JAC S5 Instruction manual
S5 Workshop Manual Engine
EM-1
Engine
EM Engine Structure
Precautions
Precaution for Draining Engine Coolant:
■ Drain engine coolant after the engine is in cooling condition.
Precautions for Disconnecting Fuel Pipe:
■ Before starting to work, make sure there is no article which may cause combustion
or spark in working area.
■ Before disconnecting and dismantling, first release fuel pressure. For methods to
release fuel pressure, please refer to "the release of fuel pressure in fuel pipe".
■ After disconnecting pipe, plug the opening to avoid fuel leakage.
Precaution of Dismantling and Disassembly:
■ If it is required to use special repair tools, please use special repair tools. Always
keep safe operation, and do not force to do or conduct improper operation.
■Be careful not to damage the matching surface or sliding surface.
■ If necessary, use adhesive tape or equivalent to seal the opening of engine system,
to avoid foreign matters from entering.
■Methodically mark and arrange the dismantled parts, to facilitate troubleshooting
and re-assembly.
■ The basic principles for loosening bolts and nuts are to loosen the exterior first, and
then loosen the diagonal position, and so on. If the loosening sequence is specified,
please follow the specified sequence.
Precaution of Inspection, Repair and Replacement:
■ Before repairing or replacing, completely inspect parts. Use the same methods to
inspect the replaced parts. If necessary, please replace.
Precaution of Assembly and Installation:
■ The basic principles for tightening bolts and nuts are to first tighten middle with the
same tightening torque, and then tighten exterior diagonal position. If the tightening
sequence is specified, please follow the specified sequence.
■ Cushion, oil seal or rubber sealing ring are easy to be damaged during dismantling.
If necessary, replace them.
■ Completely flush, clean and blow each part to dry condition. Carefully inspect
whether engine oil or engine coolant pipe is blocked.
■ When refilling engine coolant after drain it out, it is necessary to release air from
pipe.
■ After repairing, start the engine and increase engine rotation speed to inspect
whether the engine coolant, fuel, engine oil and tail gas have leakage.
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-2
Parts to be tightened according to the Specified Angle:
■ Use angle wrench to finally tighten the following engine parts:
—— Cylinder head bolt
—— Main bearing cover bolts
—— Connecting rod cap nut
—— Crankshaft belt pulley bolts (it is unnecessary to use angle wrench, because bolt
flange is used for fixing groove tightened according to fix angle).
■ Do not finally tighten them according to torque value.
■ Torque value of these parts is applied to pre-tightening steps.
■ Keep surface of thread and base seat clean and apply oil on it.
Dismantling Sealant:
■ After dismantling fixing nuts and bolts,
use a scraper to separate matching surface
and dismantle oil sealant.
■ Pay attention not to damage matching
surface.
■ Insert the scraper, and then, as shown
in figure, knock it and slide it from the
side.
■ In some places where it is difficult to
use scraper, please use plastic hammer to
slightly knock the parts and dismantle
them.
■ If it is inevitable to use screwdriver and other tools, please pay attention not to
damage the matching surface.
Steps for Application of Sealant:
■ Use a scraper to remove oil sealant on
the surface of cushion and matching
surface.
■ Completely remove oil sealant from the
groove, fixing bolts and bolt holes.
■ Use lead-free gasoline to clean sealant
application surface and matching surface,
and remove the attached water, grease
and foreign matters.
■ Put the sealant with the specified size
completely onto the specified position.
EM001
EM002
Strike
Slide
Scraper
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-3
EM00
■ If there is a groove to place sealant, please put the sealant into this groove.
■ For bolt holes, generally apply sealant into the holes. Sometimes, apply sealant
outside of the hole.
■ Install binding parts within 5mins after applying sealant.
■ If there is dirt on the sealant, immediately clean it.
■ Do not re-tighten locking bolts or nuts after installation.
■ After 30 mins of installation, refill engine oil and engine coolant.
■ If there is special instruction in this manual.
EM00
Interior
Interior
Bolt hole
Groove
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-4
Preparation Work
Special Tool Table
No.
Tools
Name
Overall diagram
Code
Purpose
1
Valve spring
compressor
JAC-T1F001
It is used for
dismantling
engine valve
and relevant
parts when it is
unnecessary to
dismantle.
2
Camshaft oil
seal installer
JAC-T1F002
Install engine
camshaft oil
seal
3
Crankshaft
front oil seal
guider
JAC-T1F003
It can guide to
install
crankshaft front
oil seal.
4
Crankshaft
front oil seal
installer
JAC-T1F004
Install
crankshaft front
oil seal
5
Dismantle
tool of
piston pin
JAC-T1F005
It is used for
dismantling of
engine piston
pin.
6
Timing gear
pulley
stopper
JAC-T1F006
It is used for
supporting
fixing balance
axle chain
wheel.
Guider
Oil seal
Front
cover
Press rod
Forward
mark
Forward
mark
Guide block
Base
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-5
7
Handle
JAC-T1F007
Mounting
bearing used
with relevant
installer.
8
Crankshaft
rear oil seal
installer
JAC-T1F008
Install
crankshaft rear
oil seal
9
Double-teeth
special
sleeve
JAC-T1F009
It is used for
dismantling
front cover plug
cock of the
engine.
10
Valve oil
seal installer
JAC-T1F010
Install valve oil
seal
11
Flywheel
stop dog
JAC-T1F011
Fixed flywheel,
easily dismantle
12
Valve spring
compressor
JAC-T1F012
Dismantling
engine valve
and relevant
parts when
disassembly
13
Valve guide
pipe
dismantle
tool
JAC-T1F013
Dismantle valve
duct
Handle
Handle
Installer of
rear oil seal of
crankshaft
Special
socket for
two teeth
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-6
14
Balance
shaft oil seal
installing
tool
JAC-T1F014
It is used for
installing oil
seal on engine
balance shaft.
15
Oxygen
sensor
wrench
JAC-T1F015
It is used for
dismantling and
installing
oxygen sensor.
16
Mounting
tools for
pulley oil
seal
JAC-T1F016
It is used for
installing oil
seal on engine
timing belt
pulley.
17
Oil pan
unloaded
JAC-T1F017
It is used for
dismantling of
oil pan.
18
Fuel
pressure
gauge
JAC-T1F018
Measure fuel
pressure
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-7
Auxiliary Material Table of Engine Assembly
No.
Name
Application
Specification Brand
1
oil
Oil filling, oil for assembly
5W-30 (in winter of northern
areas) 15W-40 (in summer of
northern areas and full year in
southern areas) quality grade is SJ
or above.
2
Silica gel
Oil pump, water pump, oil pan,
crankshaft rear oil seal housing
LT5699 or equivalent
3
Sealant
Oil pressure switch, drain plug,
flywheel bolt
LT243 or equivalent
4
Sealant
Coolant temperature sensor, water
temperature warning switch
LT648 or equivalent
5
Gasoline
RON93# and above grade of
lead-free gasoline
6
Sealant
Double-end bolt
LT271 or equivalent
Auxiliary Material Table for Cylinder Head Assembly
No.
Name
Present material and model
Assembly position
1
Oil
5W-30 (in winter of northern
areas) 15W-40 (in summer of
northern areas and full year in
southern areas) quality grade is SJ
or above.
Valve head, camshaft,
rocker arm, rocker arm
shaft, camshaft oil seal
2
Sealant
LT271 or equivalent
Double-end bolt
3
Sealant
LT962T or equivalent
Spark plug guide sleeve,
cylinder body/cylinder
cover dash-shaped plug,
filler neck
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-9
Structure Parameter of Engine:
Structure Parameter Table of Engine
Model
HFC4GA3.1D
Type
L4/16.DOHC.MPI
Cylinder number
4
Fuel chamber
Pentroof type
Total displacement (CC)
1997
Cylinder bore mm
85.0
Stroke mm
88.0
Compression ratio
8.5
Valves and drive mechanism
DOHC-4
Cylinder distance mm
93
Cylinder body height mm
235
Big and small center distance of connecting rod
150
Valve
Number
Air intake valve
8
Air exhaust valve
8
Output
Max. power
130 kW / 5200 rpm
Max.torque
235 N•m / 2000-4000 rpm
Fuel octane value
RON93# and above 93# grade of lead-free
gasoline
It meets emission laws and rules.
State V
Overall dimensions
Length 692 mm× width 675 mm× height 704
mm
Engine weight (Kg)
(Dry condition)
Lubrication system
Pressure oil supply
Fuel supply way
Electric fuel pump, without oil return system
Oil pump type
Cycloid gear pump
Cooling system
Forced circular water cooling
Water pump type
Centrifugal, impeller type
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-11
Inspection before Dismantling:
1. Inspect whether the pulley has crack, abrasion and oil stain. If yes, please replace it.
2. Inspect whether the pulley is correctly installed in the groove of belt pulley.
3. Inspect the deflection of belt in the middle point of the pulley.
Notes:
■ The inspection should be conducted when the engine is in cooling condition, or
turned off for 30 mins.
■ Use a pulley tensometer for inspection.
■ If the deflection value exceeds limit value, adjust it.
Dismantling:
1. Unscrew locking bolt of power steering pump belt, select the tension of adjusting
bolt, and then loosen power steering pump and air conditioning compressor drive belt.
2. Remove power steering pump and air conditioning compressor drive belt.
3. Unscrew adjusting locking bolts of electric generator, and then loosen engine drive
belt.
4. Remove electric generator drive belt from electric generator pulley.
Installation:
1. Install belt onto the pulley according to the reverse order of dismantling.
Notes:
■ After replacing belt, adjust its "new belt" value to make it suitable for pulley
groove.
■ When installing belt, make sure that the belt and pulley groove are aligned and
arranged correctly.
■ Do not splash engine oil, power steering fluid and engine coolant onto belt and each
pulley groove.
■ Do not excessively wind or bend the belt.
2. Adjust the tension of belt. First adjust it to the specified value, and then rotate
crankshaft for two circles. Re-inspect whether it reaches the specified value, to avoid
the deflection change between pulleys.
3. Tighten bolts and nuts to the specified torque.
4. Make sure that the tension of all belts is within standard range.
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-12
Air Filter and Air Pipe
Component Position Schematic Diagram
1-PCV hose 2-Air intake hose 3-Air filter assembly
Dismantling:
1. Loosen intake hose locking clamp and PCV hose clamp.
2. Dismantle upper cover buckle of air filter.
3. Dismantle intake hose and remove upper cover of filter and intake hose.
4. Dismantle 3 fixing bolts of air filter seat, and remove the seat.
■ Tightening torque: 8 ~ 12 N•m
Inspection after Dismantling:
Inspect whether air pipe has crack or abrasion. If yes, please replace it.
Installation:
Install it according to the reverse order of dismantling.
Notes:
■ Install each joint in good condition and place and tighten clamp.
3
1
2
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-13
Inspection and Replacement of Air Filter Element:
Dismantling:
1. Loosen upper cover locking buckle of
air filter, and rise up upper cover.
2. Dismantling air filter element.
Inspection after Dismantling:
■ Regularly clean and replace air filter
element according to the recommended
time.
■ Use compressed air to blow from the
back of air filter element until it is clean.
Installation:
Install it according to the reverse order of
dismantling.
EM008
EM007
EM006
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-14
Engine Cylinder Block
1. Component
2. Dismantling
Dismantle cylinder head, oil pump housing, timing belt, flywheel, piston and
crankshaft. For detailed information, please refer to relevant section.
3. Inspection:
1) Inspect whether cylinder body has scratch, rusting and corrosion. Meanwhile,
inspect whether there is crack or other defect. If there is any defect, replace cylinder
body.
2) Measure the bore on three shown height in A and B directions by using a cylinder
gauge.
Height 1: Position of the first piston ring at TDC (upper stop point).
Height 2: Intermediate of cylinder.
Height 3: Bottom of cylinder.
EM009
Cylinder block
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-15
3) If the cylinder exceeds the specified cylindricity or roundness after inspection, or
cylinder wall has serious abrasion or scratch, re-bore the cylinder and grind cylinder
body. And install new piston and piston ring.
Standard Value:
Cylinder Bore:85 + 0.03 mm
Cylindricity or roundness of the bore: maximum 0.01 mm
4) If the top of cylinder has projected mark or deposited carbon, use a reamer or
No.600 sand paper to remove them.
5) If the re-bored cylinder hole is excessive, keep the specified clearance between
piston and cylinder, and make sure that all used pistons have the same size. Outer
diameter of piston is measured on 12 mm above the bottom of piston skirt of the
piston and measured along the thrust force.
Clearance between piston and cylinder:
0.02 - 0.04 mm
6) Inspect whether there is damage or crack.
7) Inspect the flatness of upper surface of cylinder body. If it exceeds limit value,
grind it to minimum limit value or replace it.
Standard value:
Cylinder body flatness:
Max. 0.05 mm
Maintenance limited value:
Cylinder body flatness 0.1 mm
Notes:
■ When assembly cylinder head, the grinding size of less than 0.2 mm is allowed.
4. Repair Cylinder
1) For cylinder repair, it is necessary to re-bore the cylinder hole, and then install a
new cylinder sleeve.
Notes:
■ To avoid deformation due to high temperature during grinding, cylinder hole should
be bored according to ignition sequence.
2) Grind cylinder and modify it to suitable size (outer diameter of piston + clearance
between cylinders).
EM011
EM010
Measurement point
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-16
3) Inspect clearance between piston and cylinder.
Notes:
When repairing cylinder, repair four cylinders to make them have the same size. Do
not only bore one cylinder.
5. Installation
Install the following parts by referring to relevant sections:
1) Crankshaft
2) Flywheel
3) Piston
4) Cylinder Hood
5) Timing belt chain
6) Oil pump housing
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-17
Camshaft
1. Component
2. Dismantling
1) Disconnect negative pole from battery.
2) Discharge coolant of engine.
3) Dismantle breathing hole between air filter and rocker arm housing.
Engine hood front
bracket components
Engine hood rear
bracket components
Cover plate components of
cylinder head protective cover
Cylinder head protective
cover component
Sealing ring of cylinder
head protective cover
Sealing ring of spark plug
Rear bearing cover
Camshaft position sensor
Camshaft signal wheel
Rocker arm
Hydraulic tappet
Oil separator
Intake camshaft
Exhaust camshaft
Bearing cover
Camshaft oil seal
Camshaft chain wheel
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-18
4) Dismantling air filter.
5) Dismantling timing belt shield.
6) Dismantle rocker arm and crankshaft position sensor.
7) Loosen fixing bolt of camshaft chain wheel, and then dismantle camshaft chain
wheel.
8) Loosen camshaft bearing cover bolts, and remove bearing cover, camshaft, rocker
arm and hydraulic tappet.
Notes:
■ Gradually loosen cover bolts to avoid
bending camshaft.
3. Inspection
1) Rocker arm
Inspect the rotation of roller wheel. If it can't rotate smoothly or there is any
loosening, replace it.
Inspect the surface of roller wheel. If there is any depression or obvious scratch,
replace it.
Inspect whether valve contact surface has damage or obvious scratch. If necessary,
replace it.
2) Camshaft
Inspect whether camshaft journal has abrasion. If the journal has serious abrasion,
replace camshaft.
Inspect whether the tip point of cam has damage. If the tip point has damage, or
excessive abrasion, replace camshaft.
Cam Height
Standard Value
Air intake : 35.493 mm
Air exhaust : 35.204 mm
EM013
EM012
EM011
Roller wheel
Contact surface
Cam
height
Journal
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-19
Limiting Value
Air intake : 34.993 mm
Air exhaust : 34.704 mm
3. Installation
1) Install camshaft onto cylinder head, but do not install rocker arm.
Notes:
■ Apply oil onto the journal and cam of
camshaft.
■ There is a cutting groove at the back of
exhaust camshaft to install camshaft
position sensor signal wheel.
2) Install bearing cover.
Marks on the cover are to identify air
intake / air exhaust.
I: Air intake camshaft
E: Air exhaust camshaft
3) Inspect camshaft to make sure it can be
rotated easily with hands. After
inspection, dismantle bearing cover and
camshaft, and then install rocker arm.
4) Make sure that the positioning pins at
the end of camshaft chain wheel are
located on the top.
EM017
EM016
EM015
EM014
Exhaust side
Installing port of
signal wheel
Intake side
Position number
Intake, exhaust
identification numbers
Positioning pin
Intake side
Exhaust side
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
S5 Workshop Manual Engine
EM-20
5) Tighten bearing cover to the specified torque in two or three times according to the
figure.
Notes:
■ Uniformly tighten rocker arm
Tightening Torque
Main bearing cover bolt:
19 ～21 N•m
6) Use special tool, camshaft oil seal
installer and guide rod (JACF125,
JACF126).
Make sure to apply oil on the surface of
oil seal, and then insert oil seal along the
front of camshaft. Use a hammer to push
the installer until the oil seal is in its
proper position.
7) Install and tighten camshaft chain
wheel bolts to the specified torque.
Tightening torque
Camshaft sprocket bolt:
80 ～100 N•m
EM021
EM020
EM019
EM018
Front end
Oil seal
Camshaft
www.cargeek.ir
www.cargeek.ir
www.CarGeek.ir
Table of contents
Other JAC Automobile manuals
