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JAC S2. Engine. Service Manual - part 6

Engine Mechanical System

Engine Mechanical System 59

11). Tighten the bolts of crankshaft bearing cap according to the
order.

12). Smear the thread and fixing surface of bolts of main bearing

cap with engine oil. Tighten main bearing cap screws step by

step.

Torque

(35±2)N·m+60°

～ 64°。

13). After installing main bearing cap screws, make sure crankshaft
can be rotated by hands flexibly.

Assemble piston connecting rod components

1). Smear the engine oil to the outer circle of piston pin.

2). Install piston and connecting rod to piston pin installation base.

△

Caution

While installing piston pin, make sure the direction

mark of piston top is the same with the direction of
connecting rod.

3). Install piston pin with press machine

△

Caution

If the Pressure distribution load exceeds the

regulation, please replace piston pin and piston
assembly and connecting rod, or replace both.

Standard value

：(108±54)N·m

4). Install piston ring with piston ring expander

△

Caution

Be careful not to damage piston while installing

piston ring.

△

Caution

Be careful not to damage piston due to excessive

expansion

3ml

guide sleeve

guide

sleeve

⴪

Piston

expander

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Engine Mechanical System

Engine Mechanical System 60

5). Install grommet of oil ring into piston ring groove, then install
annulus of oil ring.

△

Caution

Do not use piston expander to hold loop, otherwise it

may cause scraper to crack.

6). After installing oil ring body, check if it can slide towards 2
directions.

7). Install gaseous ring with piston expander, the identification sign on

the gaseous ring

should be towards top of piston.

8). Install pitman box to connecting rod and connecting rod cap.

△

Caution Before installing pitman box, smear its surface with

engine oil.

△

Caution should use special tools to install the

pitman box to

guarantee the installation location: as shown in the

following drawing

， the length difference between

A and Bis less than 0.5mm

。

5. Install piston connecting rod component

1). Rotate the crankshaft journal of the to-be-installed connecting
rod to the bottom center.

2). Smear the cylinder bore/piston and crankshaft journal with
engine oil.

3). Install the connecting rod to the corresponding cylinder hole
according to the mark on the connecting rod.

△

Caution

Make sure the forward mark on top of

piston towards front.

4). Use piston guiding tool, put the piston connecting rod assembly

from cylinder fire surface into the guiding tool, and press the

piston into cylinder with rubber stick.

△

Caution

Please do not let the connecting rod big end

damage cylinder wall and crankshaft journal.

5). Install the connecting rod bearing cap of cylinder 2 which is
marked with no. 2.

6). Install and tighten the bolts of connecting rod bearing cap of
cylinder 2.

Torque

5N·

m → 10N·

m → 13N·

m+45+45°

7). Install the piston connecting rod component of other 3
cylinders in the same way.

△

Caution

Before installing bolts, smear engine oil to its

thread and base surface.

△

Caution

After installing piston connecting rod assembly,

rotate crankshaft to check if it can be rotated
flexibly.

6. Install cylinder cover assembly

7. Install alternator adjusting arm bracket

8. Install engine rear lifting lug

9. Install camshaft

10. Install timing chain

11. Install chain wheel compartment cover

12. Install crankshaft front oil seal

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Engine Mechanical System

Engine Mechanical System 61

13. Install cylinder cover shield component

14. Install oil sump assembly

15. Install oil level gauge component

16. Install crankshaft pulley

17. Install water pump pulley

18. Install idle wheel

19. Install compressor assembly

20. Install alternator

21. Install alternator belt

22. Install engine oil pressure switch

23. Install

pressure regulating valve

24. Install

knocking sensor

25. Install crankshaft position sensor

26. Install camshaft position sensor

27. Install water temperature sensor

28. Install absolute pressure sensor

29. Install electronic throttle valve

30. Install carbon tank solenoid valve

31. Install PCV valve

32. Install exhaust manifold

33. Install intake manifold

34. Install air filter bracket II

35. Install air filter bracket I

36. Install vacuum servo steel tube

37. Install warm wind backwater pipe

38. Install

oil pressure guide rail component

39. Install spark plug

40. Install ignition coil

41. Install engine assembly

42. Install transmission assembly

43. Install right driving axle assembly

44. Install left driving axle assembly

45. Install right front wheel

46. Install left front wheel

47. Install starter

48. Install clutch working cylinder

49. Install back-up lamp switch

50. Install battery tray

51. Install battery

52. Install air filter assembly

53. Install water inlet and outlet assembly of warm wind

54. Install pipe and expansion valve assembly

55. Install intake hose

56. Fill Freon, refrigerant oil

57. Fill coolant

58. Fill engine oil

59. Fill transmission lubricant

60. Fill clutch hydraulic oil

61. Install engine right front cover shield

62. Install left front cover shield

63. Connect battery cathode cable

64. Close engine cove

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Engine lubricating system

Engine intake system 62

Engine lubricating system

I. Overview

(I) Structure overview

System description

The air intake system consists of oil sump, engine oil filter and engine oil pressure switch.

1. The oil sump is installed at the bottom of crankcase and the oil pump abstracts the engine oil from the

sump that flows through 2 oil galleries to cylinder and cylinder head respectively after the oil filter. The

oil in one gallery flows to connecting rod then to piston and cylinder through crank oil passage; the other

one flow to camshaft lubricating air valve assy then returns to the sump in the end.

2. This model has adopted the rotary fuel pump, its shell, inner and outside roller and relief valve are

integrated on the cover of sprocket wheel housing, and the inner rotor is driven by the gear installed on

crankshaft. The oil pump extracts the oil from the sump and transports it to every part of engine. A

filtering net is installed at the inlet of oil pump, the congestion of filter will cause oil pump unable to feed

oil further to cause the lubricating system failure in working, under this case, it would cause the engine

mechanical parts damaged. When the engine rotation speed is too high, the output pressure of oil pump

exceeds the limits; the relief valve will open when the surplus oil flows back to the oil inlet chamber of

pump. In normal oil-supply conditions, the relief valve stays closed.

(II) System principle

Lubricating system description

The oil filter is installed on cylinder body and the engine oil flows upward through filter from the down

oil gallery, after being filtered clean, the oil returns to cylinder body through the upper gallery. The front

oil gallery feeds oil to each cylinder head, main bearing oil gallery, OCV solenoid valve, camshaft

position actuator.

The oil gallery of each cylinder head distributes the oil to cylinder head and camshaft bearing journal. The

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Engine lubricating system

Engine intake system 63

engine oil reaches to the OCV solenoid valve actuator through the OCV filter and oil chamber. The OCV

solenoid valve is for controlling the air inlet camshaft position actuator while the ECM controls OCV

solenoid valve. When the OCV is power on, it directs the engine oil up flowing through cylinder head and

front camshaft bearing cover. The engine oil gets into the holes drilled on camshaft journal through the oil

gallery of camshaft bearing cover and flows into the front part of the mounting surface of air inlet

camshaft; then it flows to the oil gallery of camshaft position actuator.

The OCV solenoid valve directs the pressurized engine oil to the relative galleries working on the inner

blades of camshaft position actuator that will cause the air-inlet camshaft rotating against sprocket wheel.

During idling, the inner lock pin fixes the inner rotor at the outside shell of air-inlet camshaft position

actuator and during start-up, it maintains the air-inlet camshaft position actuator at the original place. The

OCV solenoid valve directs engine oil to release lock pin and starts working of air-inlet camshaft position

actuator.

Lubricating system schematic diagram

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Engine lubricating system

Engine intake system 64

(III) Technical and service data

Item

Specification

Tooth tip clearance

0.06 ～ 0.18mm

Side clearance 0.04 ～ 0.11mm

Shell body clearance 0.10 ～ 0.18mm

Output pressure of oil pump 0.6MPa (87psi)

Relief valve opening pressure 0.4~0.5MPa ( 58~72.5psi)

(IV) Torque parameters

Key component torque table

SN Item

Torque (N·m)

Remarks

Pressure switch

10±2

Drain plug

39±5

Engine oil filter

11±1

Oil suction filter fixed bolt

8.4±0.6

Oil sump bolt

11±1

Oil dipstick tube components

8.4±0.6

II. Failure diagnosis

(I.) Diagnosis analysis table

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Engine lubricating system

Engine intake system 65

SN Failure

phenomenon

Failure causes analysis

Solution

Engine oil

leakage

Oil level too high

Drain out the excessive oil

Oil of over-high pressure

Check oil filter or pressure

by-pass valve for

congestion or failure

Engine ventilation system gets

congested or has failure

Check and clean the PCV

valve and its relevant tubes

Improper tightening of fasteners

Change the damaged parts

and tighten them at the

regulated torque

Relative parts has rupture or crack Change the damaged parts

Sealing surface wearout, sealing

mat in poor installation

Repair or replace the

damaged parts

(II) Diagnosis procedures table

Engine oil of over-low pressure

Engine oil over-consumption

III. Engine oil drainage and filling

1. Open engine hood

2. Disconnect the cathode wires of battery

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Engine lubricating system

Engine intake system 66

3. Drain out the engine oil

1). Screw off the cover of engine oil port on cylinder head.

2). Take down the drain plug and gasket and drain the oil into the container

Attention: The engine oil temperature may be high and be careful with burning.

Attention: The draining-out time shall be more than 15min.

3). Clean drain plug and change the new liner during installation.

Tighten torque (39±5)N•m

4. Dismantle the oil filter

1). Take down the oil filter by the wrench

5. Install oil filter

1). Smear few engine oil on the O type ring of oil filter.

2). When the O type ring gets contact with the flange of filter bracket and screw in 3/4 round by the

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Engine lubricating system

Engine intake system 67

special wrench.

Tightening torque (11±1)N•m

6. Filling engine oil

1). Fill in the clean engine oil

2). Install oil filling port cover.

7. Check if the engine oil has leakage

1). Start the engine.

2). Check if the filter and drain plug have oil leakage

IV. Engine oil pressure switch

(I) Dismantlement

1. Open the engine hood.

2. Disconnect the cathode wires of battery

3. Dismantle the air filter assy

4. Dismantle the electric throttle

5. Dismantle the air-intake manifold

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Engine lubricating system

Engine intake system 68

6. Dismantle the engine oil pressure switch

1). Disconnect the wires connector of engine oil pressure switch

2). Dismantle the oil pressure switch by the special sleeve.

3). Take down the oil pressure switch.

(II) Installation

1. Install the oil pressure switch

1). Smear the sealing glue on the thread of oil pressure switch.

2). Tighten the oil pressure switch

Tighten torque (10±2)N•m

3). Connect the wires connector of oil pressure switch and check and make sure it’s in good connection.

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Engine lubricating system

Engine intake system 69

2. Install air intake manifold

3. Install the electric throttle.

4. Install the air filter assy

5. Connect the cathode wires of battery

6. Close the engine hood

V. Oil filter

(I) Disassembly

1. Open the engine hood

2. Disconnect the cathode wires of battery

3. Dismantle the oil filter

1). Dismantle the oil filter by the special wrench

Attention: Use the JAC original oil filter

Attention: Be caution of the hot engine oil.

Attention: Prepare a wiping cloth for wiping off the splash-out or leaked out engine oil

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Engine lubricating system

Engine intake system 70

(II) Installation

1. Install the engine oil filter

1). Smear few engine oil on the O type ring of oil filter.

2). When the O type ring gets contact with the flange of filter bracket and screw in 3/4 round by the

special wrench.

Tightening torque (11±1)N•m

Attention: It must use the special wrench to tighten the oil filter. It may have the leakage problem due to

insufficient torque as tighten the filter manually.

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Engine lubricating system

Engine intake system 71

2. Connect the cathode wires of battery

3. Close the engine hood.

VI. Oil filter components

(I) Disassembly

1. Open the engine hood

2. Disconnect the cathode wires of battery

3. Dismantle the oil filter components

1). Screw off the 3 fixed bolts

2). Take down the oil filter components and its bracket mat.

(II) Installation

1. Install the oil filter components

1). Install the 3 fixed bolts

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Engine lubricating system

Engine intake system 72

2. Connect the cathode wires of battery

3. Close the engine hood

VII. Oil sump assy

(I) Disassembly

1. Open the engine hood

2. Disconnect the cathode wires of battery

3. Dismantle the front left cover of engine

4. Dismantle the front right cover of engine

5. Drain out the engine oil

6. Dismantle the oil sump assembly

1). Loosen the 16 fixed bolts at the reverse sequence of the shown in below diagram

2). Take down the oil sump by the special device

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Engine lubricating system

Engine intake system 73

Attention: Do not damage the matching surface

(II) Installation

1. Install the oil sump assy

1). Clean the shell and mounting surface.

2). Smear the sealing glue on oil sump

3). Tighten the 16 fixed bolts and nuts according to the sequence shown by the below diagram

Tighten torque: (11±1)N•m

2. Fill in the engine oil

3. Install the front left cover of engine

4. Install the front right cover of engine

5. Connect the cathode wires of battery

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Engine lubricating system

Engine intake system 74

6. Close the engine hood

VIII. Suction filter

(I) Disassembly

1. Open the engine hood

2. Disconnect the cathode wires of battery

3. Dismantle the front left cover of engine

4. Dismantle the front right cover of engine

5. Drain out the engine oil

6. Dismantle the oil sump assy

7. Dismantle the suction filter

1). Screw off the 3 fixed bolts

2). Take down the suction filter

(II) Installation

1. Install the suction filter

1). Install the fixed bolts of suction filter

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