JAC S2. Engine. Service Manual - part 3

Engine Mechanical System

Engine Mechanical System 33

Engine accelerating is poor

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Engine Mechanical System

Engine Mechanical System 34

Engine shake while idling

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Engine Mechanical System

Engine Mechanical System 35

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Engine Mechanical System

Engine Mechanical System 36

III、Alternator belt

(I)Disassembly

1. Open engine cover

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

3. Disassemble alternator belt

1). Mark on relative location of alternator and upper bracket of alternator;

2). Loosen alternator adjusting nut;

3). Adjust belt tension, remove alternator belt.

(II)Check

1. Check alternator belt

1). Check if the belt is worn/cracked/oil stains. If necessary, please

replace.

△

caution

Please operate after engine is off.

(III)Installation

1. Install alternator belt

1). Install belt, tighten alternator adjusting nut

torque

(22.5±2.5)N·m

2. Connect battery
cathode cable

3. Close engine cover

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Engine Mechanical System

Engine Mechanical System 37

IV、Cylinder cover shield component

(I)Disassembly

1. Open engine cover

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

3. Disassemble ignition coil, refer to ignition coil

4. Disassemble spark plug, refer to spark plug

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

6. Disassemble air filter bracket I, refer to air filter bracket

7. Disassemble PCV valve, refer to PCV valve

8. Disassemble cylinder cover shield component

1). Disconnect respirator ventilation ducting and cylinder cover shield component

2). Disassemble 10 fixing bolt of cylinder
cover shield component
3). Remove f cylinder cover shield component
and cylinder cover shield seal ring

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(II)Installation

1. Install cylinder cover shield component

1). Replace with new cylinder cover shield seal ring, install it to cylinder cover shield component

2). Smear sealant equably to cylinder cover shield seal ring

3). Install cylinder cover shield component, tighten fixing nut

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Engine Mechanical System

Engine Mechanical System 38

4).Connect respirator ventilation hose and cylinder cover shield component

2. Install PCV valve

3. Install air filter bracket I

4. Install air filter assembly

5. Install spark plug

6. Install ignition coil

7. Connect battery cathode
cable

8. Close engine cover

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Engine Mechanical System

Engine Mechanical System 39

V、engine assembly

(I)Disassembly

1. Open engine cover

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

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

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

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

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

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

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

9. Drain coolant, refer to the replacement of coolant

10. Recycle freon/ refrigerant oil, refer to freon/ refrigerant oil

11. Disassemble intake hose, refer to intake hose assembly

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

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

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

15. Disassemble battery, refer to battery

16. Disassemble battery tray, refer to battery tray

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

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

19. Disassemble starter, refer to starter

20. Disassemble left front wheel, refer to wheel

21. Disassemble right front wheel, refer to wheel

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

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

24. Disassemble transmission assembly, refer to transmission assembly

25. Disassemble engine assembly

1). Disconnect water inlet and outlet assembly of

warm wind and cylinder cover.

2). Disconnect cylinder cover and respirator ventilation hose.

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Engine Mechanical System

Engine Mechanical System 20

3).Disconnect engine harness and ECM.

4). Cut the connection between radiator outlet pipe
and water pump inlet.

5). Cut the connection between radiator

inlet pipe

and cylinder cover.

6). Disassemble the screw bolts and nuts connecting
engine right suspension and engine.

7). Desend engine assembly.

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Engine Mechanical System

Engine Mechanical System 21

(II)Installation

1. Install engine assembly

1). Put the engine assembly under the engine compartment, lift up the engine assembly

2). Install the 2 nuts and 2 bolts connecting engine right suspension

and engine.

3). Connect radiator inlet pipe and
cylinder cover.

4). Connect radiator outlet pipe and water
pump inlet.

5). Connect engine compartment harness
and ECM.

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Engine Mechanical System

Engine Mechanical System 22

6). Connect cylinder cover and the ventilation hose of respirator

7). Connect inlet and outlet pipe assembly
of warm wind and cylinder cover.

2. Install transmission assembly

3. Install right driving axle assembly

4. Install left driving axle assembly

5. Install right front wheel

6. Install left front wheel

7. Install starter

8. Install clutch working cylinder

9. Install back-up lamp switch

10. Install battery tray

11. Install battery

12. Install air filter assembly

13. Install water inlet and outlet assembly of
warm wind

14. Install pipe and expansion valve assembly

15. Install intake hose

16. Fill Freon, refrigerant oil

17. Fill coolant

18. Fill engine oil

19. Fill transmission lubricant

20. Fill clutch hydraulic oil

21. Install engine right front cover shield

22. Install engine left front cover shield

23. Connect battery cathode cable

24. Close engine cover

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Engine Mechanical System

Engine Mechanical System 23

VI、Idle wheel

(I)Disassembly

1. Open engine cover

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

3. Disassemble alternator belt, refer to alternator belt

4. Disassemble idle wheel

1). Disassemble 1 fixing bolt

2). Remove idle wheel

(II)Installation

1. Install idle wheel

1). Install idle wheel to chain wheel compartment cover, tighten bolt.

2. Install alternator belt

3. Connect battery
cathode cable

4. Close engine cover

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Engine Mechanical System

Engine Mechanical System 24

VII、Crankshaft pulley

(I)Disassembly

1. Open engine cover

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

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

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

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

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

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

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

9. Drain coolant, refer to the replacement of coolant

10. Recycle freon/ refrigerant oil, refer to freon/ refrigerant oil

11. Disassemble intake hose, refer to intake hose assembly

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

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

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

15. Disassemble battery, refer to battery

16. Disassemble battery tray, refer to battery tray

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

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

19. Disassemble starter, refer to starter

20. Disassemble left front wheel, refer to wheel

21. Disassemble right front wheel, refer to wheel

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

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

24. Disassemble transmission assembly, refer to transmission assembly

25. Disassemble engine assembly, refer to engine assembly

26. Disassemble alternator belt, refer to alternator belt

27. Disassemble

crankshaft pulley

1). Use flywheel stop to fix flywheel

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Engine Mechanical System

Engine Mechanical System 25

2). Remove 1 fixing bolt
3). Remove crankshaft pulley

(II)Installation

1. Installation crankshaft pulley

1). Use flywheel stop to fix

flywheel

2). Install crankshaft pulley to chain wheel compartment

cover, tighten fixing bolt.

torque

(100±5)N·

m+ (90±2)°

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Engine Mechanical System

Engine Mechanical System 26

2. Install alternator belt

3. Install engine assembly

4. Install transmission assembly

5. Install right driving axle assembly

6. Install left driving axle assembly

7. Install right front wheel

8. Install left front wheel

9. Install starter

10. Install clutch working cylinder

11. Install back-up lamp switch

12. Install battery tray

13. Install battery

14. Install air filter assembly

15. Install water inlet and outlet pipe assembly of warm wind

16. Install pipe and expansion valve assembly

17. Install intake hose

18. Fill Freon/refrigerant oil

19. Fill

cooling liquid

20. Fill engine oil

21. Fill transmission lubrant

22. Fill clutch hydraulic oil

23. Install engine right front cover

24. Install engine left front cover

25. Connect battery cathode cable

26. Close engine cover

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Engine Mechanical System

Engine Mechanical System 27

VIII、Flywheel component

(I)Disassembly

1. Open engine cover

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

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

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

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

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

7. Disassemble battery, refer to battery

8. Disassemble battery tray, refer to battery tray

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

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

11. Disassemble starter, refer to starter

12. Disassemble left front wheel, refer to wheel

13. Disassemble right front wheel, refer to wheel

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

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

16. Disassemble transmission assembly, refer to transmission assembly

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

refer to Disassemble clutch cover and platen assembly, clutch

driven plate

18. Disassemble flywheel component

1). Use flywheel stop to fix flywheel

2). Disassemble 6 fixing bolts

3). Remove flywheel component

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Engine Mechanical System

Engine Mechanical System 28

(II)Installation

Install flywheel component

1). Use flywheel stop to fix flywheel

2). Install 6 fixing bolts of flywheel.

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

3. Install right driving axle assembly

4. Install left driving axle assembly

5. Install right front wheel

6. Install left front wheel

7. Install starter

8. Install clutch working cylinder

9. Install back-up lamp switch

10. Install battery tray

11. Install battery

12. Fill transmission lubricant

13. Fill clutch hydraulic oil

14. Install engine right front cover shield

15. Install engine left front cover shield

16. Connect battery cathode cable

17. Close engine cover

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