JAC J2 User manual



Maintenance Manual for J2 Sedan

Foreword

Maintenance Manual for J2 Sedan
Foreword

Master Table of Contents

General Description &
Maintenance
Engine
Chassis

Body Electrical & Structure
Circuit Troubleshooting

This manual is intended to help the
professional maintenance technicians
authorized by JAC Passenger Car Sales
Company provide effective and correct
maintenance and service for JAC J2
Sedan series models. The warm service
and proper operation from the
professional maintenance technicians of
JAC passenger cars are essential for
ensuring customer satisfaction to JAC
passenger car products. Therefore, the
maintenance technicians must
understand this manual fully. This
manual should be placed in a handy
place for your convenient reference.
All contents of this manual including
pictures and technical parameters are
latest. In case maintenance works are
affected due to product improvement,
JAC Passenger Car Sales Company will
provide technical bulletins or
supplementary volumes. Therefore, you
should use this manual and pay close
attention to obtaining latest update
relevant information.JAC Passenger Car
Sales Company reserves the rights to
change, add or improve designs of its
products.
No
part
of
this
manual
is
allowed
to
be
reproduced or modified in any form,
including but not limited to electronic
media, paper, sound and image, and
mechanical media, without written
authorization from JAC Passenger Car
Sales
Company
.
Use of non genuine spare parts for
JAC passenger cars or nonconforming
oils during maintenance and service
processes of JAC
passenger
car
product
s may cause vehicl
e damage.
Chapter I General Description
Chapter II

Maintenance

Chapter I Engine mechanical system
Chapter II

Engine electrical system

Chapter III engine electronic control
system
Chapter I

Clutch & Manual
Transmission

Chapter II

Traveling system

Chapter III

Braking system

Chapter I

Body Electrical

Chapter II Body Structure



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Maintenance Manual for J2 Sedan
Contents
Contents of Overview and Service
Chapter
I
Overview.................
................................................................................
.........1

Section I General Instructions ...................................................................................................... 1
I.
Summary
.............................................................................................................................. 1
II.
Operations
............................................................................................................................
1
Section II

Ve
hicle
Information
.....................................................................................................
2
I. Identification Information Position ........................................................................................ 2
II. Nameplate ............................................................................................................................ 2
III.
Vehicle
Identification
Number
(VIN)
.....................................................................................
3
IV.
Engine
Number......................
...............................................................................................
4
Section III
Lifting,
Protection and
T
owing
of V
ehicle
.................................................................. 6
I. Lifting of
Vehicle
................................................................................................................... 6
II.
Protection
of
Vehicle........
.....................................................................................................
6
III.
Towing
of
Vehicle
.................................................................................................................
7
Chapter
II
Service
............................................................................................................8

Section
I
Service......................................
.........................................................................................
8
I. Prepara
tools
........................................................................................................................ 8
II.
General
Service..............................................................
...................................................... 8
III.
Regular
Service
....................................................................................................................
9
IV.
Recomme
nded
Oil
and
Lubricant.............................
..........................................................
10
V.
Service
of
Engine
............................................................................................................... 11
VI.
Service
of
Chassis
and
Body
............................................................................................. 19
VII. Maintenance
Data
..............................................................................................................
27



Maintenance Manual for J2 Sedan
Overview
1
Chapter
I Overview
Section
I
General
Instructi
󰁯
󰁯󰁯
󰁯
ns
I. Summary
This Manual provides the procedures required by
service operations, including:
1.
Structure
and composition
2. Principles
3.
Dismantlement
and
installatio
n
steps
4. Inspection methods
5.
Adjustment
&
commissioning methods
6.
Common
trouble
diagnosis
procedures
7.
T
echnical
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 technician
s in this
Manual.
II.
How to use
This Manual comprises four parts, i.e. engine volume, chassis volume, electrical appliance & structure
volume of vehicle body and electric circuit inspection volume. In front of each part is given a detailed
content index, in which you
can find the section you
want quickly
.
This Manual provides
following information:
1.
Working
principles;
2.
Component
position
3.
Inspection
and
service
specificati
ons
4.
Component
dismantlement
& installati
on
steps
5. Common troubles and repair procedures
Such information are in
compliance with current model at time published.

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Maintenance Manual for J2 Sedan
Overview
2
Section
II
Vehicle
Informat
ion
I.
Identification
Information
Position
Position of vehicle ID
1-
Name
plate
of
vehicle
2-
ID
number
of
vehicle
II. Nameplate
1.
Position of
nameplate:
at
the
firewall of
engine
compartment.
2.
Instructions
of
nameplate
Example of Nameplate
Made by China Anhui
Jianghuai Automobile Co., Ltd.

Ex-factory no.

Ex-factory date Jan.
2010
Max. gross weight
Fixed
number
5
persons

Engine ModelRated power

Engine displacement

Model
Brand: Jianghuai

1
2

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Maintenance Manual for J2 Sedan
Overview
3
III.
Vehic
le Identification Number (VIN)
1)
VIN posit
ion: on
the n
ameplate
or at
the le
ft bott
om
of wind
shield.
2)
Illustration
of
VIN
Part 1: Word Manufacturer Identification (WMI), consists of 3 numbers according to GB16737, which
should be applied, approved and filed. WMI for
JAC is
LJ1, which applicable for freight tr
uck, incomplete
vehicle, bus, passenger car, tractor and special vehicle of JAC. Word Manufacturer Identification (WMI)
is shown in table below.
T
able
Worldwide
Manufacturer
Identificat
ion

ID
Manufacturer
Applicable
Models
LJ1
JAC
Co.,
Ltd,
ANHUI
Freight truck,
incomplete vehicle, bus, passenger car, tractor,
special vehicle
Part 2: vehicle description Code (VDS), as specified in GB 16737, this part should be made up with 6
digitals to presents basic features
of vehicle model.
VDS making-up:
Inspection digit
Code of engine type and rated power
Max. gross weight
Body type
Vehicle type
Truck wheelbase / passenger cars, buses
and
chassi
s l
en
th
Geographical region
Country
Manufacturer
Vehicle Description
Check Character
Digitals
Order number
Assembled in
Model year
Representative letter
or number
Representative number
Digitals

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Maintenance Manual for J2 Sedan
Overview
4
①

Vehicle
type
：
2 Means passenger cars
F: 3 chambers & 4 doors
②

Body
type
G: 2 chambers & 5 doors
③

Max. Gross
Weight:
K: >1000-2000
④

Truck wh
eelbase /
passenge
r cars, buses a
nd chassis
length: R>
2390 - 260
0
1:
gasoline

≤
70Kw
⑤

Code of engine type and rated power

2:
gasoline
>70-90Kw
3:
gasoline
>90-110Kw
Part 3: indication of vehicle, 8
digitals
4:
General Assembli
ng Workshop of Passenger C
ar Manufacture Company

Factory assembled

7:
General Assembli
ng Workshop of Passenger C
ar Manufacture Company

8: 2008
Year
9: 2009
A: 2010
IV Engine Number
1.
Position
of
engine
number
Engine number is stamped on the exhaust side of cylinder
block (See figure below).
Production SN

Factory assembled

Year

Digitals

Fig. 2.1.001

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Maintenance Manual for J2 Sedan
Overview
5
2.
Meaning
of
Engine
Number
3GB4.C – Engine model: 1.0 3-cylinder gasoline engine
☆
A3408769
☆:
A
– the year
of 2010
3 - engine type (petrol, local parts)
408769– Production SN
Fig. 2.1.002

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Maintenance Manual for J2 Sedan
Overview
6
Section III
Lifting, Protection and Towing
of
Vehicle
I.
Lifting
of
Ve
hicle
1.
Vehicle’s
Supporting
Points
The positions of vehicle’s supporting points are shown in figure below.
Attention:


Don’t lift the vehicle by using the point other than those specified; otherwise vehicle body
may be damaged.
Positions of Vehicle’s Supporting Points
2.
Operation
of
Lifter
The lifter should be operated strictly
in accordance with the specifications of manufacturer
.
Caution:


The operation against the specifications may cause damage of vehicle or personnel injury or
even death.
II. Protection
of
Vehic
le
1.
Appearance
Protection
Be sure to use the four protection appliances including seat cover, steering wheel cover, gearshift
lever cover, and foot mat before any operation. A protective pad must be applied on the fenders
when engin
e hood is open
ed for inspection
.
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
ignition switch
to
“OFF”
position;
2)
Disconnect
negative
pole
of
battery;
3)
Ground the
welding
equipme
nt carefu
lly at
a point
nearby
the weldi
ng area
;
4)
Cover other exposed equipment around the
welding
area to prevent solders from spl
ashing o
n.
Supporting point


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Maintenance Manual for J2 Sedan
Overview
7
III.
Towing
of Vehicle
If vehicle needs to be towed, please contact the local authorized after-sales service center or a
special vehicle towing service company.
1.
T
owing
with
tractor
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 personnel injury.
2.
T
owing
with
wheel
lifter
1) Turn ignition switch
to
“ACC (accessory)” position;
2) Turn on the hazard warning indicator
flashing;
3)
Shift
to
neutral
position;
4)
Release
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 set under
front wheels. Don’t make f
ront wheels in contact with ground in
towing;
otherwise 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
driver is required in the
vehicle for steerin
g 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.
Caution:


The vehicle may be damaged when towed by rope.
In order to
minimize such damage
,
①

If no other towing
equipmen
t is available, the
towing ho
le 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 are f
ixed firmly
on the tow
ing hole.
2)
Rear towing
hook: It can used to tow another vehicle
only under e
mergency (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 hook. Don’t apply force
to the towing hook from any
ohter directions. Don’t
start towing sharply otherwise damage may be caused.

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Maintenance Manual for J2 Sedan
Service
8
Chapter
II
Service
Section
I
Service
I. Preparation
1.
Maintenance
Tools
List of Maintenance Tools
No.
Tools
Outside
View
Description
1 Power tool
For dismantlement and
installation of bolts and
nuts
2
Ignition plug
socket
For dismantlement and
installation of ignition
plug
II.
General
Service
General Service means the inspection and maintenance items which should be performed everyday
during normal use of vehicles. These
service items are ver
y important, for
normal operation performan
ce
of vehicle. The owners can perform these inspections by themselves, or go to a JAC franchised store for
assistance. Followed is content of general service:
1. Exterior
of
Vehicle
The following inspection and maintenance items should 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; adjust pressure in accordance with technical data if necessary. Check
whether there’s any da
mage, crack or exc
essive worn tear carefu
lly.
Windsh
ield
Clean
the
windshield
regularly.
Check
whether
there’s
any
crack
or
other
damage
of
the
windshield every six m
onths or more fre
quently. Repair as re
quired.
Windshield
wiper blade
If the wiper doesn’t work efficiently, check for worn or torn.
Door and
engine hood
Check whether all of the doors, engine hood, boot cover and tail door can be normally
opened and closed normally, whether all the door locks are locked closely. Lubricate as
required. Moreover, If the vehicle often travels on the salt-spread roads or in the areas
with corrosive substances
, always inspect lubr
icating conditio
ns.
Tyre exchange
The tyre exchange should be conducted
after eac
h 8000 km traveling.

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Maintenance Manual for J2 Sedan
Service
9
Vehicle
lamps
Verify that headl
amps, brake i
ndicators, tail lam
ps, turning signa
l indicator and ot
her
lighting units work normally and have been stably fixed. Meanwhile, inspect focusing
function of headlamp.
2. Interior of
Vehicle
The following inspection and maintenance items should be performed regularly.
List of Items to be Regularly Inspected for Interior of Vehicle
Item Inspection
Alarm light and
buzzer
Make sure all the
alarm lights and buzzers are
working normally.
Windshield wiper
and washer
Check whether the wiper and cleaner are working normally; check whether there
is any crack in the wiper.
Windshield defroster
Check whether the air can be correctly bled from the air outlet of defroster,
whether the heater
or air conditioner can breathe
enough air during
operation of
heater or air
conditioner.
Steering wheel
Check whether the free travel of steering wheel is in the standard range. Inspect
changes of steering performance, such as the free travel beyond range, hard
steering and abnormal noise etc.
Seat Belt
Check whether all the components of seat belt system are flexible and working
normally and fixed firmly and stably. Check seat belt for cracking, worn out or
other damage.
Throttle pedal
Check whether the pedal can be operated smoothly, make sure that the pedal
would not be se
ized or loaded une
venly. Keep floor
pad away from the pedal.
Brake pedal and
booster
Check if the pedal can be operated smoothly; make sure the pedal still keeps an
appropriate distance from the bottom plate when it is completely pressed down.
Inspect the function of brake vacuum booster. Make sure that the bottom plate
pad is away from the pedal.
Parking brake
Check
travel
of
handle.
3.
Engine
and Vehicle
Chassis
The following inspection and maintenance items should 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
in
reservior.
Level of engine coolant Check the coolant level
when
the
engine
is cold.
Engine
oil
level
Stop
the
vehicle
on
a
level
ground
and
turn
off
engine;
check
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” marks on reservoir.
Battery
Inspect
conditions
of
voltage
and
battery
poles.
Liquid
leakage
After
the vehicle has been
stopped
for
a while, check
for
any
leakage of fuel, engine oil, coolant or other liquid under the
vehicle. Water drop from the air conditioner which has just
been used is normal. In case of obvious leakage or petrol
fume,
find out the causes and repair immediately.
III.
Regular
Service
Each item is expressed in travel distance and time (months), whichever comes first (distance or time)
should be used as the basis for inspection.

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Maintenance Manual for J2 Sedan
Service
10
Service operational code:
I-examination; R-replaceme
nt; C-washing
Service cycle (odometer readings and the number of months, whichever comes first)
1000km 1 10 20 30 40 50 60 70 80 90 100
Item
Month

—
6 12 18
24
30 36 42 48
54
60
1
Driving
belt
I: every 10,000 km or 6 months
R: every 60,000 km or two years
2Check oil and gas control systems of
crankcase for normal working
I I
3 Spark plug I I R I I R I I R I
4 Change coolant R R R R R
General conditions
of
use C: every
5,000km
R: 15,000km
5
Air filter
element
Harsh
conditions
of
use C: every
3,000km
R: 10,000km
General conditions
of
use R: every
5,000
km or
6
months
6
Oil and oil
filter
Harsh
conditions
of
use R: every
3,000
km or 3 months
7 Carbon monoxide content
with
engine idling I I I I I I I I I I
8
Ignition
timing
I I I I I
9 Hose I I I I I I I I I I
10 Exhaust fittings leakage I I I I I I I I I I
11 Throttle
body
C C C C C
12
Injector
C*
C*
C*
C*
C*
C*
C*
C*
C*
C*
13
V
alve clearance I I I I I I
Notes:
C *---For cleaning operation of fuel injector, it is recommended that dedicated fuel injector cleaning
analyzer is used; Check every
3 months or
5000km; if there are nozzle clogging or blockage failures and
they are non-product quality problems, they should be maintained at users’ expenses.
"Harsh conditions of use" specifications are only used in severe conditions of use of vehicles. Harsh
conditions of use include the
following:

①
Driving in dusty areas or the vehicle is regularly exposed to salty air or
sea water.

②
Driving on rugged road, r
oad with water accumulation or on mountain roads.

③
Driving in cold areas.
④
In the cold season, the engine idles a long time or
used frequently in short-distance traveling.

⑤
Frequent use of brakes, regular emergency braking. .

⑥
As tractor

⑦
As taxi or leasing

⑧
At
temperatures above
32 ℃
, driving in urban heavy traffic for more than 50% of the total travel
time.


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Maintenance Manual for J2 Sedan
Service
11
⑨
At a
temperature below 30
℃
, driving at 120km/h or higher speed limits for more than 50% of the
total travel time.

⑩
Overloaded traveling.
IV. Recommended Oil
and
Lubricant
Which listed below are the types of oil
and lubricant recommen
ded by JAC:
List of R
ecomme
nded Oil and
Lubricant
Item
Capacity
(L)
Recommended oil
/
lubricant
Engine
oil
3.8
Factory filled
oil: SAE10W-30
Ambient temperature for use
: -25
℃
- 35
℃

User must select the appropriate oil according to local ambient
temperature
Quality level: SJ or above
Cooling
system
5.5
High-quality
HF-C
anti-freezing
solution
Manual
transmissi
on gear oil
2.0
API GL-4, SAE 75W/90
Brake
fluid
and
clutch
fluid
0.56±0.05
DOT4
(Great
Wall)
AC refrigerant
600±25g
R134a
Wiper
cleaning
liquid
3
Water
AC compressor lubr
icating oil
0.12
PAG56
V.
Service
of
Engine
1.
Inspection
of
Driving
Belt
Warnings
■Be
sure
to
operate
only
with
engine
stopped.
1)
Check f
or belt ag
ing, crack,
wear and
oil stain.
Replace as
required.
2)
Check the
belt tensio
n at th
e mid-po
int betwee
n both
pulleys.
■Inspection should be conducted in the
engine c
old state or when it has been stop
ped after
30min.
■Range of
tension f
orce – Alternator belt: 500±50N Please be noted th
at the exp
erience equation for
tensioning force of reused belt is as
below: Tensionin
g force for
new belt *
1.2/1.5
■
If
the belt tension is out
of
range,
adjust.
Attention
：
：：
：

■
For chec
king b
elt tension
installation, firstly
adjust to
the sp
ecified va
lue, then
turn the
crank
for more than two laps to re-adjust to the specified value in order to avoid tension between
pulleys changing.
2.
Adjustment
of
Tension

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Maintenance Manual for J2 Sedan
Service
12
Tension Adjustment Table
Part
Adjusting
Method
Generator belt
Turn
adjusting
bolt of
generator
belt
Attention:
■
After replaced
with ne
w
belt, adjust
the belt
tension so
as
to meet
requirements.
■During installation
of belt, ma
ke sure
that the belt
is in correct engagement with
the pulley
groove.
■
Don’t spil
l any
engine
oil
or engin
e
coolant
on
the
belt.
■Do not over wind or bend belt
; for us
ed bel
t, be
aware of mounting direction.
3.
Change
Coolant of
Engine
Caution:
■
In order
to av
oid s
cald,
never
change
coolant
with
engine
hot.
■Wrap the radiator cap
with thick
cloth and unscrew it carefully. Release
the pressure
inside
the radiator at first,
and then completely unscrew it to op
en the radiator.
■
Be aw
are not to
spill
the engin
e co
olant on
the d
riving be
lt.
1) Drain engine
coolant
①

Dismount t
he right def
lector of en
gine. See
“Engine De
flector”.
②
Open the water drain
plug at the bo
ttom of radiator, a
nd then open t
he cap of radiator.
③
If necessary, please dismount coolant reservoir, drain the engine coolant, and reinstall it after
cleaned.
④

Check if there’s any foreign
matter such as rust or any color change in the discharg
ed engine
coolant.
■
In case it
is polluted,
please
wash the
engine coo
ling system.
See “Wa
shing th
e Cooling S
ystem”
please.
2)
Refill
engine
coolant
①
Reinstall dism
antled coo
lant reservoir and the drain plug of radiator.
Attention:
■
The drain
screw
plug m
ust be
cleaned,
a ne
w O
-ring must
be ins
talled.
②

Make sure th
at all the h
ose clam
ps have bee
n stably tig
htened.
③
Dismount the upper cover of air filter and the intake hose. Please refer to “Air Filter Assem
bly”.
④
Disconnect outlet tube of heater pipe. Please lift the hose as high as possible.
⑤
Fill coolant into radiator and coolant reservoir to speci
fied level; the engin
e coolant must be f
illed
slowly, such as to gradually bleed air from the system.
Attention:
■
Please mix the
original JAC engine c
oolant or equivalent pr
oduct with w
ater. See
“Recommended Oil and Lubricant”.



Maintenance Manual for J2 Sedan
Service
13
■If coolant overflo
ws from
the heater
outlet pipe,
disconnect p
ipe and
reconnect a
nd then
continue the filling of coolant.
⑥
Install air filter upper cover and intake hose. Please refer to “Air Filter Assembly”.
⑦
Install radiator cap.
⑧

Warm
up the en
gine until
the thermo
stat is switche
d on.
■
Examine
if there’s
warm wa
ter flowing
out by tou
ching the
lower hos
e of rad
iator, such a
s to che
ck
whether the therm
ostat has been sw
itched on.
Attention:
■Watch on engine temperature meter,
such
as to
avoid overhe
ating of
engine.
⑨

Stop the
engine,
allow en
gine tem
perature dr
ops.
■
The
cooling
time
can
be
reduced
by
using
fan.
⑩

Fill engine coolant in coolant until the
MAX level reached.
⑪

Install radiator
cap, and
repeat step
s
③
-
⑨
for more than
two times until the level
of engine coolant
doesn’t go down any more.
⑫

Start engine, che
ck for any leak
age in the cooling system.
3)
Wash
cooling
system
①

Install water dra
in plug of
radiator and co
olant reservoir rem
oved above.
Attention:
■The drain
screw
plug m
ust be cleaned,
a ne
w O
-ring must
be ins
talled.
②
Dismount air filter upper cover and the
intake hos
e. Refer to
“Air Filter Asse
mbly”.
③
Disconnect outlet tube of heater pipe. Please lift the hose as h
igh as possible.
④

Fill engine
coolant into
the radiator an
d coolant res
ervoir, install cap
of radiato
r.
If coolant overflows from the heater outlet pipe, disconnect pipe and reconnect and then continue
filling of coolant.
⑤
Install air filter
upper cover a
nd intake hose. Refe
r to “Air Filter A
ssembly”.
⑥

Start the engi
ne, warm
up it to n
ormal workin
g temperat
ure.
⑦

Speed up
the eng
ine for
several tim
es without
load.
⑧

Stop engi
ne, and
wait till
engine
cooled d
own.
⑨
Discharge coolant inside
system. Refer
to “Draining
Engine Co
olant”.
⑩
Repeat steps
①
-
⑨
until the radiator starts to discharge clear water.
4.
Inspection of Cooling System
Caution:
■
Never open
the radiator
cap w
ith engine
hot. The
high temperat
ure and
high pressur
e liquid
overflowing from the radiator may cause severe scald.
■Wrap the radiator cap
with thick
cloth and unscrew it for 1/4 circle to release the pressure
inside radiator at first, and
then completely unscrew it to open radiator.

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
Maintenance Manual for J2 Sedan
Service
14
1) Inspection of
cooling
system
hose
■
Check t
he hose
for inc
orrect installa
tion, crac
k, dam
age, lo
ose co
nnection,
worn or
ageing.
■
Please
repair
or
replace
the
damaged
compon
ents
as req
uired.
2)
Inspection
of
radiator
cap
①
Check valve seat of radiator cap
■
Check whe
ther the valve seat
expands o
utward, i.e.
when the
plunger is
vertically lifted
from the
top,
end of plunger is out of view.
■
Check
valve
seat
for
any
dust
or
damage.
②
Pull out nega
tive pressure valve to
open it,
and upon the pressure is released, check
whether it can be
completely clos
ed.
■
Make
sure
there
isn’t
any
smudge
or d
amage
on the valve seat.
■Make sure that
the
valve
seat
can be
normally
opened and closed.
③

Check t
he pressure
released
by radiator
cap.
Standard: 78-98 KPa
Limit: 59 KPa
— Connect the radiator cap to radiator leak
detector, paste engine coolant onto the
sealing face of cap.
■
If any
failure
is found in above-mentioned
three inspection items, replace radiator cap.
Attention:
■For installation
of radiator
cap, please wipe the
radiator filler
carefully to cle
ar away any
paraffin residue or f
oreign substance.
3)
Inspection
of
radiator
Check for any mud or
clogging situation in radiator. If any,
clean with following method.
■
Be
aware
not
to tw
ist o
r dam
age
the
radiation
fins.
■
In case of
cleaning
without dis
mounting
the radiator,
all accessories
such as
cooling fa
n, wind
collection hood and horn should be dismounted. Wrap connectors of wire harness with adhesive
tape for water proofing.
①

Wash b
ack of radiator fins from the top
to the bottom w
ith water spraying nor
mal to radiator.
②
Wash
each s
urface of the radiator
every other
minute.
③

In case no dirt is wash
ed away from th
e radiator, the wa
shing work shou
ld be stopped
.
Fig. 2.2.001
Fig. 2.2.002

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
Maintenance Manual for J2 Sedan
Service
15
④
Blow the back of radia
tion core with compresse
d air vertically from top to bottom. The pressur
e of
compressed air should be less than 490 KPa,
and a distance of more than
30 cm should be kept.
⑤

Blow radiator core surfac
e with compressed air every other minute until no water can be blown
away.
4)
Check
for
leakage
of
cooling
system
①

Check for leakage thro
ugh applying pressure to the cooli
ng system with a leakage dete
ctor of
radiator cap.
■Test
pressure:
157 KPa
Caution:
■Never remove the radiator cap with engine hot;
otherwise 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.

■
In case
the e
ngine c
oolant
is found
decreased,
please
refill engin
e co
olant into
the radia
tor.
②

If any component is found damaged, repair or replace.
5. Inspection of Fuel Pipeline
Check the fuel pipeline, fuel filler cap and fuel tank for
incorrect installation, leakage, crack, damage, loose
connection, worn or aged.
■
Repair or replace dama
ged compon
ent as
required.
6.
Replaceme
nt
of
Air
Filter
1) Dismantlement
①

Unscrew lo
ck bo
lt of air filter upper cover lift up the
cover.
Fig. 2.2.005
Fig. 2.2.004
Fig. 2.2.003
Engine
Fuel pipeline
Fuel tank



Maintenance Manual for J2 Sedan
Service
16
②

Take off air
filter
element.
2) Inspection After Dismantlement
■The air filter must be
regularly
cleaned or
replaced
according to recommended schedule. Please
refer to “Regular Service”.
■
Blow bac
k of
air filter
element
with compressed air until nothing can
be blow
n away.
3) Installation
Install with steps
contrary to dismantlement.
7. Replacement
of
Engine
Oil
Attention:
■
Be ca
reful
not
to be
scalded
since
oil tempera
ture
is
high.
■Long-time direct contact between skin and the used oil should be avoide
d. In case
contacted,
wash with soap or detergent thoroughly as soon as possible.
1)
Warm up
the engine, an
d check for any oil
leakage in t
he engine com
partment. Refe
r to “Leakage of
engine oil”.
2)
Stop
engine
and wait
for
ten minutes.
3)
Loosen
engine
oil fil
ler cap,
and the
n remove
the oil
drain screw
plug.
4)
Discharge
engine
oil.
5) Install the
oil
drain screw plug
with
new gasket.
Attention:
■
Any dirt such as
iron debris
on oil drain
screw
plug must be
cleaned, a
nd new
gaskets
should be installed.
■
Tightening
torque
of
oil
drain
bolt:
34-44
N·m.
6)
Refill
new
oil.
For specification and viscosity of
engine oil, please refer to “Recommended Oil and Lubricant”.
■
Engine
oil
quantity:
3.8L
Attention:
■During th
e filli
ng of
engine
oil, please do n
ot re
move oil gage.
■
The filling
amount of
engine
oil may
vary according
to oil
temperature and
oil drain
time.
Quantity above is for reference only.
Fig. 2.2.006



Maintenance Manual for J2 Sedan
Service
17
■Oil rule should be used all the w
ay to chec
k whethe
r the filling
amount of e
ngine oil
is
proper.
7) Warm up
the engine, ch
eck areas around the oil drain screw plug and o
il filter for leak
age.
8) Stop
engine
and wait
for
ten minutes.
9)
Inspect
oil
level.
See
also
“Engine
oil
level”.
8.
Change
Oil
Filter
1) Dismantlement
①

Use oil filter wrench to
dismount
the
filter.
Attention:
■JAC original engine oil or equivalent product
should
be used.
■
Be car
eful not to be scalded since
engine
and oil are hot.
■During dismantlement, a
cloth should
be prep
ared to
wipe up the leaked or splashed oil.
■Please
keep
the
driving
belt free from
engine
oil.
■
Clean
any
oil
splashed
on
engine
and
vehicle.
2) Installation
①
Clear any foreign substance on mounting
surface of oil filter.
②

Paste a film o
f engine oil o
nto the oil seal
surface of new filter.
③
Tighten.
■
Tightening
torque:
10-12N·m
Attention:
■The
engine
oil
filter
must be
tightened
with
a
filter
wrench.
■Manual
tightening ma
y cause
oil leak
age
due to
the ina
dequate
tightening torque
.
3)
Post-installation
inspection
①

Inspect oil l
evel, and fi
ll engine
oil when
it is inade
quate. See
also “Engine
Oil”.
②

Start
engine,
check
for
any
oil
leakage.
③

Stop engine and wait
for
ten minutes.
④

Inspect oi
l level,
and f
ill en
gine o
il. See
also
“Engine
Oil”.
9.
Replacement
of
Ignition
Plug
Fig. 2.2.007



Maintenance Manual for J2 Sedan
Service
18
1) Dismantlement
①

Dismount
the en
gine
hood.
See a
lso “Inta
ke m
anifold”.
②

Disassemble
the i
gnition
coil. P
lease
refer to
“Ignition
Coil”.
③

Dismount
the
ignition plug
with
plug
socket.
Attention:
■
Be
aware
not
to
drop
or
shock
the
ignition
plug.
2)
Inspection
after
the
dismantlem
ent
Generally, the standard ignition plug should be used.
In the following conditions, if carbon deposition frequently occurs with standard ignition plug, the hot
ignition plug should be
used:
■
Engine
is
frequently
started.
■
Ambient
temperature
is
low.
In the following conditions, in case ignition knock frequently occurs with standard ignition plug, the cold
ignition plug should be
used:
■
Long-time
traveling
on
the
expressway;
■
Engine
is
frequently
running
with
high
speed.
Attention:
■
Be
sure
not
to
drop
or
shock
the
ignition
plug.
■
Steel
brush
should
not
be
used
for
cleaning.
■If there’s carbon deposition on i
gnition plug
end,
remove
with ig
nition plug cleaner.
■
During the re
placement
interval, the ignition
plug gap s
hould be c
hecked when it is
necessary.
Ignition plug gap: 0.7-0.8 mm
3) Installation
Install with steps
contrary to dismantlement. Tightening torque of ignition plug: 25-30 N·m.
10.
Replaceme
nt of
Fuel Fi
lter
1) Dismantlement
Caution:
■
Be s
ure to
read
the
“General
Precautions”
before
any ha
ndling
of fuel
system.
See
“General
Precautions”.
①

Open
the
fuel
filler
cap.