JAC HFC7151M1V-U221B Instruction manual

江淮汽车 部门：客户服务部
WORKSHOP MANUAL
HFC7151M1V-U221B
Engine
Version No：JAC-201511030415001

江淮汽车 部门：客户服务部
Engine
FOREWORD CONTENT
This Manual is helpful for technical maintenance
staff for JAC and provides effective and correct
maintenance and service for JAC vehicle. To ensure
the customer satisfaction of the JAC products, it is
extremely essential that the professional maintenance
technicians for JAC have the friendly service and the
capability of proper operation; therefore, the
maintenance technicians must fully understand the
contents in this Manual. This Manual shall be
accessible for reference at any time.
All contents in this Manual, including pictures,
technical parameters are the latest. But if product
modification affects maintenance, JAC will provide
technical bulletin or supplementary volume. Therefore,
please obtain the latest information about this Manual.
JAC reserves the right to make change in design,
addition or improvement for the product.
This manual is a guide for vehicle maintenance, maintenance personnel must be strictly in
accordance with the maintenance manual operation. This product is a product that has precise
requirements, maintenance personnel must be professional with relevant skills, and
non-professional personnel are forbidden to disassemble vehicle privately. Due to complexity of
actual problem, for items not contained in the manual, please contact with company's customer
service, and operate under its guidance.
During the process of maintaining JAC vehicle, if genuine parts that are not from JAC or
disqualified oil, the vehicle may be damaged.
Overview & maintenance
Engine
Chassis
Body structure& electrical
Circuit

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Engine
All rights reserved, without the written consent of JAC, it may not be translated all or a part
of this manual.
Tel：[phone]
Fax：[phone]
JAC International Customer Service Depart.
2015.11

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Contents
Engine Contents
Chapter I Mechanical Part of Engine
Section I Engine Body
I. General Precautions
II. Preparation
III. Engine Assembly
IV. Drive Belt
V. Air Filter and Air Duct
VI. Intake Manifold and Exhaust Manifold
VII. Exhaust System
VIII. Timing sprocket mechanism
IX. Cylinder head
X. Valves
XI. Cylinder Body Assembly
XII. Diagnosis of Common Troubles
XIII. Parameters for Maintenance
Section II Engine Lubrication System
I. Precautions
II. Preparation
III. Lubrication system schematic diagram
IV. Engine Oil
V. Oil Pan and Engine Oil Pump
Section III Cooling System of Engine
I. Cooling Circuit
II. Engine Coolant
III. Radiator Cooling Fan
IV. Water Pump
V. Thermostat Sub-assembly
VI. Water Piping Sub-assembly
VII. Trouble Analysis
VIII. Parameters for Maintenance
Section IV Fuel Supply System of Engine
I. General Precautions
II. Preparation
III. Fuel System
IV. Fuel Injector and Guide Rail

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Contents
V. Fuel Filter
VI. Fuel Pump Assembly
VII. Fuel Tank Assembly
Section V Emission Control System of Engine
I. Fuel Evaporation Control System
II. Forced Ventilating System of Crankcase
Chapter II Electrical Part of Engine
Section I Ignition System
I. Ignition coil
II. Diagnosis of Common Troubles
III. Parameters for Maintenance
Section II Starting and Charging System
I. Principle Diagram of Starting and Charging System
II. Battery
III. Starting System
IV. Charging System

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Mechanical Part of
Engine
Chapter 1 Mechanical Part of Engine
Section 1 Engine Body
I. General Precautions
1. Precautions on Discharging Engine Coolant
Discharge coolant after 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) Disconnect the piping, plug openings to prevent leakage of fuel.
3. Precautions on Dismantlement and Disassembly
1) Use special tools as required in Instruction. Always operate safely; any forcible operations and
operations other than that specified in Instructions are forbidden.
2) Take particular care not to damage the matching face or the sliding face.
3) Use the adhesive tape or equivalent to cover 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 specified.
4. Precautions on Check, Repair and Replacement
Thoroughly check the parts before repair or replacement. Check the substitutive parts by the same
means, and then replace as required.
5. Precautions on Assembly and Installation
1) Use the torque spanner to tighten the nuts and bolts.
2) When tightening the nuts and bolts, follow this basic principle: screw up the central nuts and bolts
with the same torque in steps, and then carry out the same operation with the internal and external
diagonal ones. Perform the operation in accordance with the tightening sequence, if it is specified.
3) Replace gaskets, 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 cloth scraps or the dust. Before assembly, paste the sliding face with engine oil.
6) When refilling engine coolant after draining completely, release air from the pipes at first.
7) After repair, start the engine and run with high speed to check for any leakage of the engine coolant,
fuel, engine oil and exhaust gas.

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Mechanical Part of
Engine
6. Parts Needed to Be Tightened with Specified Angle
1) Use the angle spanner to finally screw up following engine parts:
- Cylinder head bolt
- Bolt of main bearing cap
- Connecting rod bolt
2) Please follow the specified tightening methods.
3) Make sure that the surfaces of threads and pedestal are clean and coated with engine oil.
II. Precautions on Sealant
1. Removal of Sealant
After dismounting fixing nuts and bolts, use the
scraper to detach the matching faces and remove
old sealant.
Attention:
■ 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
scraper, lightly knock the parts to
dismount them with a plastic hammer.
■ If you have no choice but to use the tools
such as a screwdriver, be careful not to
damage the matching faces.
2. Application Steps of Sealant
1) Remove the attached old sealant from the
application and matching faces of liner with
scraper.
Attention:
■ Thoroughly remove the old sealant from
the groove on surfaces, fixing bolts and
bolt holes where the sealant was applied.
2) Wipe sealant surface and matching surface clean with a special cleaner, remove water drops,
grease and foreign substances.
JAC-T1F017
Fig.1.1.001
Fig.1.1.002
Slide
Knock
Scraper

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Mechanical Part of
Engine
3) Position sealant with the specified size.
■ Put the sealant into the groove for it (if any).
■ Generally, the sealant is put inside the bolt hole; however, it is occasionally put outside the bolt hole.
■ Install the matching part in a certain period of time after applying sealant.
■ Eliminate any dirt from the sealant.
■ Do not re-tighten the bolts or nuts after installation in order to avoid failures of bolts or nuts.
■ Add engine oil and coolant 30min after the installation has been finished.
Attention:
■ Conduct the operation in accordance with the instructions specified in this manual.
Fig.1.1.003

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Mechanical Part of
Engine
II. Preparation
1. Tools for Maintenance
List of Special Tools
No. Tool Appearance Code Description
1 End forked clamp
JAC-T1D001
Fix camshaft
timing
sprocket
2 Pin
Used together
with the end
forked clamp
3 Locating tool for
piston pin
JAC-T1F005
Used to install
and dismantle
the piston pin
4 Guide sleeve
Used together
with the
locating tool
for piston pin
5 Flywheel chock JAC-T1F011 Used to fix
the flywheel
6 Valve spring
compressor JAC-T1F012
Used to
compress the
valve spring
Install valve
cotter

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Mechanical Part of
Engine
7 Oxygen sensor
socket JAC-T1F015
Used to install
and dismantle
the oxygen
sensor
8 Dismantlement
tool for oil pan JAC-T1F017
Used to
dismantle the
oil pan
9 Installer for valve
oil seal JAC-T3F001
Used to install
the valve oil
seal
11
Guide for front oil
seal of
crankshaft
JAC-T3F003
Functioning as
a guide during
the installation
of front oil seal
of crankshaft
12
Installer for front
oil seal of
crankshaft
JAC-T3F004
Used to install
the front oil seal
of engine
crankshaft
13
Installer for rear
oil seal of
crankshaft
JAC-T3F005
Used to install
the rear oil seal
of crankshaft

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Mechanical Part of
Engine
2. List of Auxiliary Materials for Assembling Engine
List of Auxiliary Materials for Assembling Engine
No. Name Application Specification and Grade
1 Engine
oil Used during filling and assembly
Factory filled oil: SAE10W-30
Ambient temperature: -25℃-35℃
User must select the appropriate oil
according to the local temperature
Quality level: SJ or above
2 Silica
gel
Engine oil pump, water pump, oil pan
and rear oil seal housing of crankshaft LT5699 or equivalent
3 Sealant Oil pressure switch, draining screw plug
and flywheel bolt LT243 or equivalent
4 Sealant Coolant temperature sensor and water
temperature alarm switch LT648 or equivalent
5 Petrol 93# unleaded petrol or above
6 Sealant Stud bolt LT271 or equivalent
3. List of Auxiliary Materials for Assembling Cylinder head
List of Auxiliary Materials for Assembling Cylinder head
No. Name Present Material and Model Assembly Position
1 Engine oil
5W-30 (winter) 15W-40
(summer),with SJ-class quality
level and above
Valve head, camshaft and camshaft oil seal
2 Sealant LT271 or equivalent Stud bolt
3 Sealant LT962T or equivalent Guide sleeve of spark plug, bowl patch of
cylinder body/cover, connecting pipe nozzle

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Mechanical Part of
Engine
III. Engine Assembly
1. Precautions on Installation and Dismantlement
Caution:
Operation in violation of the following instructions may incur personal injury!
■ Park the vehicle on flat and firm ground.
Attention:
■ Always pay attention to safe operation, and do not conduct any forcible operations or
operations other than that specified in Instructions.
■ Do not start before the exhaust system and engine coolant have completely cooled down.
■ If the necessary items or operations are not mentioned in the sections of Engine, see
relevant chapters.
■ Use the specified lifting points all the time and select appropriate lifters according
conditions.
2. Preparation for Dismounting Engine and Transmission Assembly
1) General
Dismount the engine and transmission assembly from the vehicle, and then detach the engine from
transmission.
2) Preparation
①Discharge the engine coolant from the radiator. See “Change Engine Coolant”.
②Discharge the engine oil, transmission oil and clutch oil. See "Engine Oil", “Transmission Oil” and
“Clutch Pipeline”.
③Collect the refrigerant in AC pipeline.
④Discharge power steering fluid.
Attention:
■ Perform this step after the engine has cooled down.
■ Do not spill engine cooling fluid or brake fluid to the drive belt.
⑤Dismount the following parts:
■ Engine trimming cover. See “Intake Manifold”.
■ Front wheels and tyres. See “Wheels and Tyres”.
■ Engine deflectors (left and right).
■ Air duct and air filter assembly. See “Air Duct”.
■ Battery, battery base and base support. See “Battery”.
■ Radiator assembly and radiator fan. See “Radiator”.

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Mechanical Part of
Engine
3. Dismantlement of Related Elements in Engine Compartment
①Disconnect the following pipelines and put them aside.
Attention:
Use plugs to prevent leakage when disconnecting the pipelines.
■ Inlet pipe of fuel injector. See “Fuel 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 pipes. See “Power
Steering Pump”.
■ Low and high-pressure pipes of air compressor. See “Air Compressor”.
②Dismount the steering fluid reservoir.
③Dismantling of shifting cable.
④Disconnect the wire harness connectors and buckles of the following parts and then take them
away:
■ Oxygen sensor
■ Engine coolant temperature sensor
■ Crankshaft position sensor
■ Camshaft position sensor
■ Speed sensor
■ VVT oil control valve harness
■ Throttle opening sensor
■ Absolute intake pressure sensor
■ Ignition coil
■ Fuel injector
■ Knock sensor
■ Generator
■ Starter
■ Air conditioner switch
4. Dismantlement of Components of Chassis
①Dismount the front drive shaft. See “Front Drive Shaft”.
②Dismount the front exhaust pipe. See “Exhaust System”.

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Mechanical Part of
Engine
③Dismount the engine supporting beam. See “Engine Supporting Beam”.
5. Dismantlement
①Attach the lifting device hook to the hanging lug of the engine
②Lift the engine and fix it in place.
③Use the manual lifting stand or equivalent to firmly support the bottom of engine and transmission
assembly; adjust the lifting tension.
Attention:
■ A soft pad may be placed on the supporting surface so as to ensure a totally stable state.
④Detach left, right, front and rear suspensions of engine. See “Engine Suspension”.
⑤Carefully lower the engine and transmission assembly. Be aware of following items during
operation:
■ Make sure that the work will not affect the vehicle.
■ Make sure that all connecting parts have been disconnected.
■ In order to avoid falling due to changes of vehicle gravity, use the jack to support the rear lifting
point.
6. Detachment
①Dismount the power steering pump assembly and air conditioner compressor assembly from engine
and transmission assembly. See “Power Steering Pump”.
②Dismount starter. See “Starter”.
③Lift engine and transmission assembly with specified lifter, and then detach them.
Attention:
■ Before lifting, check whether each connection wiring harness has been disconnected.
7. Installation
Be aware of following items to install with steps contrary to dismantlement.
1) Do not damage the soft pad of engine suspension. Meantime, avoid spilling engine oil onto the soft
pad.
Fig.1.1.004 Fig.1.1.005

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Mechanical Part of
Engine
2) Make sure that all engine suspensions have been properly fixed. Then, tighten the nuts and bolts.
8. Check after Installation
1) Check for any leakage.
The steps for checking oil and fluid leakage, lubricating oil leakage and the exhaust leakage are as
follows:
■ Before starting engine, check oil and fluid levels (including engine oil and coolant). Refill to specified
level as required..
■ Check for fuel leakage with following steps：
- With ignition switch turned to the “ON” position, check whether there is fuel leakage at the
connecting positions.
- With engine started, recheck whether there is fuel leakage at the connecting positions during engine
increasing.
■ During running of engine, check for any abnormal noise and/or vibration.
■ With engine warmed up, verify that there are no leakage of fuel, exhaust gas or other oil and liquid
(including engine coolant and oil).
■ Bleed air and replenish by using specified ports and hoses.
■ After engine cooled down, recheck oil and liquid levels (including engine oil and coolant). If
necessary, refill them to the specified levels.
2) General of Check Items
List of Leakage Check Items
Item Before Startup During Engine
Operation
After Engine
Stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission oil, brake fluid, power steering
fluid and clutch fluid
Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust — Leakage —

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Mechanical Part of
Engine
IV. Drive Belt
1. Check Drive Belt
Warnings:
■Be sure to operate only when engine stopped.
1) Check belt for aging, crack, wear and oil stain. Replace as required.
2) Check the belt tension at the mid-point between pulleys.
■ Inspection should be conducted with cold state of engine or when it has been stopped for at least
30min.
■ Tension range - Generator belt: 550 ± 50N; power steering pump belt: 475 ± 50N. Be aware that the
tension of belt reused should be calculated by using the empirical formula: tension of new belt *
1.2/1.5.
■ Adjust if tension is out of range.
Attention:
■ When checking belt tension after installation, firstly to adjust tension to specified value.
Then revolve the crankshaft for more than two laps to re-adjust in order to avoid tension
between pulleys changes.
2. Adjustment of Tension
List of Tension Adjustment
Part Method
Generator belt Screw adjusting bolt of generator
Belts of power steering pump Screw adjusting bolt of power steering pump
Attention:
■ After replacing with the new belt, adjust the tension so as to meet the requirements
■ When installing the belt, ensure the proper engagement with the belt pulley groove.
■ Do not splash the engine oil or engine coolant onto the belt.
■ Do not over wind or bend belt; for worn belt, pay attention to mounting direction.

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Mechanical Part of
Engine
3. Generator Belt
1) Loosen the generator adjusting nuts and supporting nuts. Then adjust the tension by using the
adjusting bolt.
2) Tighten generator adjusting and supporting nuts.
■ Tightening torque: Generator adjusting nuts: 22.5 ± 2.5 Nm
Generator supporting nuts: 47±5 N.m
4. Belt of Power Steering Pump
1) Loosen the power steering pump adjusting and supporting bolts.
■ Tightening torque: Adjusting nuts: 4 - 6N.m
Supporting nuts:20-25N.m
2) Adjust tension with the adjusting bolt.
3) Lock adjusting bolt and power steering pump fixing bolt.
5. Dismantlement of Drive Belt
1) Completely loosen all belts in accordance with the instructions in “Tension Adjustment”.
2) Dismount the belt of power steering pump, and then the generator belt.
6. Installation of Drive Belt
1) Mount the belt onto the pulley with steps contrary to dismantlement.
Attention:
■ Make sure that the belt has properly engaged with the groove of pulley.
■ Make sure that no engine oil or coolant splashed onto any belt or pulley groove.
2) Verify that the tension of every belt is within the standard range. See “Inspection of Drive Belt”.
Fig. 1.1.006 Fig. 1.1.007
Fig. 1.1.008 Fig. 1.1.0009

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Mechanical Part of
Engine
V. Air Filter and Air Duct
1. Intake Pipe
1) Dismantlement
①Dismount the fixing bolt of front intake pipe,
take off the front intake pipe assembly.
■ Tightening torque: 17-19 N·m
②Dismount the locking bolt on upper cover of air
filter.
■ Tightening torque: 5-7 N·m
③Disconnect the locking clamp of intake hose, and then take off upper cover and intake hose.
■ Tightening torque: 6-9 N·m
④Dismount the fixing bolt of air filter base, and
then take down the base.
■ Tightening torque: 8-12 N·m
2) Check after Dismantlement
Check whether there is any crack or wearing on the air duct assembly. If any, replace.
3) Installation
Install with steps contrary to dismantlement.
Fig. 1.1.014
Fig. 1.1.013
Fig.1.1.012

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Mechanical Part of
Engine
Attention:
■ Properly mount every joint and tighten the clamp.
3. Replacement of Air Filter element
1) Dismantlement
①Loosen the locking bolt on upper cover of air
filter and lift the upper cover.
②Dismount air filter element.
2) Check after Dismantlement
■ Periodically clean or replace the filter element with recommended period. See “Periodical
Maintenance”.
■ Blow the filter element from its back side with compressed air, till nothing is blown off.
3) Installation
■ Install with steps contrary to dismantlement.
VI. Intake Manifold and Exhaust Manifold
Fig. 1.1.016
Fig.1.1.015

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Mechanical Part of
Engine
Decomposition Diagram of Intake and Exhaust Manifolds
1. Intake Manifold
1) Dismantlement
Caution:
■ Do not discharge the engine coolant when the engine is hot, otherwise you would be scalded.
①Discharge the engine coolant. See “Engine Coolant”.
②Dismount the engine trimming cover.
■Tightening torque: 8-12 N·m
③Dismount the air filter assembly. See “Air filter Assembly”.
④Disconnect the wire harness connectors of the following parts:
■Absolute intake pressure sensor
■Fuel injector
■Electronic throttle opening sensor
■ Carbon canister control solenoid
⑤Disconnect the following hose joints:
■ Water hose joint (insert a plug to prevent the engine coolant leakage)
■ PCV hose