B-Class MPV Service Manual Engine-Contents

Engine
General Information and Maintenance....................... GI-1
GI General Information........................................ GI-1
Precautions..................................................................................... GI-1
How to Use This Manual................................................................. GI-6
Model Identification Information.................................................... GI-7
Lifting Points.................................................................................. GI-12
Tow Truck Towing.......................................................................... GI-13
Tightening Torques of Standard Bolts.............................................. GI-14
Terminology.................................................................................... GI-15

MA Maintenance............................................................... MA-1
Preparation...................................................................................... MA-1
General Maintenance...................................................................... MA-2
Periodic Maintenance...................................................................... MA-3
Recommended Oils and Lubricants................................................. MA-4
Engine Maintenance........................................................................ MA-6
Chassis and Body Maintenance....................................................... MA-11

Engine............................................................................ EM-1
EM Engine Mechanical..................................................... EM-1
Precautions..................................................................................... EM-1
Preparation...................................................................................... EM-3
Engine Structure Overview............................................................. EM-6
Drive Belts...................................................................................... EM-8
Air Cleaner and Air Duct................................................................ EM-10
Intake Manifold.............................................................................. EM-12
Exhaust Manifold and Three Way Catalyst...................................... EM-14
Ignition Coil and Spark Plug........................................................... EM-15

1
 B-Class MPV Service Manual Engine-Contents

Fuel Injector and Fuel Rail.............................................................. EM-17

Timing Belt..................................................................................... EM-21
Camshaft and Rocker Arm.............................................................. EM-24
Oil Seal........................................................................................... EM-27
Cylinder Head and Valves............................................................... EM-30
Cylinder Block and Crankshaft....................................................... EM-37
Oil Pan and Oil Strainer.................................................................. EM-50
Positive Crankcase Ventilation........................................................ EM-52
Engine Assembly Removal and Installation..................................... EM-53
Trouble Diagnosis........................................................................... EM-56
Service Data and Specifications...................................................... EM-59

LU Lubrication System....................................................... LU-1

Precautions..................................................................................... LU-1
Preparation...................................................................................... LU-1
Engine Oil....................................................................................... LU-2
Oil Filter......................................................................................... LU-4
Oil Pump......................................................................................... LU-6
Service Data and Specifications...................................................... LU-8

CO Cooling System............................................................. CO-1

Precautions..................................................................................... CO-1
Preparation...................................................................................... CO-2
Cooling System Circuit................................................................... CO-3
Engine Coolant............................................................................... CO-4
Radiator.......................................................................................... CO-6
Cooling Fan.................................................................................... CO-8
Water Pump.................................................................................... CO-9
Water Inlet and Thermostat Assembly............................................. CO-10
Water Outlet and Water Piping........................................................ CO-12
Trouble Diagnosis........................................................................... CO-13

2
 B-Class MPV Service Manual Engine-Contents

Service Data and Specifications...................................................... CO-15

FL Fuel System.................................................................... FL-1

Precautions..................................................................................... FL-1
Preparation...................................................................................... FL-2
Fuel System Composition............................................................... FL-2
Fuel Injector and Fuel Rail.............................................................. FL-3
Fuel Filter....................................................................................... FL-4
Feed Pipe Assembly and Vapor Pipe Assembly............................... FL-6
Fuel Level and Sensor Unit............................................................. FL-6
Fuel Tank........................................................................................ FL-9
Fuel Pump....................................................................................... FL-9
Fuel Evaporative Emission System................................................. FL-12
Trouble Diagnosis........................................................................... FL-14
Service Data and Specifications...................................................... FL-15

ACC Accelerator Control System....................................... ACC-1

Accelerator Control Unit................................................................. ACC-1
Service Data and Specifications...................................................... ACC-2

EC Engine Control System................................................. EC-1

Precautions..................................................................................... EC-1
Preparation...................................................................................... EC-2
Engine Control System Overview................................................... EC-3
Engine Control System Components............................................... EC-9
On-Board Diagnostic (OBD) System.............................................. EC-25
Trouble Diagnosis........................................................................... EC-29
Service Data and Specifications...................................................... EC-85

3
 B-Class MPV Service Manual General Information and Maintenance

How to follow trouble diagnoses:

Description:
Trouble diagnoses indicate work procedures required to diagnose problems effectively.
Read the following instructions before diagnosing.
1. Before performing trouble diagnoses, read the “Preliminary Check”, the
“Symptom Chart” or the “Work Flow” first.
2. After repairs, recheck that the problem has been completely eliminated.
3. Refer to Component Parts and Harness Connector Location for the Systems
described in each section for identification/location of components and harness
connectors.
4. Refer to the Circuit Diagram Volume.
If you need to check circuit continuity between harness connectors in more detail,
such as when a sub-harness is used, refer to Wiring Diagram and Harness Layout in
each individual section for identification of harness connectors.
5. When checking circuit continuity, ignition switch should be set to OFF position.
6. Before checking voltage at electrical components, check battery voltage first.
7. After accomplishing the Diagnostic Procedures and Electrical Components
Inspection, make sure that all harness connectors are reconnected as they were.
Model Identification Information
Vehicle type:

Body number Engine model Manual transmission number

B-Class MPV 4G93D DL F5M41-G6

Vehicle identification number (VIN):

1) Vehicle identification number (VIN) location: On name plate or at lower left
corner of windshield.

GI-7
 B-Class MPV Service Manual General Information and Maintenance

General Maintenance
General maintenance includes those items which should be checked during the normal
day-to-day operation of the vehicle. They are essential if the vehicle is to continue
operating properly. The owners can perform these checks themselves or have their JAC
dealers do them.
Outside the vehicle:
The maintenance items listed here should be performed from time to time, unless
otherwise specified.

Item

Check tire pressure (including spare tire) with a pressure gauge at a service station
Tires regularly. Adjust to the specified pressure if necessary. Check tires carefully for
damage, cracking or excessive wear.

Clean the windshield on a regular basis. Check the windshield at least every six
Windshield
months for cracks or other damage. Please repair or replace as necessary.

Windshield
Check for fracture or wear if they do not wipe properly.
wiper blades

Check that all doors as well as the engine hood and tail gate can be opened and
closed normally. Also make sure that all latches lock securely. Lubricate if
Doors and necessary. Make sure that the secondary latch keeps the hood from opening when
engine hood the primary latch of the engine hood is released.
When always driving in areas using road salt or other corrosive materials, check
lubrication frequently too.

Tire rotation Tires should be rotated every 8,000 km.

Make sure that the headlights, fog lights, stop lights, taillights, turn signal lights,
Lamps and other lighting are all operating properly and fixed securely. Also check
headlight aim.

Inside the vehicle:

Item

Warning lights
Make sure that all warning lights and buzzers are operating properly.
and buzzers

Windshield, Check that the wipers and washer operate properly and that the wipers do not
wipers and washer streak.

Windshield Check that the air comes out of the defroster outlets properly and that air is
defroster sucked in sufficient quantity when operating the heater or air conditioner.

Check that it has the specified free play (<35 mm); check it for hard steering or
Steering wheel
abnormal noise.

MA-2
 B-Class MPV Service Manual General Information and Maintenance

leakage. MA009
 Check ball joint dust cover for cracks or
other damage.

Strut Ball joint

Tires:
For safe driving of your vehicle, type and size of tires must be suitable for the vehicle
model; in addition, tire treads must be in good condition and appropriate tire pressures
must be provided.
The way to service tires and the method for tire replacement are described below.

Warning!
 Use of excessively worn or under inflated tires will cause accidents resulting in
personal injury or death.
 All instruction regarding tire inflation and maintenance in the Operation Manual
must be observed.
Overview of inflation:
Keeping tires properly inflated provides the best combination of steerability, tread life
and driving comfort.
 Underinflation may cause uneven wear of tires and affect steerability and fuel
consumption, and much more likely result in air leaks due to overheating.
 Overinflated tires will make your ride in the vehicle uncomfortable, are more likely
to be damaged by rugged roads, and are subjected to uneven wear.
Measure tire pressure with a tire gauge at least monthly. Even pressure of a tire in good
condition may decrease by 10~20KPa (0.1~0.2kgf/cm2) per month. Also check spare
tire each time all tires are checked.
Measure tire pressure when tires are cold. This means that the measurement should be
made after your vehicle has been parked for at least 3 hours or when travel distance
does not exceed 1.6km. If necessary, inflate or deflate tires until their tire pressures
reach the value recommended for cold tires in the name plate on driver side door frame.
When pressure of a tire is checked when hot (after a travel of several kilometers), the
reading will be 30~40KPa (0.3~0.4kgf/cm2) higher than that when cold, which is
normal. Do not deflate the tire in order to reach the specified cold tire pressure reading,
otherwise tire underpressure will result.
When a tubeless tire is punctured, its self-seal function will be activated. If pressure of
a tire starts to drop, locate air leak carefully.

MA-15
 B-Class MPV Service Manual EM Engine Mechanical

3. Disconnect wire connector from ignition EM014

coil assembly.
4. Screw off 2 bolts securing ignition coil,
and take out ignition coil.
5. Disconnect secondary cable from
ignition coil.

Inspection after removal:

1) Ignition coil
 Check resistance of primary coil between terminals.
Resistance of primary coil: 0.77~0.95Ω
 Check resistances between high voltage terminals of No. 1 and No. 4 cylinders
and those of No. 2 and No. 3 cylinders.
Resistance of secondary coil: 7.75~10.23KΩ
Caution:
 When measuring coil resistance, be sure to pull off ignition coil harness
connector.
2) Spark plug
Checking spark plug:
 Check spark plug insulator for damage or fracture.
 Check for spark plug fouling. See the following table for causes of fouling.
Analysis Sheet of Causes of Spark Plug Fouling

Symptom Black carbon White carbon

Impurities content in fuel filled Impurities content in fuel filled, or ignition timing
Cause
or mixture too rich incorrect, or spark plug not tightened

 Check spark plug electrode for damage.

 Check spark plug gap.

EM-16
 B-Class MPV Service Manual EM Engine Mechanical

Inspection after removal:

Piston rings:
1. Check piston ring side clearance. If the
clearance exceeds the specified limit
value, replace piston ring or piston or
both.
Standard value:
Feeler gauge
Top ring: 0.03-0.07mm
Second ring: 0.02-0.06mm
Limit value: Push in together with piston

Top ring: 0.1mm

Second ring: 0.1mm
2. Put piston rings in cylinder bore, and
push them down using piston.
Ensure that piston top comes into
contact with piston rings and that rings Piston ring Gap clearance

are perpendicular to cylinder wall.

Then measure the piston ring end gap
with a feeler gauge. If the end gap is
too large, replace piston ring.
Standard value:
Top ring: 0.25-0.40mm
Second ring: 0.40-0.55mm
Oil ring: 0.10-0.35mm
Limit value:
Top ring: 0.8mm
Second ring: 0.8mm
Oil ring: 1.0mm

Connecting rod bearing shell clearance

(plastigage method): Contrast scale

1. Wipe off all engine oil from

connecting rod journal and connecting Plastic ruler
rod bearing shell.
2. Put a plastigage cut to a length equal to
bearing shell width on connecting rod
journal. Plastigage must be placed at
center of connecting rod journal and is
parallel to axis of the journal.

EM-44
 B-Class MPV Service Manual LU Lubrication System

Essential service material:

Lubricant

Item Recommended lubricant Quantity (including lubricant in oil filter)

Engine oil (API grade) 15W-40 SJ grade or above 3.5L

Engine Oil

Engine oil level: LU002

Note:
Before starting engine, park vehicle
horizontally and firmly and check the engine
oil level. If engine is already started, stop it
and wait 10 minutes before checking.
1. Pull out oil level gauge and wipe off
engine oil on it with a clean rag.
2. Insert oil level gauge fully back to its
tube. Upper limit mark
3. Pull out oil level gauge again to check Lower limit mark
the oil level and make sure the level is
within the range shown in the figure at
top right.

4. If the oil level is below “MIN” scale, refill with designated engine oil.
5. Start engine and stop it after idling it for 5 minutes, and then wait a moment
before checking if the engine oil level is within the specified range.
Engine oil appearance:
 Check engine oil for white turbidity or heavy contamination.
 If engine oil becomes turbid and white, it is highly probable that it is
contaminated with engine coolant. Repair or replace damaged parts.
Engine oil leak check:
Check for engine oil leakage around the following areas:
 Oil pan
 Oil pan drain bolt
 Oil pressure switch
 Oil filter
 Mating surface between cylinder block and cylinder head
 Crankshaft oil seals (front and rear)

LU-2
 B-Class MPV Service Manual FL Fuel System

Graduation line Reference resistance (Ω)

3/4 58±3

7/8 49±3

F 40±2

② Check that resistance changes smoothly FL009

when the float moves slowly between F Stopper
(Highest) and E (Lowest) positions.
Position F
2) Heights of float of fuel gauge sensor (highest)
component: Move the float, and
measure F (Highest) and E (Lowest) Position E
(lowest)
positions as well as heights A and B Stopper

when the float rod comes into contact

with the stopper.
 Standard values:
A: 2.75mm
B: 158.8mm

Disassembly: FL010
1. Disconnect harness connector.
 Hold connector by fingers and pull it out,
because there is no stopper release tab. Wire color: white

Wire color: black

Harness connector

2. Remove fuel level sensor unit as FL011 Fuel level sensor unit
follows:
① Using suitable tool, pull up tabs points
as shown in the figure to release the
lock.
Caution:
 Be careful not to damage it. Pull up projecting part
Suitable tool
 An example of using Allen wrench
[2.0mm (0.08 in)] is as shown.

FL-7
 B-Class MPV Service Manual EC Engine Control System

Installation:
Installation is the reverse order of removal.
Caution:
 Tightening torque: 20N·m
 Be careful not to allow the sensor’s prolonged contact with fluids such as engine
oil, coolant, brake fluid, and water.
 Note that use of washers of any type is not allowed during installation. The
sensor must cling to cylinder block through its metal surface.
 When laying signal cables of the sensor, be careful not to resonate the cables in
order to prevent fracture.
 Avoid applying high voltage between 1# and 2# pins when inspecting the sensor,
otherwise piezoelectric element will be damaged.
Throttle position sensor:

1) Component position description: EC009

It is mounted on throttle body.
2) Component description:
The throttle position sensor (TPS) is a rotary
variable resistor. It rotates around throttle
spindle to sense throttle angle. When
throttle spindle rotates, throttle angle of the
TPS will change. The ECM detects throttle
opening according to output signals from the
TPS. EC010
3) Descriptions of component pins:
Pin 1: 39#-ground, ECU
Pin 2: 18#-5V power supply from ECU
Pin 3: 26#-output signal to ECU

4) Symptoms and inspection methods:

 Symptoms: Poor acceleration, etc.
 Inspection methods:
① Check resistance between pins 1 and 2.
 Resistance: 2kΩ±20% (at normal temperature)
② Check resistance between pins 1 and 3. When throttle is rotated, the resistance
should change linearly in response to throttle opening.

EC-14
 B-Class MPV Service Manual EC Engine Control System

SN DTC Description

37 P0264 Control circuit of fuel injector in No. 2 cylinder short to ground

38 P0267 Control circuit of fuel injector in No. 3 cylinder short to ground

39 P0270 Control circuit of fuel injector in No. 4 cylinder short to ground

40 P0262 Control circuit of fuel injector in No. 1 cylinder short to power

41 P0265 Control circuit of fuel injector in No. 2 cylinder short to power

42 P0268 Control circuit of fuel injector in No. 3 cylinder short to power

43 P0271 Control circuit of fuel injector in No. 4 cylinder short to power

44 P0300 Misfire in several cylinders

45 P0301 Misfire in No. 1 cylinder

46 P0302 Misfire in No. 2 cylinder

47 P0303 Misfire in No. 3 cylinder

48 P0304 Misfire in No. 4 cylinder

49 P0317 Rough road test ABS signal fault

50 P0318 Rough road test sensor signal fault

51 P0321 CKP sensor reference point failure

52 P0322 No CKP sensor pulse signal (open or short)

53 P0327 KS signal circuit voltage too low

54 P0328 KS signal circuit voltage too high

55 P0340 Installation position of CMP sensor improper

56 P0341 Poor contact of CMP sensor

57 P0342 CMP sensor short to ground

58 P0343 CMP sensor short to power

59 P0420 TWC oxygen storage capacity deterioration (excess emission)

60 P0444 Control circuit of canister control valve open

EC-36
 B-Class MPV Service Manual EC Engine Control System

9) DTC P0105: IAP sensor signal unchanged (frozen)

Step 1: Read “Mode 3” and “Mode 7” with a diagnostic tester.

Read result 1 Read result 2

In Mode 3 In Mode 7 In Mode 3 In Mode 7

Fault information Fault information not Fault information not Fault information
available available available available

P0105 P0105

Maintenance tips: Maintenance tip:

The fault has been recognized. Its causes may The fault has not been finally recognized.
be the following: Check the following:
1) IAP sensor vacuum leak or clogging 1) Reinstall after checking or cleaning sensor
vacuum tube. Read after-start pressure
2) IAP sensor serious aging with a diagnostic tester in “Mode 1”.

10) DTC P0106: IAP sensor signal improper

Step 1: Read “Mode 3” and “Mode 7” with a diagnostic tester.

Read result 1 Read result 2

In Mode 3 In Mode 7 In Mode 3 In Mode 7

Fault information Fault information not Fault information not Fault information
available available available available

P0106 P0106

Maintenance tips: Maintenance tip:

The fault has been recognized. Its causes may The fault has not been finally recognized. It
be the following: may be an intermittent fault. Check the
following:
1) Air leak from sensing unit in the sensor
1) The sensor is a free voltage sensor, so it
2) Sensor damaged can not be diagnosed by reading pressure
3) Air leak from installation position of the parameters in diagnostic tester. Therefore,
sensor wait for the system to give a final
diagnostic result.
4) Migration characteristics of the sensor

EC-44
 B-Class MPV Service Manual EC Engine Control System

P0318 P0318

Maintenance tips: Maintenance tips:

The fault has been recognized. Its causes may The fault has not been finally recognized. It
be the following: may be an intermittent fault. Check the
following:
1) Short to ground exists in the circuit
connected to ECU pin. 1) Check resistance to ground of the circuit
connected to ECU pin.
2) The circuit connected to ECU pin short to
power or open 2) Check voltage of the circuit connected to
ECU pin.
3) Installation position or support of
acceleration sensor loose 3) Check that installation position and
support of acceleration sensor are normal.
4) Acceleration sensor damaged

51) DTC P0321: CKP sensor reference point failure

Description of source of trouble: The system uses a 60-2 tooth speed measuring
system. Mounted on flywheel, the 60-2 induction ring gear will generate magnetic
changes in the sensor when it follows flywheel (with same speed as that of crankshaft)
to rotate, so that an induced AC voltage of which the frequency depends on speed is
generated. The ECU signal circuit converts the input sine waves into square waves.
When ECU finds that the distance between falling edges of 2 square waves is greater
than 2 X pitch, the reference position is then detected. Physically, this reference
pitch corresponds to a specific position of No. 1 cylinder. It is defined in the system
that the second falling edge after the reference pitch be the reference point signal of
the software (BM) and that the crank angle from the signal to TDC of No. 1 cylinder
be a fixed value 108°CA. The system will receive a BM at each crankshaft turn. In
addition, the system keeps pace with crankshaft position according to this BM thus
ensuring correct control over fuel injection, intake and ignition timing.
If any of the following cases is found, you can judge that a BM fault occurs:
① It is frequently found that the measured BM appears at the position ahead of or
behind the expected position;
② Speed signals can be detected but BM can not be detected;
③ BM is missed frequently.

Step 1: Read “Mode 3” and “Mode 7” with a diagnostic tester.

Read result 1 Read result 2

In Mode 3 In Mode 7 In Mode 3 In Mode 7

Fault information Fault information not Fault information not Fault information
available available available available

P0321 P0321

EC-57
 B-Class MPV Service Manual EC Engine Control System

Inspection Follow-up
SN Work procedure
result procedure

Pull off CTS connector, start the engine, and observe if Service line or
Y
the engine then starts successfully. (Or connect a 300Ω replace sensor.
3
resistor to CTS connector in series to replace the sensor,
and observe if the engine then starts successfully.) N Next step

Y Service or replace.
Check vacuum tube of fuel pressure regulator for
4
looseness or air leaks.
N Next step

Y Change fuel.
Check fuel condition, and observe if the symptom
5
occurs just after a refueling.
N Next step

Seek for diagnosis

Connect an EFI system adapter, turn ignition switch Y
help.
ON, and check 12#, 13#, 44#, 45#, and 63# pins for
6
normal power supply; check 3#, 51#, 53#, 61#, and 80#
pins for normal ground connections. Repair or replace
N
harness.

4. Hard cold starting

General trouble locations:
① Moisture in fuel; ② fuel pump; ③ CTS; ④ fuel injector; ⑤ ignition coil; ⑥
throttle body and idle air bypass; ⑦ engine mechanical parts.
General diagnostic flow:

Inspection
SN Work procedure Follow-up procedure
result

Connect a fuel pressure gauge with its access point Y Next step
at front end of fuel inlet pipe of fuel rail assembly,
1
start the engine, and check if the fuel pressure is Service fuel supply
around 300kPa in idling mode. N
system.

Pull out ignition cable from one of the cylinders, Y Next step
connect a spark plug with the distance from its
2 electrode to engine body kept at around 5mm, and
then start the engine to check for blue-white Service ignition
N
high-voltage sparks. system.

Pull off CTS connector, start the engine, and Service line or replace
Y
observe if the engine then starts successfully. (Or sensor.
3 connect a 2,500Ω resistor to CTS connector in
series to replace the sensor, and observe if the
engine then starts successfully.) N Next step

EC-75