step
3 the ignition plug to make the ignition plug electrodes around 5mm
away from the engine body, and start the engine to check whether Overhaul the ignition
No
there is the blue and white high-voltage fire. system
Check the ignition plug of each cylinder to observe whether its Yes Next step
4
model and gap are in compliance with the specification.
No Adjust or replace
Pull out the connector of coolant temperature sensor and start the Overhaul the lien or
Yes
5 engine to observe whether the engine is successfully started at this replace the sensor
time.
No Next step
Wash the air throttle

Yes
6 Gently step down the throttle to observe whether it is easy to start. and idle air passage
No Next step
Dismantle the fuel injector and use the cleaning analyzer special Replacement of
Yes
7 for fuel injector to check whether there is leakage or blockage in trouble
the fuel injector.
No Next step
8
No Next step
Eliminate the
Check the pressure states of all the cylinders of engine and Yes mechanical trouble of
9
observe whether the pressure of engine cylinder is insufficient. engine
No Next step
Yes Next step

Check whether the ignition sequence of engine and ignition timing
10
is in line with the specification. Overhaul the ignition
No
timing
11 ignition switch to check whether the power supplies of the pins #16,
No
210
Electronic Control
Trouble phenomenon 6: Normal start-up but unstable idle at any time

1. Poor quality of fuel; 2.Fuel injector ; 3.Ignition plug; 4.Air throttle body and idle bypass air passage;
5.Intake passage; 6.Idle adjustor (stepper motor ); 7.Ignition timing; 8.Ignition plug; 9.Mechanical
part of engine.
Detection
Results
Overhaul the intake

1 system
passage is leaked.
No Next step
Yes Wash or replace

2 Check whether the idle adjustor is jammed.
No Next step
Check the ignition plug of each cylinder to observe whether its model Yes Next step
3
and gap are in compliance with the specification.
Check whether there is carbon deposit in the air throttle body and Yes Wash
4
idle bypass air passage.
No Next step
Dismantle the fuel injector and use the cleaning analyzer special for Replacement of
Yes
5 fuel injector to check whether there is leakage, blockage or too poor trouble
flow in the fuel injector.
No Next step
6
No Next step
Eliminate the
Check the pressure states of all the cylinders of engine and observe Yes mechanical trouble of
7
whether the pressure difference of each engine cylinders is large. engine
No Next step
Yes Next step

Check whether the ignition sequence of engine and ignition timing is
8
in line with the specification. Overhaul ignition
No
timing
9
Overhaul the
#17, #8 and #51 are normal; check whether the groundings of pins No
corresponding line
#5, #43 and #48 are normal.
211
Electronic Control
Trouble phenomenon 7: Normal start-up but unstable idle speed during the warm-up process
1. Poor quality of fuel; 2. Coolant temperature sensor; 3.Ignition plug; 4.Air throttle body and idle
bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Mechanical part of engine.
Detection
Results
Overhaul the intake

1 system
passage is leaked.
No Next step
Check the ignition plug of each cylinder to observe whether its model Yes Next step
2
and gap are in compliance with the specification.
Wash the related

Dismantle the idle adjustor to check whether there is carbon deposit Yes
3 components
in the air throttle body, idle adjustor and idle bypass air passage.
No Next step
Pull out the connector of coolant temperature sensor and start the Overhaul the lien or
Yes
4 engine to observe whether the idle speed of engine is unstable replace the sensor
during warm-up process.
No Next step
Yes
No Next step
6
No Next step
Eliminate the
Check the pressure states of all the cylinders of engine and observe
Yes mechanical trouble of
7 whether the pressure difference of each engine cylinders is large.
engine
No Next step
8
No
212
Electronic Control
Trouble phenomenon 8: Normal start-up but unstable idle speed after the warm-up process
1. Poor quality of fuel; 2. Coolant temperature sensor; 3.Ignition plug; 4.Air throttle body and idle
bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Mechanical part of engine.
Detection
Results
Check whether the air filter is blocked and whether the Yes Overhaul the intake system
1
intake passage is leaked.
No Next step
Check the ignition plug of each cylinder to observe Yes Next step
2 whether its model and gap are in compliance with the
specification. No Adjust or replace
Dismantle the idle adjustor to check whether there is Yes Wash the related components
3 carbon deposit in the air throttle body, idle adjustor and
idle bypass air passage. No Next step
Pull out the connector of coolant temperature sensor and Overhaul the lien or replace
Yes
4 start the engine to observe whether the idle speed of the sensor
engine is unstable during warm-up process.
No Next step
Dismantle the fuel injector and use the cleaning analyzer Yes Replacement of trouble
5 special for fuel injector to check whether there is
leakage, blockage or too poor flow in the fuel injector. No Next step
6
No Next step
Check the pressure states of all the cylinders of engine Eliminate the mechanical
Yes
7 and observe whether the pressure difference of each trouble of engine
engine cylinders is large.
No Next step
Connect the adapter of electric control system and turn Yes Diagnosis help
on the ignition switch to check whether the power
8 supplies of the pins #16, #17, #8 and #51 are normal; Overhaul the corresponding
check whether the groundings of pins #5, #43 and #48 No
line
are normal.
213
Electronic Control
Trouble phenomenon 9: Normal start-up but unstable idle speed or flameout under some certain loads
(for example, when the air conditioner is on)
1. Air conditioning system; 2. Idle adjustor; 3.Fuel injector
Detection
Results
Wash the related

Dismantle the idle adjustor to check whether there is carbon deposit Yes
1 components
No Next step
Observe whether the output power of engine is increasing when Yes To step 4
turning on the air conditioner, namely, use the electric control system
2
diagnosis apparatus to observe the changes of ignition advance
No Next step
angle, fuel injector pulse width and intake volume.
Connect the adapter of electric control system and disconnect the Yes Next step
connecting wire of the pin #75 of electronic control module to check
3
whether there is high level signal at the wire harness end when Overhaul the air
No
turning on the air conditioner. conditioning system
Check whether the pressure of air conditioning system, Yes Next step
4 electromagnetic clutch of compressor and the compression pump of
Overhaul the air
air conditioner are normal. No
conditioning system
Yes

No Next step
6
No
214
Electronic Control
Trouble phenomenon 10: Normal start-up but too high idle speed
1. Air throttle body and idle bypass air passage; 2.Vacuum pipe; 3.Idle adjustor; 4.Coolant temperature
sensor; 5.Ignition timing
Detection
Results
Yes Adjust
1 Check whether the throttle wiredrawing is jammed or too tight.
No Next step
Overhaul the intake

Yes
Check whether there is air leakage in the intake system and vacuum system
2
pipeline.
No Next step
Wash the related

Yes
Dismantle the idle adjustor to check whether there is carbon deposit components
3
No Next step
Overhaul the lien or

Pull out the connector of coolant temperature sensor and start the Yes
replace the sensor
4 engine to observe whether the idle speed of engine is too high at this
time.
No Next step
Yes Next step

Check whether the ignition timing of engine is in line with the
5
specification.
Overhaul ignition
No
timing
Connect the adapter of electric control system and turn on the

Yes Diagnosis help
6
#17, #8 and #51 are normal; check whether the groundings of pins
Overhaul the
#5, #43 and #48 are normal. No
corresponding line
215
Electronic Control
Trouble phenomenon 11: Rotating speed fails to increase or flameout occurs during the acceleration
1. Poor quality of fuel; 2. Intake pressure sensor and air throttle position sensor; 3.Ignition plug; 4. Air
throttle body and idle bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Fuel injector;
8.Ignition timing; 9.Exhaust pipe.

Overhaul the intake
Yes
1 Check whether the air filter is blocked. system
No Next step
front end of the induction manifold of the fuel distribution pipe
2 assembly) to the engine and start the engine to check whether Overhaul the fuel
supply system
350kPa.
3
Dismantle the idle adjustor to check whether there is carbon Wash the related
Yes
4 deposit in the air throttle body, idle adjustor and idle bypass components
air passage.
No Next step
Yes Next step
Check whether the intake pressure sensor, air throttle position
5
sensor and its line are normal. Overhaul the lien or
No
replace the sensor
Yes
No Next step
7
No Next step
Yes Next step
Check whether the ignition sequence of engine and ignition
8
timing is in line with the specification. Overhaul ignition
No
timing
Yes Next step
9 Check whether the operation of the exhaust pipe is smooth.
No
exhaust pipe
10 ignition switch to check whether the power supplies of the pins
#16, #17, #8 and #51 are normal; check whether the Overhaul the
No
216
Electronic Control
Trouble phenomenon 12: Slow reaction during the acceleration
1. Poor quality of fuel; 2. Intake pressure sensor and air throttle position sensor; 3.Ignition plug; 4.Air
throttle body and idle bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Fuel injector;
8.Ignition timing; 9. Exhaust pipe.
Overhaul the intake

Yes
1 Check whether the air filter is blocked. system
No Next step
2 assembly) to the engine and start the engine to check whether Overhaul the fuel
supply system
350kPa.
3
Yes
4 deposit in the air throttle body, idle adjustor and idle bypass air components
passage.
No Next step
Yes Next step

5
sensor and its line are normal. Overhaul the lien or
No
replace the sensor
Yes
No Next step
7
No Next step
Yes Next step

Check whether the ignition sequence of engine and ignition
8
timing is in line with the specification. Overhaul ignition
No
timing

9 Check whether the operation of the exhaust pipe is smooth. No
exhaust pipe
ignition switch to check whether the power supplies of the pins
10
No
217
Electronic Control
Trouble phenomenon 13: Powerlessness and poor performance during the acceleration
1. Poor quality of fuel; 2.Intake pressure sensor and air throttle position sensor; 3.Ignition plug;
4.Ignition coil; 5.Air throttle body and idle bypass air passage; 6.Intake passage; 7.Idle adjustor;
8.Fuel injector ; 9.Ignition timing ; 10.Exhaust pipe.
Check whether there are such troubles as the clutch slipping, Yes Repair
1 low tire pressure, brake drag, wrong size of tire and incorrect
alignment of four wheels etc. No Next step
Yes Overhaul the intake system

2 Check whether the air filter is blocked.
No Next step
3 assembly) to the engine and start the engine to check whether Overhaul the fuel supply
system
350kPa.
Pull out the high-voltage wire of one of the cylinders and Yes Next step
connect the ignition plug to make the ignition plug electrodes
4 Overhaul the ignition
around 5mm away from the engine body, and start the engine No
system
to check whether the strength of high-voltage fire is normal.
5
model and gap is in compliance with the specification.
Yes
6 deposit in the air throttle body, idle adjustor and idle bypass air components
passage.
No Next step
Yes Next step
7
sensor and its line are normal. Overhaul the lien or replace
No
the sensor
Dismantle the fuel injector and use the cleaning analyzer Yes Replacement of trouble
8 special for fuel injector to check whether there is leakage or
blockage in the fuel injector. No Next step
9
No Next step
Check whether the ignition sequence of engine and ignition Yes Next step
10
timing is in line with the specification.
No Overhaul ignition timing
11 Check whether the operation of the exhaust pipe is smooth. No
exhaust pipe
12 ignition switch to check whether the power supplies of the pins
No
218
Contents of Overview and Maintenance
Chapter I Overview..........................................................................................................1
Section I General Instructions.....................................................................................................1
I. Summary.............................................................................................................................1
II. How to Use This Manual .....................................................................................................1
Section II Vehicle Information....................................................................................................2
I. Identification Information Position .......................................................................................2
II. Nameplate...........................................................................................................................2
III. Vehicle Identification Number (VIN) ....................................................................................3
IV. Engine Number ...................................................................................................................3
Section III Lifting, Protection and Traction of Vehicle ...............................................................5
I. Lifting of Vehicle..................................................................................................................5
II. Protection of Vehicle ...........................................................................................................5
III. Traction of Vehicle ..............................................................................................................6
Chapter II Maintenance ...................................................................................................8

Section I Maintenance ....................................................................................................................8
I. Preparation .........................................................................................................................8
II. General Maintenance..........................................................................................................8
III. Regular Maintenance ..........................................................................................................9
IV. Recommended Oil and Lubricant......................................................................................11
V. Maintenance of Engine .....................................................................................................12
VI. Maintenance of Chassis and Body....................................................................................20
VII. Maintenance Data.............................................................................................................28
1
Maintenance Manual of Tojoy Sedan Overview
Chapter I Overview
Section I General Instructions
I. Summary
This Manual provides the procedures required by service operations, including:
1. Structure and composition
2. Principles
3. Dismantlement and installation steps
4. Inspection methods
5. Adjustment & commissioning methods
6. Common trouble diagnosis procedures
7. Technical parameters
The simple operations that can be conducted through the observation of vehicle are left out in this
Manual. No description is given for the necessary basic skills of maintenance technicians in this Manual.
II. How to Use This Manual

This Manual covers four parts, i.e. engine volume, chassis volume, electrical appliance & structure
volume of vehicle body, and circuit overhaul volume. In the front of each part is given a detailed content
index, in which you can find the section you want quickly.
The content provided in this Manual includes the following information:
1. Working principles;
2. Element position
3. Overhaul specifications
4. Component dismantlement & installation steps
5. Common troubles and overhaul procedures
Such information accords with the current model when this Manual is published.
1
Section II Vehicle Information

I. Identification Information Position
II. Nameplate
1. Position of nameplate: it is located at the firewall of engine compartment.
2. Instructions of nameplate
Made
Madebyby China
China Anhui
Anhui Jianghuai
Jianghuai Automobile
Automobile Co.,
Co., Ltd.
Ltd.
Brand Jianghuai VIN LJ12FKR1584200046
Model HFC7130AG Engine displacement 1.30L
Engine Model 4G13S1 Rated power 68.5 Kw
Max. gross weight 1475 Kg Fixed number 5 persons
Ex-factory no. 8420046 Ex-factory date Sep. 2008
Example of Nameplate
2
III. Vehicle Identification Number (VIN)

1) VIN position: it is located on the nameplate or at the bottom left corner of windshield.
2) Illustration of VIN
Production SN
Assembly factory
4: General Assembly Workshop of Passenger Car
Manufacture Company
7: General Assembly Workshop of Passenger Car
Inspection
digit
Year code
8: 2008
9: 2009
A: 2010
Vehicle type
2: passenger car
Code of engine type and rated

Wheelbase power
R: >2390~2600 1: gasoline ≤70Kw
2: gasoline >70~90Kw
3: gasoline >70~110Kw
Manufacturer Body type Max. gross weight
LJ1: Anhui Jianghuai F: 3 boxes & 4 doors K: >1000~2000
Automobile Co., Ltd. G: 2 boxes & 5 doors
IV. Engine Number

1. Position of engine number
It is printed on the rear left of cylinder body.
Fig. 1.2.001
3
2. Meaning of Engine Number

Fig. 1.2.002
4G13S1 – Engine model
☆D284S0027☆:
D284S0027 – Production Code
D2 – Division symbol of engine model
8 – 2008
4 – April
S0027 – Production SN
4
Section III Lifting, Protection and Traction of Vehicle

I. Lifting of Vehicle
1. Vehicle’s Supporting Points
The positions of vehicle’s supporting points are shown in the figure below.
Attention:
Don’t lift the vehicle by using the point out of the designated positions; or else, the body may be
damaged.
Supporting point
Positions of Vehicle’s Supporting Points
2. Operation of Lifter
The lifter shall be operated strictly in accordance with the specifications of manufacturer.
Caution:
The operation against the specifications may cause the damage or injury to vehicle or personnel.
II. Protection of Vehicle

1. Appearance Protection
Before working, make sure that the vehicle is fitted with four appliances, i.e. seat cover, steering
wheel cover, gearshift lever cover, and foot mat. A protective pad must be applied on the fenders
when opening the engine hood for overhaul.
2. Preventive Measures Before Welding
Since electrical components are installed on the vehicle, the following procedures must be carried
out in order to avoid too large current through such components in welding.
1) Turn the ignition switch to “OFF” position;
2) Cut off the negative wiring of storage battery;
3) Ground the welding equipment carefully at a point nearby the welding area;
4) Cover other equipment around the welding area to prevent solders from splashing on them.
5
III. Traction of Vehicle

If the traction of vehicle is required, please contact the local authorized after-sales service center or
a special vehicle towing service company.
1. Traction by towing vehicle
Caution:
No passenger allowed in the vehicle being towed;
Don’t allow the traction speed over the safety speed or the stated speed limit;
Make sure the vehicle being towed are fixed firmly;
Operation against above-mentioned precautions may cause physical injury.
2. Traction by wheel lifter
1) Turn the ignition switch to “ACC (accessory)” position;
2) Turn on the hazard warning flash lamp;
3) Shift to neutral gear;
4) Release the parking brake;
5) Make sure the front wheels are away from ground.
Attention:
If it is necessary to tow the vehicle from the back, the supporting wheel of traction device should be
applied under front wheels. Don’t allow front wheels in contact with ground in towing; or else, the
transmission may be seriously damaged.
3. Emergency towing
If no towing vehicle is available under emergency, a rope may be fixed to the emergency towing
hole under the vehicle for temporary traction.
1) Front towing hole: It is under the front bumper. A Fig. 1.3.001
driver is required in the vehicle for steering and
braking purposes in towing. Such traction method
is applicable only on hard pavement with towing
distance and speed limited to certain extent. In
addition, such parts as wheels, axles, drive
system, steering system, and brakes must be in
good conditions.
Towing hole
6
Caution:
The vehicle may be damaged when towed by rope.
In order to minimize such damage,
① If no other towing equipment is available, the towing hole must be used;
② Always tow the vehicle from its forehead;
③ Keep the towing rope away from the bumper;
④ Check the towing rope by pulling it to make sure

both ends of it are fixed firmly on the towing hole.
Fig. 1.3.002
2) Rear towing hook: It can used to tow another
vehicle only under emergency (when a vehicle is
trapped in a ditch, heavy snow or mud pit). When
using the rear towing hook, always keep the rope or
chain perpendicular to the towing hook. Don’t apply
force to the towing hook from any side. Don’t start the
towing sharply to avoid any damage.
Towing hook
7
Maintenance Manual of Tojoy Sedan Maintenance
Chapter II Maintenance
Section I Maintenance
I. Preparation
1. Maintenance Tools
List of Maintenance Tools
No. Tools Outside View Description
For dismantlement and

1 Power tool installation of bolts and
nuts
For dismantlement and

Ignition plug
2 installation of ignition
socket
plug
II. General Maintenance

General maintenance means the inspection and maintenance items which shall be performed everyday
during the normal use of vehicles. These maintenance items are very important, for they can keep the
vehicle under normal service performance. Vehicle owners can perform these inspections by
themselves, or go to a JAC franchised store for assistance. As follows is content of general
maintenance:
1. Exterior of Vehicle
The following inspection and maintenance items shall be frequently conducted.
List of Items to be Frequently Inspected for the Exterior of Vehicle
Item Inspection
Tyre Use an air gauge to inspect the pressure of tyres (including spare tyre) in the service
station regularly, and adjust the pressure in accordance with technical data if necessary.
Check whether there’s any damage, crack or excessive wear and tear carefully.
Windshield Clean the windshield regularly. Check whether there’s any crack or other damage in/to
the windshield every six months or more frequently. And repair it, if necessary.
Windshield If the wiper doesn’t work efficiently, please check whether it is free from tear or wear.
wiper blade
Door and Check whether all of the doors, engine hood, boot cover and tail door can be normally
engine hood opened and closed, and whether all the door locks are locked close. Lubricate any of
them, if necessary. Moreover, If the vehicle often travels on the salt-spread roads or in the
areas with corrosive substances, inspect the lubricating state frequently.
Tyre rotation The tyre rotation shall be conducted after each 8000 km traveling.
Vehicle lamps Check whether the headlamp, stop lamp, tail lamp, turning signal light and other lighting
units are working normally, and have been stably fixed. Meanwhile, inspect the focusing
function of headlamp.
8
2. Interior of Vehicle
The following inspection and maintenance items shall be regularly performed.
List of Items to be Regularly Inspected for the Interior of Vehicle
Item Inspection
Alarm light and Make sure all the alarm lights and buzzers are working normally.
buzzer
Windshield wiper Check whether the wiper and cleaner are working normally; check whether there
and cleaner is any crack in the wiper.
Windshield defroster Check whether the air can be correctly bled from the air outlet hole of defroster,
and if the heater or air conditioner can breathe enough air during the operation of
heater or air conditioner.
Steering wheel Check whether the free travel of steering wheel is in the standard range. And
inspect the changes of steering performance, such as the free travel beyond the
range, hard steering and abnormal noise etc.
Safety Belt Check whether all the components of safety belt system are flexible and working
normally, and fixed firmly and stably. Inspect whether the safety belt is cracking,
worn out or damaged in other ways.
Accelerator pedal Check if the pedal can be operated smoothly, and ensure that the pedal would not
be seized or loaded unevenly. And also make sure that the bottom plate pad is far
from the pedal.
Brake pedal and Check if the pedal can be operated smoothly, and make sure the pedal still keeps
booster an appropriate distance from the bottom plate when it is completely pressed
down. Inspect the function of brake vacuum booster. And make sure that the
bottom plate pad is far from the pedal.
Parking brake Check the travel of handle.
3. Engine and Vehicle Chassis
The following inspection and maintenance items shall be regularly performed.
List of Items to be Regularly Inspected for the Engine and Vehicle Chassis
Item Inspection
Cleaning liquid for windshield Check whether there is adequate cleaning liquid within the
stock solution tank.
Level of engine coolant Check the coolant level when the engine is cold.
Engine oil level Stop the vehicle on a level ground, then switch off the engine,
and check the engine oil level.
Levels of brake fluid and clutch fluid Make sure that the levels of brake fluid and clutch fluid are
between the “MAX” line and “MIN” line of stock solution tank.
Storage battery Check the state of voltage and electric pole terminal posts of
storage battery.
Liquid leakage After the vehicle has been stopped for a while, check if there is
any leakage of fuel, engine oil, water or other liquid under the
vehicle. The dripping from the air conditioner which has just
been used is normal; however, in case of obvious leakage or
petrol fume, we shall find out the cause, and immediately
perform relative maintenance.
III. Regular Maintenance
The regular maintenance intervals and items for vehicle in general traveling conditions are shown in the
following table. These maintenances shall be preformed by a JAC franchised store.
9
Maintenance List of Vehicle in General Driving Conditions
Illustration of symbols: ● = inspection, adjustment or cleaning, replacement, if necessary; ▲ =

replacement; T = tightening to specified torque. (Note: mileage or months, whichever comes first.)
Interval Mileage (km) × 1000 5 10 20 30 40 50 60 70 80 90 100
Item months 3 6 12 18 24 30 36 42 48 54 60
Engine oil, engine oil Replaced after every 5,000 km or six months
filter
Filter element of air Cleaned after every 5,000 km, and replaced after every 15,000
filter km
A/C warm air system ● ● ● ● ● ●
Coolant ● ● ▲ ● ▲ ● ▲ ● ▲ ● ▲
Cooling system hose
● ●
and clamping band
Vent hose and
Engine ● ● ● ● ● ●
connector
Positive crankcase
● ●
ventilation system
Fuel filter ▲ ▲ ▲ ▲ ▲
Exhaust pipe and
● ● ● ● ● ●
installation seat
Ignition plug ▲ ▲ ▲
Ignition timing ● ●
Timing belt ● ● ● ● ● ● ● ▲ ● ● ●
Maintenance List of Vehicle in General Driving Conditions (Continued)

replacement; T = tightening to specified torque. (Note: mileage or months, whichever comes first.)
Interval 5 10 20 30 40 50 60 70 80 90 100
Mileage (km) × 1000
Item
months 3 6 12 18 24 30 36 42 48 54 60
Clutch pedal free
● ● ● ● ● ● ● ● ● ● ●
travel
Clutch pedal free
● ● ● ● ● ● ●
travel and brake
Brake pad and
● ● ● ● ● ● ● ● ● ● ●
brake disc
Brake fluid and hose ● ● ● ● ▲ ● ● ● ▲ ● ●
Steering wheel and
● ● ● ● ● ●
transmission
Four-wheel
● ● ● ● ● ● ● ● ● ● ●
alignment
Chassis and
Ball pin and dust
Body ● ● ● ● ● ● ● ● ● ● ●
boot
Transmission gear
▲ ▲ ▲ ▲ ▲ ▲
oil
Front and rear
● ● ● ● ● ●
suspensions
Bolt and nut T T T T T T T
Tyre and inflation
● ● ● ● ● ● ●
pressure
Power steering fluid ● ● ● ● ▲ ● ● ● ▲ ● ●
Air conditioner / cool
● ● ● ● ● ● ●
air
10
While the vehicle is operating under the following particular or severe conditions, the supplementary
maintenance shall be performed or the maintenance interval shall be shortened.
1. Repeated short-distance traveling;

2. Continuous idle running or long-time intermittent driving;
3. Traveling on the sand ground or in dusty conditions;
4. Frequently travels in traffic congestion condition;
5. Frequent high-speed driving.
Maintenance List of Vehicle in Particular or Severe Driving Conditions

replacement; T = item needs to be tightened to specified torque. (Note: mileage or months, whichever
comes first.)
Interval Mileage (km) × 1000 5 10 20 30 40 50 60 70 80 90 100
Item months 3 6 12 18 24 30 36 42 48 54 60
Drive belt Check and adjust it every 10,000 km, replace it when
necessary.
Engine oil, engine oil Replaced after every 5,000 km or three months
filter
Filter element of air Cleaned after every 3,000 km, and replaced after every 10,000
Engine
filter km
Vent hose and
● ● ● ● ●
connector
Ignition plug ▲ ▲ ▲ ▲ ▲
Idle speed ● ● ▲ ● ▲ ●
Clutch pedal free It shall be adjusted every 5，000 km.
travel
Tyre and inflation
● ● ● ● ● ● ● ● ● ● ●
pressure
Chassis and
Dust filtering screen ● ● ▲ ● ▲ ● ▲ ● ▲ ● ▲
Body
Front wheel
● ● ▲ ● ▲ ● ▲ ● ▲ ● ▲
alignment
Transmission gear
● ● ● ▲ ● ● ▲ ● ● ▲ ●
oil
IV. Recommended Oil and Lubricant
As shown in the following list are the types of oil and lubricant recommended by JAC:
List of Recommended Oil and Lubricant
Item Capacity (L) Recommended oil / lubricant

Engine oil 3 SAE5W-30 (winter in the north), SAE15W-40 (full year
in the south or summer in the north) grade SJ or above
Cooling system 5.5 High-quality HF-C anti-freezing solution
Manual transmission gear oil 2.0 API GL-4, SAE75W/90
Power steering fluid 0.9 PSF-3
Brake fluid and clutch fluid 0.56±0.05 DOT4 (Great Wall)
A/C refrigerant 480g R134a
Wiper cleaning liquid 3 JAC—A10010
A/C compressor lubricating oil 0.12 PAG56
11
V. Maintenance of Engine
1. Inspection for the Driving Belt

1) The inspection shall be performed only when the engine is cold or after the engine has been
stopped for 30 min.
2) Check visually whether there is any damage, wear or crack on the inside or edges of belt.
3) Rotate the crank pulley clockwise for two times, and then check whether the tension values of all
belts are same through testing.
4) During the measurement of deflection, a force of 98 N shall be applied.
5) If the deflection exceeds the limited value, corresponding adjustment shall be performed.
■ Belt deflection: 7~10 mm.
Attention:
■ After installation, the belt deflection shall be immediately inspected in this way: adjust the deflection
to the specified value at first, and then rotate the crankshaft for more than two circles, after that, in
order to avoid the variation of deflection between belt pulleys, adjust it to the specified value again.
2. Adjustment of Tension Degree
List of Adjustment of Tension Degree
Part Adjusting Method
Generator belt Adjust the adjusting bolt on the generator
Belts of power steering pump and A/C Adjust the adjusting bolt on the power steering pump
compressor
Attention:
■ Upon the old belt is replaced by a new one, the deflection of new belt shall be adjusted, such as to
make it fit in with the pulley groove.
■ After installation, the belt deflection shall be immediately inspected in this way: adjust the deflection
to the specified value at first, and then rotate the crankshaft for more than two circles, after that, in
order to avoid the variation of deflection between belt pulleys, adjust it to the specified value again.
■ During the installation of belt, please make sure that the belt is in correct mesh with the pulley
groove.
■ Don’t spill the engine oil or engine coolant on the belt.
■ Don’t excessively wind or twist the belt.
3. Replacement of Engine Coolant
Caution:
■ In order to avoid scald, please do not replace the coolant when the engine temperature is still very
high.
■ Use thick cloth to wrap the radiator cap, and unscrew it carefully. Release the pressure inside the
radiator at first, and then completely unscrew it to open the radiator.
■ Be careful, so as not to spill the engine coolant on the driving belt.
1) Draining the engine coolant
12
① Dismount the right deflector of engine. See “Engine Deflector” please.

② Open the water drain plug at the bottom of radiator, and then open the cap of radiator.
③ If necessary, please dismount the stock solution tank, drain the engine coolant, and clean the stock
solution tank prior to the reinstallation.
④ Check if there’s any foreign matter such as rust or any color change in the discharged engine
coolant.
■ In case it is polluted, please wash the engine cooling system. See “Washing the Cooling System”
please.
2) Refilling the engine coolant
① Install the dismantled stock solution tank and the water drain plug of radiator.
Attention:
■ The water drain plug must be cleaned, and a new O-ring must be installed.
② Please make sure that all the hose clamps have been stably tightened.
③ Dismount the upper cover of air filter and the intake hose. Please refer to the “Air Filter Assembly”.
④ Cut off the outlet tube of warm water pipe. Please lift the hose as high as possible.
⑤ Fill coolant into the radiator and stock solution tank to the specified level; the engine coolant must be
filled in a slowly way, such as to gradually remove the air from the system.
Attention:
■ Please mix the original JAC engine coolant or equivalent product with water. See “Recommended
Oil and Lubricant” please.
■ When the engine coolant overflows from the warm air outlet pipe, cut off the connection, and then
reconnect them and continue the filling of engine coolant.
⑥ Install the upper cover of air filter and intake hose. Please refer to “Air Filter Assembly”.
⑦ Install the radiator cap.
⑧ Warm up the engine until the thermostat is switched on.
■ Examine if there’s warm water flowing out by touching the lower hose of radiator, such as to check
whether the thermostat has been switched on.
Attention:
■ Observe the water temperature gauge of engine frequently, such as to avoid the overheating of
engine.
⑨ Stop the engine, such as to lower the temperature.
■ The cooling time can be reduced through the use of fan.
⑩ Fill the engine coolant in the stock solution tank to the MAX level.
⑪. Install the radiator cap, and repeat steps ③~⑨ for more than two times until the level of engine
coolant doesn’t go down any more.
13
○
12 Start the engine, and check if there’s any leakage in the cooling system.
3) Washing the cooling system

① Install the water drain plug of radiator and the stock solution tank which have been dismantled.
Attention:
■ The water drain plug must be cleaned, and a new O-ring must be installed.
② Dismount the upper cover of air filter and the intake hose. Please refer to the “Air Filter Assembly”.
③ Cut off the outlet tube of warm water pipe. Please lift the hose as high as possible.
④ Fill engine coolant into the radiator and stock solution tank, and install the cap of radiator.
When the engine coolant overflows from the warm air outlet pipe, cut off the connection, then reconnect
them and continue the filling of engine coolant.
⑤ Install the upper cover of air filter and intake hose. Please refer to “Air Filter Assembly”.
⑥ Start the engine, warm up it to the normal working temperature.
⑦ Speed up the engine for several times with it unloaded.
⑧ Stop the engine, and wait for the engine to cool down.
⑨ Discharge the water inside the system. Please refer to “Draining the engine coolant”.
⑩ Repeat steps ③~⑨ until the radiator starts to discharge the cleared water.
4. Inspection for the Cooling System
Caution:
■ Never open the radiator cap when the temperature of engine is still very high. The high temperature
and high pressure liquid overflowing from the radiator may cause severe scald.
■ Use thick cloth to wrap the radiator cap, firstly unscrew it for 1/4 circle to release the pressure inside
the radiator, and then completely unscrew it to open the radiator.
1) Inspection for the hose of cooling system
■ Check the hose for incorrect installation, crack, damage, loose connection, wear or ageing.
■ Please repair or replace the damaged components if necessary.
2) Inspection for radiator cap
① Check the valve seat of radiator cap.
■ Check whether the valve seat expands outward, i.e. when the plunger is vertically lifted from the top,
the end of plunger is out of view.
■ Check if there’s any dust or damage on/to the valve seat.
14
② Withdraw the negative pressure valve and

Fig. 2.1.001
open it, and upon the pressure is released,
check whether it can be completely closed.
■ Please make sure that there isn’t any smudge
or damage on/to the valve seat.
■ Make sure that the valve seat can be normally
opened and closed.
③ Check the pressure released by radiator cap.
Standard: 78~98 KPa
Limit: 59 KPa Fig. 2.1.002
— Connect the radiator cap to the radiator leak
detector, and please apply engine coolant
onto the sealing face of cap.
■ In case abnormal situation is found in the
above-mentioned three inspection items,
please replace the radiator cap.
Attention:
■ During the installation of radiator cap, please wipe the radiator filler carefully to clear away all the
paraffin residue or foreign substance.
3) Inspection for radiator
Check whether there’s any mud or clogging situation inside the radiator. If necessary, please clean the
radiator surface according to the following method.
■ Don’t twist or damage the radiation fins.
■ In case the cleaning work is performed without dismounting the radiator, all the accessories such as
cooling fan, wind collection hood and horn shall be dismounted. Then, use adhesive tape to wrap up
the connectors of wire harness for water proofing.
① Use a water hose to wash the back of radiator core from the top to the bottom vertically.
② Wash each surface of the radiator core every other minute.
③ In case no dirt is washed away from the radiator, the washing work shall be stopped.
④ Blow the back of radiation core with compressed air vertically and downwards. The pressure of
compressed air shall be less than 490 KPa, and a distance of more than 30 cm shall be kept.
⑤ Wash each surface of the radiator core with compressed air every other minute until no water can
be blown away.
4) Inspect whether there’s leakage in the system
① The leakage situation shall be inspected through applying a pressure to the cooling system with a
leak detector of radiator cap.
15
■ Test pressure: 157 KPa

Fig. 2.1.003
Caution:
■ Never open the radiator cap when the temperature
of engine is still very high; or else the high
temperature and high pressure liquid overflowing
from the radiator may cause severe scald.
Attention:
■ A pressure exceeds the specified test pressure
may cause damage to the radiator.
Note: In case the engine coolant is found decreased, please refill engine coolant into the radiator.
(1) If any component is found damaged, please repair
or replace it.
5. Inspection for Fuel Pipeline Fig. 2.1.004
Check the fuel pipeline, fuel filler cap and fuel tank for
incorrect installation, leakage, crack, damage, loose
connection, wear or ageing. Fuel pipeline
Engine
Fuel tank
■ Please repair or replace the damaged component
if necessary.
6. Replacement of Air Filter

Fig. 2.1.005
1) Dismantlement
① Unscrew the lock bolt of upper cover of air filter,
and lift up the upper cover.
② Dismount the filter element of air filter. Fig. 2.1.006
2) Inspection After the Dismantlement
■ The air filter must be regularly cleaned or replaced

according to the recommended schedule. Please
refer to “Regular Maintenance”.
16
■ Use compressed air to blow the back of filter element of air filter until nothing can be blown away.
3) Installation
7. Replacement of Engine Oil
Attention:
■ The temperature of engine oil is very high, so you should be careful not to be scalded.
■ Long-time direct contact between skin and the used oil shall be avoided. In that case, the skin shall
be thoroughly washed with soap or detergent as soon as possible.
1) Warm up the engine, and check whether there’s engine oil leakage in the engine hatch. Please refer
to “Leakage of engine oil”.
2) Switch off the engine, and wait for ten minutes.
3) Loosen the engine oil filler cap, and then dismount the oil drain bolt.
4) Discharge the engine oil.
5) Install the oil drain bolt with new gasket.
Attention:
■ The foreign matters such as iron dust on the oil drain bolt must be cleaned, and new gaskets shall
be installed.
■ The tightening torque of oil drain bolt is 34~44 N·m.
6) Refill the new engine oil.
Concerning the specification and viscosity of engine oil, please refer to “Recommended Oil and
Lubricant”.
■ Engine oil quantity: 2.5~3.5 L
Attention:
■ During the filling of engine oil, please do not withdraw the oil rule.
■ The filling amount of engine oil shall vary with engine oil temperature and oil drain time. The content
above is only for reference.
■ Oil rule shall be used all the way to check whether the filling amount of engine oil is proper.
7) Warm up the engine, and check whether there’s any engine oil leakage around the oil drain bolt and
engine oil filter.
8) Switch off the engine, and wait for ten minutes.
9) Check the level of engine oil. See also “Engine oil level”.
8. Replacement of Engine Oil Filter
1) Dismantlement
① Use engine oil filter wrench to dismount the engine oil filter.
17
Attention:
■ Original JAC engine oil or equivalent product shall be used.
■ Both the temperatures of engine and engine oil are very high, so you should be careful not to be
scalded.
■ For the dismantlement, a cloth shall be prepared to wipe up the leaked or splashing engine oil.
■ Please keep the driving belt free from engine oil.
■ Wipe up the engine oil splashing on the engine and vehicle thoroughly.
2) Installation Fig. 2.1.007

① Clear the foreign substance on the mounting
surface of engine oil filter.
② Apply a proper layer of engine oil onto the oil
seal surface of new engine oil filter.
③ Tighten the engine oil filter.
■ Tightening torque: 1 2~20N·m
Attention:
■ The engine oil filter must be tightened with a filter wrench.
■ Manual tightening may cause oil leakage due to the inadequate tightening torque.
3) Post-installation inspection
① Check the engine oil level, and fill engine oil when it is inadequate. See also “Engine Oil”.
② Start the engine, and check if there’s any engine oil leak.
③ Switch off the engine, and wait for ten minutes.
④ Check the engine oil level, and fill engine oil. See also “Engine Oil”.
9. Replacement of Ignition Plug
1) Dismantlement
① Dismount the engine hood. See also “Intake manifold”.
② Dismount the ignition coil and high-voltage wire. See also “Ignition coil”.
③ Use ignition plug socket wrench to dismount the ignition plug.
Attention:
■ Please do not drop or shock the ignition plug.
18
2) Inspection after the dismantlement
In general conditions, the standard ignition plug shall be used.
In the following conditions, if carbon deposition frequently occurs during the use of standard ignition plug,
the hot ignition plug shall be used:
■ The engine is frequently started.
■ The ambient temperature is too low.
In the following conditions, in case ignition knock frequently occurs during the use of standard ignition
plug, the cold ignition plug shall be used:
■ Long-time traveling on the expressway;
■ The engine is frequently running under a high speed.
Attention:
■ Please do not drop or shock the ignition plug.
■ Please do not use the steel brush for washing.
■ If there’s carbon deposition in the end of ignition plug, please use ignition plug cleaner to clean it.
■ During the replacement interval, the ignition plug gap shall be checked when it is necessary.
Ignition plug gap: 1.0~1.1 mm
3) Installation
Install in the reverse order with dismantlement. The tightening torque of ignition plug is: 20~30 N·m.
10. Replacement of Fuel Filter
1) Dismantlement
Caution:
■ Prior to the treatment of fuel system, one must read the “General Precautions”. See also “General
Precautions”.
① Release the fuel pressure inside the fuel pipeline. See also “Releasing the fuel pressure”.
② Open the fuel filler cap.
③ Release the pressure inside the fuel tank.
④ Dismount the rear seat cushion. See also “Rear Seat”.
⑤ Dismount the fuel tank service cap.
⑥ Dismount the fuel filter and fuel pipe.
For detailed description, please refer to “Fuel Filter”.
19
2) Installation
Please pay attention to the following precautions and install in the reverse order with dismantlement.
① Installation direction of fuel filter Fig. 2.1.008
■ Pay attention to the installation direction of

fuel filter.
Towards the side of inlet tube.
② Installation of pipe connectors.
3) Post-installation inspection
Check whether there’s any fuel leakage according to the following steps.
① Turn the ignition switch to “ON” (while the engine is shut-off), and then check if there’s leakage at
the joints of fuel pipeline.
② Start the engine and enhance the rotating speed, then double check if there’s fuel leakage at the
joints of fuel pipeline.
11. Inspection for the Evaporator Pipeline of Fuel Evaporative Emission System (EVAP)
1) Visually check whether the installation position of EVAP evaporator pipeline is correct, and if it is
free from leakage, crack, damage, loose connection, scratching or ageing etc.
2) Check if the vacuum release valve of fuel tank cap is free from blocking, or jamming etc. See also
“Fuel Evaporative Emission System”.
VI. Maintenance of Chassis and Body
1. Inspection for Exhaust System
Check whether the positions of exhaust pipe, muffler and fixed support are correct, and if they are free
from leakage, crack, damage, loose connection, wear and ageing.
■ In case the component is found damaged,

Fig. 2.1.009
please repair or replace it.
20
2. Inspection for Clutch Fluid Level and Leakage
If the fluid level is too low, please check whether the clutch system is free from leakage.
3. Inspection for Clutch System
Check whether the installation positions of liquid pipelines and working cylinders are correct, and if they
are free from crack, damage, loose connection, wear or ageing.
4. Inspection for Manual Transmission Gear Oil
Check the oil level and if it is free from leakage. For detailed information, please refer to “Inspection for
Manual Transmission Oil”.
5. Replacement of Manual Transmission Gear Oil
1) Fully drain the oil from the oil drain plug, and then refill it with new gear oil. For detailed information,
please refer to “Replacement of Manual Transmission Oil”.
2) Check the fluid level of gear oil. For detailed information, please refer to “Inspection for Manual
Transmission Oil Level”.
6. Wheel Balance
1) Dismantlement
① Dismount the wheels and tyres which need to be adjusted.
② Dismount the used balance blocks from both sides of the wheel, and clear the foreign matters on the
treads of tyre.
Note: for new tyres, the tape on the tyre shall be removed.
Attention:
■ During the dismantlement, be careful not to scratch the tyre.
2) Adjustment for wheel balance
① Take the center hole as the guidance, and install the wheel to the wheel balancer. Start the wheel
balancer.
② When the unbalance values for both inside and outside have been displayed on the display of wheel
balancer, multiply the unbalance value of outside with 5/3, such as to define the weight of balance
blocks which will be actually applied. Then, select the outside balance block which is nearest to the
calculated value, and install it to the specified outside position, or at the specified angle in relation to
the wheel.
Attention:
■ The outside balance block shall be installed first, and followed by the inside one.
■ Prior to the installation of balance block, the fitting surface of wheel must be thoroughly cleaned.
a. Install the balance block to the position indicated in the figure.
21
b. As shown in the figure, during the installation

Fig. 2.1.010
of balance block on the wheel, the balance
block shall be placed in the groove area on the
wheel inner wall, and fix its center toward the Adhesive weight
Center of gravity
position (or angle) indicated by the wheel
balancer.
Aim toward
the groove
Position (or angle) indicated

by the wheel balancer
Attention:
■ The balance block can not be repeatedly used; it shall be replaced every time.
■ At most three balance blocks are allowed to be installed.
■ The original balance blocks shall be applied all along.
c. In case the calculated weight of balance block Fig. 2.1.011
is more than 50 g, the two balance blocks
shall be installed in a line.
Attention:
■ Please do not place a balance block on
another one.
③ Restart the wheel balancer.
Position (or angle) indicated
④ According to the position (or angle) indicated by the wheel balancer
by the wheel balancer, knock in the balance

block at the inside of wheel.
Attention:
■ At most two balance blocks are allowed to be installed.
⑤ Start the balancer. Make sure the residual unbalance value of both the inside and outside is only 5 g
or less.
■ In case the residual unbalance value of either side is more than 5 g, please repeat the installation
steps for balance block.
7. Tyre Rotation Fig. 2.1.012
■ Tyre rotation shall be performed every 8000
km.
Tyre rotation also shall be performed when the
new tyre is put on.
Note: As shown in the figure is the recommend
method for tyre rotation.
22
8. Inspection for Brake Fluid Level and Leakage Fig. 2.1.013

Highest line
If the fluid level is too low, please check whether
the brake system is free from leakage. Lowest line
Normal
9. Inspection for Brake Pipeline and Wiredrawing Fig. 2.1.014
Check whether the positions of brake pipeline and

parking brake wiredrawing are correct, and if they
are free from leakage, wear, scratching or ageing
etc.
10. Replacement of Brake Fluid
Attention:
■ Refill brake fluid “DOT4” (Great Wall).
■ Please do not reuse the discharged brake fluid.
■ In order to keep the paintwork free from damage, please do not splash the brake fluid onto the
paintwork. If the fluid is splashed onto the paintwork, please use water to clean it immediately.
1) Insert the ethylene tube into the release valve. Fig. 2.1.015
2) Press on the brake pedal, loosen the release

valve, and then discharge the brake fluid
slowly.
3) Wash the inner side of stock solution tank, and refill it with new brake fluid.
4) Loosen the release valve, press down the brake pedal slowly, and then release it. Repeat this
23
process every other 2 or 3 s until there’s outflow of Fig. 2.1.016

new brake fluid, and then press on the brake pedal
and close the release valve. Repeat this operation
process for all the wheels.
5) Release the air. See also “Air Release from the Brake Pipeline”.
11. Inspection for Brake
1) Brake disc
Check whether it is free from wear and damage.
Standard Specification Table of Brake Disc
Type Floating caliper type / with ventilated disc

Brake disc diameter 241 mm
Brake disc Brake disc thickness 19 mm
Friction block thickness 9 mm
Cylinder bore 51 mm
2) Brake drum
Check whether the inner diameter and circular runout of brake drum are in the scope of standard values.
If not, corresponding processing or replacement shall be performed.
Standard Specification Table of Brake Drum
Type Leading trailing shoe brake

Brake drum diameter 204 mm
Brake drum Cylinder bore of brake slave cylinder 17.46 mm
Clearance adjustment Automatically
Circular runout < 0.05 mm
3) Brake caliper Fig. 2.1.017
Check if there’s any oil leak.
24
4) Rear brake wheel cylinder Fig. 2.1.018
Check if there’s any oil leak.
5) Front brake shoe Fig. 2.1.019
Check the situation of wearing or damage.
■ Standard thickness: -9 mm
■ Wearing limit thickness: 2 mm
6) Rear brake shoe Fig. 2.1.020
Check the brake shoe thickness and its contact

state with the brake drum. If it fails to meet the
requirement, please replace it.
■ Standard thickness of brake shoe (A): 5 mm
■ Allowable limiting thickness (A): 1 mm
12. Inspection for Steering Gear and Pull-rod Fig. 2.1.021
1) Steering gear
■ Check whether the steering gear housing and

dust boot are free from looseness, damage
Check the leakage of
and lubricating grease leak. lubricating grease
Check the tightening torque
■ Check whether its connection with the
steering column is loose.
25
2) Steering pull-rod
Check whether the ball joint, dust boot and other components are free from looseness, wear, damage or
lubricating grease leak.
13. Inspection for Power Steering Fluid and Pipeline
Shut off the engine, and check the fluid level in the stock solution tank.
Attention: Fig. 2.1.022

■ Please do not fill excessive oil.
■ Check whether the installation position of pipeline is

correct, and if it is free from leakage, crack, damage,
loose connection, wear or ageing.
■ Check if there’s power steering fluid accumulation on

the dust boot of rack.
14. Axle and Suspension Components
Check whether the clearance between front/rear axles and suspension components is excessive, and if
they are free from crack, damage, wear or other damages.
■ Rock each wheel to check if the clearance is Fig. 2.1.023

excessive.
■ Check the working situation of wheel bearing.
■ Check whether the axle, suspension nut and bolt are

loose.
■ Check whether the shock absorber is free from oil

leak or other damages.
■ Check whether the suspension ball joint is free from

lubricating grease leak, check if the ball joint dust boot
is free from crack or other damages.
Fig. 2.1.024
26
15. Inspection for Front Drive Shaft Fig. 2.1.025
Check whether the dust boot and drive shaft are

free from crack, wear, damage and lubricating
grease leak.
16. Lubrication of Door Lock, Hinge and Engine Hood Lock Pin
Diagram of Lubricating Sites of Door Lock, Hinge and Engine Hood Lock Pin
17. Inspection for Safety Belt, Fastener and Pre-tensioner
Attention:
■ After any kind of impact, all the safety belt assemblies including the retractor and other accessories
(such as fixing bolt, guide rail device) shall be checked.
We suggest that you should replace the used safety belt assembly after an impact, unless it is still free
from any damage after slight impact.
And the safety belt assembly which is not used during the impact shall also be checked, please replace
any damaged safety belt assembly.
27
In case a front impact which activates both driver’s and passenger’s airbags happens, the safety belt
pre-tensioner shall be replaced, even though the safety belt is not used at all.
■ If any component of safety belt assembly has problems, please do not repair it, but replace the
safety belt assembly.
■ In case the safety belt is broken, worn or damaged, please replace the safety belt assembly.
■ Please do not lubricate the lock tongue and snap ring.
■ Use original safety belt assembly of JAC.
■ Check whether the anchorage is loose.
■ Check whether the safety belt is damaged.
■ Check whether the motion of retractor is flexible.
■ While the snap ring is open, check whether the snap ring and lock tongue function normally.
VII. Maintenance Data
1. Tightening Torque of Standard Components
Tightening Torque List of Standard Components
Nominal Diameter of Torque (N·m)

Thread Pitch
Thread Head mark 4 Head mark 7
M5 0.8 3~4 5~6
M6 1.0 5~6 9~11
M8 1.25 12~15 20~25
M10 1.25 25~30 30~50
M12 1.25 35~45 60~80
M14 1.5 75~85 120~140
M16 1.5 110~130 180~210
M18 1.5 160~180 260~300
M20 1.5 220~250 360~420
M22 1.5 290~330 480~550
M24 1.5 370~420 610~700
Attention:
■ The torques listed above are the standard values which are applied to the following conditions:
a. Steel, plating nuts and bolts.
b. Plated steel plain washers.
28
c. All the dry nuts, bolts and gaskets.
■ The torques listed above are not applied to the following conditions:
a. When the component is to be tightened with spring gasket and tooth washer;
b. During tightening of the plastic parts.
c. When self-tapping screw or locknut is used.
d. In case of oiled thread and surface.
■ In the following conditions, the torques listed above shall be correspondingly reduced:
a. if a spring gasket is used, the torque shall be reduced by 15%.
b. If the bolt surface is coated with engine oil, the torque shall be reduced by 15%.
29

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Maintenance Manual of Tojoy Sedan Contents

I. General Precautions ....................................................................................................1

Section II Engine Lubrication System ...........................................................................................64

Section III Cooling System of Engine............................................................................................75

Section IV Fuel Supply System of Engine ....................................................................................91

I. General Precautions ..................................................................................................91

VI. Fuel Pump Assembly .................................................................................................99

Section V Emission Control System of Engine ...........................................................................107

I. Fuel Evaporation System.........................................................................................107

Chapter 2 Electrical Part of Engine ........................................................................... 114

Section 2 Starting and Charging System ....................................................................................118

I. Basic Diagram of Starting and Charging System.....................................................118

Chapter III Electronic Control System of Engine......................................................135

I. Precautions of Supplement Restraint System (SRS) ...............................................135

Section II Structural Principle and Overhaul of Engine Control System ......................................139

I. System Illustration ...................................................................................................139

Section III Structural Principle and Overhaul of Engine Electronic Elements..............................153

I. Intake Manifold Absolute Pressure (MAP) Sensor...................................................153

XI. Carbon Canister Solenoid Valve..............................................................................168

Section IV Trouble Diagnosis Procedures for Engine Control System........................................177

I. Diagnosis by Trouble Code......................................................................................177

Chapter 1 Mechanical Part of Engine

6. Parts Needed to Be Screwed Up with Specified Angle

- Cylinder cover bolt

- Bolt of main bearing cap

- Connecting rod nut

II. Precautions on Sealant

After dismounting the fixing nuts and bolts, use the

■ Do not damage the matching faces.

■ Insert the scraper, and then knock its side to

■ For the positions where it is difficult to use the

2. Application Steps of Sealant

1) Use a scraper to remove the attached old

■ Thoroughly remove the old sealant from the

3) Put the sealant (with the specified size) in the

■ Put the sealant into the groove for it, if any.

■ Generally, the sealant is put inside the bolt Fig.1.1.004 Inner

■ Install the matching elements within 5minutes

■ Eliminate the dirt from the sealant, if any.

■ Do not re-screw down the nuts or bolts after

■ Add the engine oil and the engine coolant

■ Conduct the operation in accordance with the

List of Special Tools

Installer for rear Used to install

2. List of Auxiliary Materials for Assembling Engine

List of Auxiliary Materials for Assembling Engine

No. Name Application Specification and Grade

3. List of Auxiliary Materials for Assembling Cylinder Cover

List of Auxiliary Materials for Assembling Cylinder Cover

No. Name Present Material and Model Assembly Position

IV. Engine Assembly

■ Air duct and air cleaner assembly. See “Air Duct”.

■ Radiator assembly and radiator fan. See “Radiator”.

3. Dismantlement of Relevant Elements inside Engine Compartment

① Disconnect the following pipelines and put them aside.

Use plugs to prevent leakage when disconnecting the pipelines.

■ Inlet pipe of oil injector. See “Oil Injector”.